202 4 Edition DIVISION II: CONSTRUCTION DETAILS
Section 100: Earthwork, Grading, Demolition, Rodent Control and Borings Section 200: Drainage Section 300: Water Systems Section 400: Sub -Base, Base Courses, Shoulders, Pavements and Berms Section 500: Curb and Edging Section 600: Highway Guard, Fences and Walls Section 700: Incidental Work Section 800: Traffic Control Devices Section 900: Structures II.1 202 4 Edition SECTION 100 : EARTHWORK, G RADING, DEMOL ITION, RODENT CONTROL AND BORINGS SUBS ECTION 101 : CLEARING AND GRUBBING DESCRIPTION
101.20: General
This work shall consist of clearing, grubbing, cutting, removal and disposal of all vegetation and debris from areas as shown on the plans or designated by the Engineer. The work shall also include the preservation from injury or defacement of all vegetati on and objects designated by the Engineer to remain. CONSTRUCTION METHODS
101.60: General
The burning of trees, brush, stumps, etcetera, will not be permitted. The Contractor shall provide other satisfactory methods of disposal without additional compensation. The Contractor shall obtain written permission of the Engineer before storing debris within the Right -of-Way. Any clearing operations beyond the limits set by the Engineer shall be done with the approval of the Engineer and at the Contractor’s expense. All such areas shall be restored to a condition acceptable to the Engineer including necessary mulching, seeding, and planting without additional compensation. The Engineer shall be provided with notarized copies of agreements between the Contractor and owners of land used as disposal or storage areas. When fencing is installed outside normal clearing areas, every reasonable effort shall be made to preserve trees or shrubs whose removal is not essential to the installation of the fencing. Acceptable material obtained on the project may be used to produce wood chip mulch. The Contractor shall use an approved chipper and ¼-in. knife setting as described under M6.04.3: Wood Chip Mulch . Material obtained from Elm trees shall not be accepted for use. Wood chips produced on the project shall be stockpiled within the location and used where and as directed. Except for materials used for making wood chip mulch, the Contractor shall make all arrangements and negotiations necessary for the satisfactory disposal of trees, shrubs, stumps, roots, dead wood and other litter, in areas outside the Right -of-Way and in such manner that no condition or accumulation of material shall be permitted to disfigure or mar the finished landscape.
101.61: Clearing and Grubbing
The stumps of all trees, brush and major roots shall be grubbed and removed in all excavation areas and under all embankments where the original ground level is within 3 ft of the subgrade or slope of embankments. II.452 202 4 Edition SECTION 900 : STRUCTURES SUBSECTION 901: CEMENT CONCRETE DESCRIPTION
901.20: General
Cement Concrete with or without reinforcement as required for bridges, culverts, walls, steps, drop inlets and other work shall be constructed to the designs and dimensions indicated on the plans or as directed and to close conformity with the lines and grades established by the Engineer. Where necessary, at the direction of the Engineer, the dimensions or design may be adjusted to fit foundation, slope or construction conditions as encountered. MATERIALS
901.40: Materials
Materials shall meet the requirements specified in the following Subsections of Division III, Materials: Cement Concrete .......................................................................................................................... M4.02.00 High Performance Cement Concrete ................................................................................... M4.06.1 Reinforcing Steel .......................................................................................................................... M8.01.0 Epoxy Coated Reinforcing Bars ............................................................................................. M8.01.7 Galvanized Reinforcing Bars ................................................................................................... M8.01.8 Mechanical Reinforcing Bar Splicer ..................................................................................... M8.01.9 Stay -in-Place Bridge Deck Form ............................................................................................ M8.21.0 Preformed Expansion Joint Filler .......................................................................................... M9.14.0 Preformed Bituminous Fiber Joint Filler .......................................................................... . M3.05.3 Preformed Compression Joint Seals (Bridges) ................................................................ M9.14.1 Polyurethane Joint Sealer (Flow Type) .............................................................................. M9.14.3 Polyurethane Joint Sealer (Non -Sag Type) ....................................................................... M9.14.4 Bonded Closed Cell Joint System ........................................................................................... M9.14.6 Plastic Water Stops ..................................................................................................................... M9.07.0 Curing Materials Impervious Liquid Membrane ........................................................................................ M9.06.5 Waterproof Paper ................................................................................................................ M9.06.0 Burlap ....................................................................................................................................... M9.06.3 White Polyethylene for Curing ....................................................................................... M9.06.1, Part B Polyethylene Coated Burlap ................................................................................................. ... M9.06.4 Concrete Penetrant/Sealer ...................................................................................................... M9.15.0 II.453 202 4 Edition Metal Masonry Plate Bearing Pads Rubber - Cotton Duck Bearing Pad ............................................................................. .. M9.16.1 Molded Fabric Bearing Pad .............................................................................................. M9.16.2 For any project that requires the placement of cement concrete for structural purposes, the Contractor shall supply to the project for the use of the Engineer the following equipment as an incidental item, if not already provided for in a previous section.
M 205M/M 205. The standard concrete cylinder shall be 6 in . in diameter by 12 in . high for regular Cement Concrete. When the nominal maximum size of the coarse aggregate does not exceed 1 in ., 4 in . in diameter by 8 in . high cylinders may be used.
diameter and approximately 2 ft long to prepare 6 -in. diameter concrete cylinders; small rod, ⅜ -in. diameter and approximately 12 in . long to prepare 4 -in. diameter concrete cylinders.
hemispherical tip of ⅝ -in. diameter. The minimum length shall be 2 ft.
hemispherical tip of ⅝-in. diameter. The minimum length shall be 18 in.
temperature measuring device shall conform to the requirements of AASHTO T 309. CONSTRUCTION METHODS
901.60: Footings
No concrete shall be placed until after the Engineer has approved the depth and dimensions of the excavation, the character of the material and the condition of the foundation. No footing shall be supported partially on rock and partially on soil. The rock shall be excavated as necessary to allow the placement of gravel borrow in accordance with Subsection 140: Excavation for Structures . The II.454 202 4 Edition Engineer may direct, in writing, such changes in dimensions or elevations of footings as may be necessary to obtain satisfactory foundations. The Plans will be revised accordingly. Shallow foundations (i.e., not supported by driven piles, drilled shafts, or other deep foundations) to be constructed under water shall be inspected prior to the placement of tremie concrete by a Diver hired by the Contractor independently and solely for the purpose of the inspection requirements of the Contract. The Diver shall be a Professional Engineer registered in the Commonwealth of Massachusetts. In general, the Diver's tasks shall include inspection of the excavations for foundations to determine their completeness and suitability for the placement of concrete, inspection of the drilling and grouting operations for any dowels that may be specified, and inspection of the tremie placement operations to ensure that the concrete placement is proceeding properly and is completed in accordance with applicable contract documents. The Diver shall be responsible to report any discrepancies in materials or workmanship to the Engineer. The Diver shall record their findings by written and photographic methods and a final report of findings, recommendations and actions taken shall be prepared for the Engineer.
901.61: Forms, Falsework, and Centering
Approved centers and forms shall be provided by the Contractor. Piles shall be used for falsework if required by the Engineer. No extra compensation for falsework or falsework piling shall be allowed, such work shall be considered part of the form work. Falsework shall be set to give the structural camber indicated on the plans or as specified, plus allowance for shrinkage, shortening under load or settlement. Forms, falsework, and centering shall be designed for a liquid head, equal to the maximum height of the liquid concrete in the forms for various placing conditions assuming the load of the liquid concrete to be 150 pcf , and in addition thereto a live load allowance of 50 psf on horizontal surfaces. All falsework or centering shall be adequate for the type of construction involved. The Contractor shall submit all shop drawings for falsework and centering, including design computations, formally signed and sealed by the Contractor's Massachusetts registered Professional Engineer. The Contractor's Professional Engineer shall certify that the falsework system has been assembled and constructed according to the approved falsework drawings, prior to placing loads on such falsework. When structures are to be constructed over railroad tracks, the centering shall also conform to the requirements of the Railroad Company as to temporary operating clearances, safety and design. Forms for all exposed portions of bridges and structures shall be lined with approved material, or form sheathing which shall consist of five -ply water -proof plywood, approved metal sheathing or other approved material in order to give the concrete a smoot h even finish and uniform appearance. This requirement shall not apply to any part of a structure that will be at least 2 ft below the surface of adjacent ground in the completed project that will not be coated with bituminous damp -proofing. Any material that will provide tight forms will be acceptable for such locations. Full sheets of plywood or other approved material shall be used wherever possible and shall be placed in a regular pattern. The use of small pieces and leftovers will not be permitted except as II.455 202 4 Edition they may be needed to complete the design. Forms in good condition may be reused, but forms for any one exposed face shall be all new or all used material and a mixture of old and new forms will not be permitted. Forms for cylindrical pier columns shall be smooth and reasonably free of joints. The sheathing shall be jointed tightly to prevent leakage from the mix and it shall be of sufficient strength to hold the concrete without bulging between supports. Forms shall be properly braced and tied so as to maintain proper dimensions. Bolts, rods, o r other approved form ties shall be used for internal ties. Wire ties will not be permitted except when directed or where concrete is not exposed to view. The Engineer may require the Contractor to employ screw jacks or hard wood wedges in connection with the centering of falsework in order to take up any distortion or settlement in the form work either before or during the placing of the concrete. Approved inserts required for form and/or falsework support shall be used in connection with all ties in the region of exposed surfaces on the concrete. They shall be so designed as to permit their removal from the concrete without injury to the concrete, and the metal remaining in the concrete shall be no closer than 1.5 in . to the surface. The inserts shall be truly round, not more than 1.5 in . in outside diameter and shall be treated with non -staining mineral oil or other satisfactory material adequate for preventing any adherence to surrounding concrete. Special tools and methods shall be used to remove the inserts from the concrete in a manner to prevent damage to the concrete. All ties and embedded devices required for form and/or falsework support tha t are to be left in place shall be either epoxy coated or galvanized to match the reinforcement within the concrete placement. Galvanizing of such ties and embedded hardware shall be in accordance with 960.64: Galvanizing . Form ties of a design with a weakened section 1.5 in . back from the concrete face may be used at places of minor pressure when permitted by the Engineer, but such ties shall be provided with special inserts so as to assure the breaking off of the ties at the proper depth inside the face of the concrete. When such ties fail to break off at the designed depth, the tie metal shall be drilled out before the tie hole is patched. Voids and forming accessory holes shall be patched as necessary to match the surroun ding texture and color to produce a uniform appearance. The use of wooden struts within forms, or of metal ties without approved inserts, as required, will not be permitted. The centers shall be true to the lines, satisfactorily supported and firmly secured. They shall remain in place as long as directed and shall be replaced with new ones if they lose their proper dimensions and shape. Forms for the roadway deck slabs shall be so construed that under full dead load, the thickness of the slabs shall be the required thickness shown on the plans and the surface of the pavement will accurately conform to the profile grades, cross sections an d alignment shown on the plans. Allowance shall be made for the camber of the floor members as erected and for the additional dead load deflections of the floor members. Slab haunches shall be provided over steel girders, floor beams or stringers. The depth of haunches shall be variable as required to maintain the uniform thickness of slab between the steel supports. All exposed edges and corners of concrete not otherwise specified on the plans shall be formed with a wooden triangular 45° chamfer strip, ¾ in. on the square sides. These triangular chamfer strips shall be machine surfaced on all sides and shall be of uniform dimensions throughout the project. II.456 202 4 Edition Any chamfered or beveled corners of concrete specified on the plans of larger size shall be formed and finished as required for other parts of the adjacent forms. Surfaces of the abutments and wingwalls that are designated to receive striation texturing shall be cast using one of the following fractured fin form liner patterns:
GREENSTREAK, 3400 Tree Court Industrial Blvd., St. Louis, MO 63122
shown on the Plans. The same form liner pattern must be used exclusively for all textured surfaces on the job. Using form liners of different manufacturers together on the same job will not be permitted. Form liners shall be installed to the limits as shown on the Plans. The Contractor shall ensure that the striation fins are plumb. Horizontal joints are not allowed in the form liner. Form liners shall be used and installed in accordance with the manufacturer's written instructions and recommendations. Additional job site training in the proper use of the form liner shall be provided by an authorized manufacturer's representative at no additional cost to the project. A test panel with a minimum size of 4 ft x 4 ft shall be erected at the job site for establishing acceptance criteria for the finished surface. Bridge bearing anchor bolts in piers shall be set accurately by a template prior to placing concrete. Anchor bolts in abutments may be set by a template or by drilling and grouting. Grout shall be a non- shrinking type approved by the Engineer. The shape, strength, rigidity, water -tightness and surface smoothness of re -used forms shall be maintained at all times. Any warped or bulged lumber must be resized before being used. Forms that are unsatisfactory in any respect shall not be used and shall be removed immediately from th e work. The inside of forms shall be coated with non -staining mineral oil or other approved material to prevent adherence of the concrete to the forms, immediately before placing the concrete. When oil is used, it shall be applied before the reinforcing steel is placed. Any material that will adhere to, discolor or affect the concrete in any manner shall not be used. Forms for bridge decks shall not be oiled but shall be dampened with water ahead of concrete placement. In the construction of copings, railings and other intricate sections, extreme care shall be taken in the construction to insure true lines. Prior to placing concrete in the forms all foreign matter and any extraneous materials shall be removed. Forms shall be inspected immediately preceding and during the placing of the concrete. All dimensions shall be checked carefully and any errors, bulges, warping or other defects shall be remedied before any concrete is placed. II.457 202 4 Edition Temporary openings shall be provided for inspection at the base of the column and wall forms and near the bottom of all deep members. The foregoing specifications for forms as regards to design, mortar -tightness, chamfers or moldings, bracing, alignment, treatment by coating with oil or other approved material, removing and reuse, shall apply to metal forms when such forms are approved for use. The metal forms used shall be of such strength that the forms will remain true to shape. All bolt and rivet heads shall be countersunk. Clamps, pins or other connecting devices shall be designed to hold the forms rigidly together and to allow removal without injury to the concrete. Metal forms which do not present a smooth surface or which do not line up properly shall not be used. Special care shall be exercised to keep metal forms free from rust, grease or other foreign matter that will tend to di scolor the concrete. Metal forms shall be provided with an adjustable metal section or occasional sections where wooden forms may be inserted to compensate for slight inaccuracies in measurement. Removable or stay -in-place forms for bridge decks may be used as alternates except in hazardous locations where stay -in-place forms shall be used. Hazardous locations are defined as high volume roadways and all railroads under the bridge. Removable forms shall be used for forming end diaphragms, bays with longitudinal construction joints, and overhanging portions of decks. Material to prevent concrete from adhering to the forms shall not be used when stay -in-place forms are used. Design of Permanent Steel Bridge Deck Forms. The following criteria shall govern the design of permanent steel bridge deck forms:
plastic concrete plus 50 psf for construction loads. The unit working stress in the steel sheets shall not be more than 0.725 of the specified minimum yield strength of the material furnished, but not to exceed 36,000 psi .
loading be less than 120 psf total. The permissible form camber shall be based on the actual dead load condition. Camber shall not be used to compensate for deflection in excess of the foregoing limits.
measured parallel to the form flutes.
American Iron and Steel Institute Specification for the Design of Cold Formed Steel Structural Members, latest published edition.
II.458 202 4 Edition 7. Permanent steel bridge deck form shall not be considered as lateral bracing for compression flanges of supporting structural members.
locations where the forms are supported by steel beam flanges subject to tensile stresses. All forms shall be installed in accordance with approved fabrication and erection plans. Form sheets shall not be permitted to rest directly on the top of the stringer or floor beam flanges. Sheets shall be securely fastened to form supports and shall have a minimum bearing length of 1 in . at each end. Form supports shall be placed in direct contact with the flange of stringer or floor beam. All attachments shall be made by permissible welds, bolts, or clips of other approved means. However, welding of form supports to flanges of steels not considered weldable and to portions of flange subject to tensile stresses shall not be permitted. Welding and welds shall be in accordance with the provisions of AWS D1.3 pertaining to fillet welds except that ⅛ -in. fillet welds will be permitted. Any permanently exposed form metal where the galvanized coating has been damaged shall be thoroughly cleaned and painted with galvanizing repair paint in accordance with 960.64: Galvanizing . Minor heat discoloration in areas of welds need not be touched up. The Contractor’s method of construction should be carefully observed during all phases of the construction of the bridge deck slab. These phases include installation of the metal forms; location and fastening of the reinforcement; composition of concrete items; mixing procedures, concrete placement and vibration; and finishing of the bridge deck. Should the Engineer determine that the procedures used during the placement of the concrete warrant inspection of the underside of the deck, the Contractor shall remove at least one section of the forms at a location and time selected by the Engineer for each span in the contract at no additional cost to the project. This should be done as soon after placing the concrete as practicable in order to provide visual evidence that the concrete mix and the Contractor’s procedures are obtaining the desired results. An additional section shall be removed at no additional cost to the project if the Engineer determines that there has been any change in the concrete mix or in the Contractor’s procedures warranting additional inspection. After the deck concrete has been in place for a minimum period of 2 days, the concrete shall be tested for soundness and bonding of the forms by sounding with a hammer as directed by the Engineer. If areas of doubtful soundness are disclosed by this procedure, the Contractor will be required to remove the forms from such areas for visual inspection after the pour has attained adequate strength. This removal of the permanent steel bridge deck forms shall be at no cost to the project. At locations where sections of the forms are removed, the Contractor will not be required to replace the forms, but the adjacent metal forms and supports shall be repaired to present a neat appearance and assure their satisfactory retention. As soon as the form is removed, the concrete surfaces will be examined for cavities, honeycombing and other defects. If irregularities do not justify rejection of the work, the concrete shall be repaired as the Engineer may direct and shall be given an Ordinary Surface Finish, in accordance with the contract specifications. If the concrete where the form is removed is unsatisfactory, additional forms, as necessary, shall be removed at no II.459 202 4 Edition additional cost to the project to inspect and repair the slab, and the Contractor’s methods of construction shall be modified as required to obtain satisfactory concrete in the slab. All unsatisfactory concrete shall be removed or repaired as directed by the Engineer. The amount of sounding and form removal may be moderated, at the Engineer’s discretion, after a substantial amount of slab has been constructed and inspected, if the Contractor’s methods of construction and the results of the inspections as outlined above indicate that sound concrete is being obtained through the slabs. The Contractor shall provide all facilities as are reasonably required for the safe and convenient conduct of the Engineer’s inspection procedure.
901.62: Reinforcement
The Contractor shall submit for approval detailed shop drawings and schedules of the reinforcing bars so that the reinforcement may be properly placed, and its mass readily computed. Coated bars shall be either epoxy coated or galvanized, as specified on the plans. Where coated bars are called for without distinction, they may be either epoxy coated bars or galvanized bars, however mixing epoxy coated and galvanized bars will not be permitted. Where coated bars are used in combination with uncoated bars in a reinforcing mat or cage and the coated bars will touch or be tied to uncoated bars with wire ties, only epoxy coated bars shall be used. All support devices and ties for galvanized bars used in deck reinforcing shall be coated so that there is no electrical continuity either between reinforcing mats or between the reinforcing and the stay -in-place forms or steel beams. All support devices and ties for epoxy coated bars used in deck reinforcing shall be either epoxy coated or coated with a plastic material compatible with the coating of the reinforcement. All coated and un -coated reinforcing bars shall be stored above the surface of the ground on platforms, skids, or other supports and shall be protected from mechanical injury and surface deterioration caused by exposure to conditions producing rust. When placed in the work, reinforcing bars shall be free from dirt, loose rust or scale, mortar, paint, grease, oil, or other non - metallic coatings that reduce bond. Reinforcing bars shall be free from injurious defects such as cracks and laminations. Any injurio us defects of the epoxy coating shall be repaired and allowed to cure completely prior to concrete placement. Epoxy coated reinforcing bars shall be coated in a certified epoxy coating applicator plant in accordance with the Concrete Reinforcing Steel Institute’s Voluntary Certification Program for Fusion -Bonded Epoxy Coated Applicator Plants. Epoxy coated reinfor cing steel shall be handled and stored by methods that will not damage the epoxy coating. All systems for handling epoxy coated reinforcing bars shall have adequately padded contact areas. All bundling bands shall be padded and all bundles shall be lifted with a strong back, multiple supports, or platform bridge so as to prevent bar to bar abrasion from sags in the bundle. Bars or bundles shall not be dropped or dragged. Epoxy coated reinforcing bars shall be stored on wooden or padded supports. Epoxy coated reinforcing steel shall be protected from sunlight, salt spray, and exposure to the weather. Provisions shall be made for continuous air circulation around the coated reinforcing to minimize condensation under the protective covering. II.460 202 4 Edition If it is impractical to obtain or use bars of the full length required, the bars shall be lapped for the length shown on the plans or joined with mechanical splicers. If no lap length is provided, the lap length shall be calculated for the type of bar used according to the latest AASHTO Standard Specifications for Highway Bridges for a Class C tension lap splice. If mechanical splicers are used proper consideration shall be given to the installation sequence and shall be so noted on the reinforcing steel shop drawings. The mechanical splicing system shall be assembled in accordance with the manufacturer’s recommend ations. Reinforcement bars to be spliced mechanically shall be marked using indelible ink prior to splice attachment to ensure sufficient embedment in the splicing device. Assembly features shall provide for reasonably error free work under construction conditions. Mechanical reinforcing bar splicers shall be staggered in accordance with the Plans. The entire splice area of epoxy coated mechanical splicing systems shall be painted with a compatible approved epoxy repair coating after the system is assembled. The entire splice area of galvanized splicing systems shall be painted with a compatible appr oved galvanizing repair coating after the system is assembled. For mechanical splicer systems that cannot be effectively sealed with an epoxy or galvanizing repair coating, an approved heat shrink tube/sleeving shall be required after installation to seal the system. The mechanical splicer shall not be encased in concrete until the visual inspection and the required testing have been completed and approved by the Engineer. The steel shall be bent in the shop true to templates and shall be placed accurately as shown on the plans with the following tolerance:
The minimum spacing cannot be decreased. The reinforcement shall be placed so as to ensure it remains in the correct position during the placing and hardening of the concrete. The clear distance between spliced bars and/or splicing devices shall not be less than 1.5 times the nominal diameter of the bars, 1.5 times the maximum size of the coarse aggregate, nor less than 1.5 in. The required distance between reinforcing steel and the forms shall be maintained by means of stays, blocks, ties, hangers or other approved supports. The spacing of reinforcing supports shall not exceed 4 ft. Steel reinforcing mats shall be firmly secured against displacement by tying every other intersection point with a maximum of 12 in . between tied joints. In addition, steel reinforcing mats (top and bottom) shall be securely connected together so that uniform vertical spacing can be maintained throughout. This connection may be accomplished by tying with coated tie wires or other means as approved by the Engineer. Connections between the top and bottom mats of reinforcement shall be placed no farther apart than 4 ft on center. Support devices may be utilized for this purpose. Connection devices shall neither deflect the steel reinforcing nor interfere with the smooth flow of concrete. Blocks for holding reinforcement from contact with the forms shall be precast mortar blocks of approved shape and dimensions. Blocks for spacing reinforcing bars shall also be precast mortar blocks of approved designs and short enough to permit their ends to be adequately covered with concrete. The precast mortar blocks shall be made from the same materials and of the same II.461 202 4 Edition proportions of sand and cement as that of the concrete in which they are to be used. They shall be cast and properly cured before use and shall have a wire of copper or other non -rusting metal or other approved device cast into each block suitably placed so that the block can be securely fastened to the reinforcement. Layers of bars, except for those placed in bridge decks, shall be separated by such blocks, which may be reinforced, and which shall have slots to receive the bars and hold them in place, or b y other approved means. Any parts of metal supports that are left in place within 3 in . of an exposed surface of the concrete shall be made of either non -rusting metal, or shall be epoxy coated or galvanized to match the reinforcement. Galvanizing of such parts shall be in accordance with 960.64: Galvanizing . The use of pebbles, pieces of broken stone, metal pipe or wooden blocks will not be permitted. Reinforcement in any member or section shall be in place and approved by the Engineer before the placing of concrete begins. In no case shall reinforcing steel be driven or forced into the concrete and any reinforced concrete placed in violation of this pr ovision will be rejected by the Engineer, and then shall be removed and replaced by the Contractor entirely at their own expense. When wire mesh is used as reinforcement, it shall be furnished and placed in accordance with the plans. If the wire mesh is shipped in rolls, it shall be straightened into flat sheets before being used. Dowels, where required, shall be furnished and placed as indicated on the plans and as directed. Reinforcement that extends continuously within the concrete of the substructure and the concrete of the superstructure, or any other reinforcement that might stain the exposed surface of the bridge shall be given a light coat of neat cement grout on the surfaces of the reinforcement that will be exposed for more than three weeks before being encased in concrete. Subsequent coats of grout may be required.
901.63: Handling and Placing Concrete
The Contractor shall notify the Engineer at least 24 hours in advance of their intention to place concrete in order to provide ample time for inspection of forms, reinforcement, materials, and equipment. All concrete shall be placed during daylight, and the placing of concrete shall not be started unless it can be completed and finished during daylight hours, except that when an adequate and approved lighting system is provided beforehand, the Engineer may waive this requirement. No concrete shall be placed in a bridge or other structure where piles are required until all piles in the structure have been driven. However, the placing of concrete in the steel shells for cast -in-place concrete piles and steel pipe piles shall be done as specified in 940.69: Placing and Protecting Concrete Filled Piles . No concrete shall be placed until the depth, character and water conditions of the foundations, the adequacy of falsework and forms, the absence of debris in the forms, the condition of the construction joints, and the condition and spacing of the reinforcing steel have been inspected and approved by the Engineer. The placing of concrete shall be so regulated that the pressures caused by the wet concrete shall not cause distortion or movement of the forms. II.462 202 4 Edition The placement and consolidation of the concrete shall be conducted so as to not cause segregation of materials nor displacement of reinforcement and shall result in a dense homogeneous concrete that is free of voids. Concrete shall be deposited in such manner that the total deflection or settlement of supporting members and the final finishing of the surface shall have occurred before initial set of the concrete takes place. An approved admixture shall be used as necessary to retard setting.
The concrete shall be transported from the mixer and placed in the forms by a method that will permit handling concrete of the slump required without segregation. Buggies and wheelbarrows used for this purpose shall be equipped with pneumatic tires. Chutes may be used but the use of long chutes will be permitted only on authority from the Engineer. If such conveyors are allowed and the quality of the concrete as it reaches the forms or the methods of placing or working it therein are not satisfactory, the Engineer may order their use discontinued and the substitution of a satisfactory method of placing. Chutes shall be constructed of aluminum free metal or metal lined and shall extend as nearly as possible to the point of concrete placement. Long chutes shall be provided with reverse flow or remixing hoppers in order to correct for segregation. All chutes shall be kept clean and free from coatings of hardened concrete. Concrete shall not be permitted to be transported through chutes or pipes composed of alumi num. Transportation of concrete by pumping will be permitted provided that the required slump or air content can be maintained at the discharge end of the hose and there is no adverse effect to the mix design. Concrete shall be sampled and tested at the end of the chute or if pumping is allowed, from the discharge end of the hose. The equipment shall be suitable in kind and adequate in capability for the work. The operation shall be such that a continuous stream of concrete without air pockets is produced. When pumping is completed, the concrete remaining in the pipeline shall be ejected in such a manner that there will be no separation of the ingredients. Pumping through aluminum pipes will not be permitted. All pipes and chutes shall be kept clean and free from coatings of hardened concrete.
The concrete shall be placed in the form in the approved manner to prevent stone pockets, voids or segregation and to reduce handling and flowing in the forms to a minimum. The concrete shall not be dropped more than 3 ft or dragged more than 10 ft in the forms. Vibrators shall not be used to transport concrete. Epoxy coated steel reinforcement shall be protected from damage from dropping concrete by limiting the maximum height of concrete drop to 2 ft . Points of deposit shall be spaced not more than 20 ft apart nor more than 10 ft from the ends of the forms. Concrete shall be properly distributed in the forms by hand shoveling. The forms shall be filled at a rate of 1 to 3 ft in depth per hour. Care shall be taken to avoid splashing the forms and reinforcing above the level of the concrete as placed. Beams and slabs shall be placed in one continuous operation.
Each layer shall be thoroughly consolidated by rodding and vibration. The face of the forms shall be carefully spaded, if possible, to bring a dense mortar to the face, and produce a good finish. II.463 202 4 Edition All concrete for structures shall be compacted by means of approved mechanical vibrators operated within the mass of the concrete. The Contractor shall provide approved methods of vibration to fully consolidate the mix. Vibrators shall be of internal type of standard make and approved capacity, and shall be capable of transmitting vibrations within the concrete at frequencies of not less than 5,500 vibrations per minute nor more than 13,500 vibrations per minute. Epoxy coated steel reinforcement shall be pr otected from damage from exposed steel headed immersion -type vibrators. Immersion -type vibrators used to consolidate concrete that is reinforced with epoxy coated reinforcement shall feature heads covered with rubber or other resilient non-metallic material approved for concrete consolidation. Vibration of forms or reinforcing shall not be permitted except where internal vibration is not practicable and then only with the approval of the Engineer. The vibrator shall be applied directly to the concrete mass at the point and time of deposit and shall be moved throughout the mass continuously from point to point for a sufficient duration to accomplish thorough consolidation. The duration of vibration shall not be prolonged to the point where segregation, serious loss of entrained air, or excessive water bleeding occurs. Vibrators shall not be used close to the forms. When concrete is placed in lifts, vibrators shall be inserted into at least half the depth of the underlying lift so as to thoroughly consolidate the two lifts into an integral mass without streaks or hardened lift lines. Vibrators shall not be used to move concrete in the forms. A sufficient number of vibrators shall be provided to obtain proper compaction in accordance with the rate of deposit. Extreme care shall be taken to prevent penetrating or disturbing previously placed concrete that has become partially set.
Concrete may be deposited in water only when provided by the plans or in the Special Provisions or by approval in writing by the Engineer; and only under the direct supervision of the Engineer. The concrete shall be of the designation required except that an additional 10 percent of cement shall be added to all concrete deposited under water except that mass concrete shall be placed with the cement content required by Special Provisions. The method and equipment to be used shall be approved by the Engineer before work has begun. Concrete deposited under water shall be carefully placed by the tremie method in a compound mass in its final position and shall not be disturbed after being deposited. Special care must be taken to maintain still water at the point of deposit. No concrete shall be placed in running water and all form work designed to retain concrete under water shall be watertight. The consistency of the concrete shall be carefully regulated, and special care shall be taken to prevent segregation of the materials. The concrete shall be distributed uniformly over the entire area between forms in order to maintain a level surface. The work shall be carried out in a continuous operation with sufficient rapidity to prevent the formation of layers or inclined seams. Concrete shall not be placed in water having a temperature II.464 202 4 Edition below 35°F. Pumping of water will not be permitted while the concrete is being deposited nor before it is sufficiently hardened. The tremie shall be watertight, consisting of a tube constructed in sections with flange couplings fitted with gaskets, and the inside diameter shall be sufficiently large to permit a free flow of concrete. The spacing of tremie tubes shall not exceed 20 ft on centers or 10 ft from the forms. Tremie tubes shall not be moved horizontally or the seal purposely broken once placing of concrete has started. The radius of influence of a tremie shall not be assumed to exceed 10 ft . The means of supporting the tremie shall be as such as to permit it to be rapidly lowered when necessary to retard or stop the flow of concrete. The discharge end shall be closed at the start of the work so as to prevent water from entering the tube and shall be kept entirely sealed at all times and the tremie tube kept full to the bottom of the hopper during the depositing of the concrete. When a batch is dumped into the hopper the t remie shall be slightly raised, but not out of the concrete at the bottom, until the batch discharges to the bottom of the hopper. The flow shall then be stopped by lowering the tremie. Special care shall be taken to maintain as nearly as practicable a uni form flow and to avoid dropping the concrete through the water. The flow shall be continuous until the work is completed. If the charge is lost during depositing, the tremie shall be withdrawn and refilled. Dewatering may start when the concrete seal has reached a compressive strength of 1,200 psi. All laitance and scale shall be removed so that sound, durable concrete is exposed to the area on which the construction is to be based and shall be leveled off with epoxy bonded concrete or mortar.
Concrete structures so located as to be subjected to the action of sea water shall be constructed in a manner to provide a maximum resistance to its disintegrating action. The concrete shall conform to M4.06.1: High Performance Cement Concrete. The water content shall be carefully controlled and so regulated as to produce concrete of maximum impermeability. In placing concrete, care shall be taken to avoid the formation of pockets and the concrete shall be thoroughly compacted to the satisfaction of the Engineer. The original surface of the concrete shall be left undisturbed. In order to secure a thick and dense surface film, the surfaces of the forms shall be heavily coated with shellac or an approved form oil. The range of possible disintegration of the concrete from an elevation below that of low tide to an elevation above that of extreme high tide shall be determined by the Engineer, and, except with their special permissi on, no construction joints shall be located within this range. In the determination of this range, due consideration shall be given to wave action, ice formation and other conditions affecting the extreme limits of possible deterioration and disintegration . Concrete in sea water within the range as above determined shall, except when especially provided for by the plans or in the Special Provisions, be deposited in the dry and no sea water shall be allowed to come in direct contact with the concrete for at le ast 30 days after placement. II.465 202 4 Edition 901.64: Protection from Adverse Weather Suitable precautions shall be taken to thoroughly protect the concrete from any damage by adverse weather conditions during and after placement.
During hot dry weather, and as directed, all new concrete shall be kept shaded from the sun, shielded from the wind and kept wet with water, or protected by other approved methods to retain the moisture in the concrete throughout the curing period. During concrete placement operations in hot weather, appropriate measures shall be taken to reduce the hazards of increased rate of cement hydration, flash set, loss of water due to evaporation, high concrete ingredient temperatures, and the increased difficulty of concrete placing and finishing. The following requirements shall be met during concrete placement operations in hot weather:
exceed 90°F.
stockpile. Chipped or crushed ice may be used in the mix as a portion of the mixing water on a pound for pound basis, provided such measure is determined at the time it is placed in the mix. If used, all ice shall be melted before the batch is dischar ged from the mixing unit. Water may also be cooled by refrigeration or other means that provide a uniform mixing water temperature.
sufficient skilled men and adequate equipment to place the concrete without delays which may cause excessive slump loss and evaporation due to over -mixing or exposure before it is placed.
that curing may begin as soon as possible.
During rainy weather all new concrete shall be properly covered, as may be necessary to prevent damage. Sufficient approved material for covering shall be available at the site of the work for immediate use as may be needed.
Cold weather is defined as any time during the concrete placement or curing period the ambient temperature at the work site drops below 40°F or the ambient temperature at the site drops below 50°F for a period of 12 hours or more. Any concrete placed durin g cold weather shall be placed at the Contractor’s risk and any damage or unsatisfactory concrete shall be removed and replaced at II.466 202 4 Edition the Contractor’s expense. When cold weather is reasonably expected or has occurred within 7 days of anticipated concrete placement, the Contractor shall include as part of their Placement and Curing Plan detailed procedures for the production, transporting , placing, protecting, curing, and temperature monitoring of concrete during cold weather. The Contractor shall include verifiable evidence of satisfactory results obtained by use of their proposed methods. Procedures for accommodating abrupt changes in we ather conditions shall be included. Placement of concrete shall not commence until the plan is accepted by the Engineer. Acceptance of the plan will take at least one day. All material and equipment required for cold weather placement and curing protection shall be available at the project site before commencing concrete placement. All snow, ice, and frost shall be removed from the surfaces, including reinforcement and subgrade, against which the concrete is to be placed. The temperature of any surface that will come into contact with fresh concrete shall be at least 35°F and shall be maintained at a temperature of 35°F or above during the placement of concrete. During the curing period, the Contractor shall provide suitable measures to maintain the concrete surface temperature which shall be monitored by continuously recording surface temperature measuring devices that are accurate within 1.8°F. One temperature measuring device shall be required to be randomly placed in an accessible location for every 1,500 ft² of concrete surface area being cured. The minimum concrete surface temperature requirements indicated in the Table 901.1 shall be continuously maintained for a curing period of at least 7 days. The 7 -day minimum curing period of time will be extended when necessary to develop satisfactory strength in the concrete. Any day during which the minimum concrete surface temperature requirement is not continuously maintained shall not count as a day contributing to the curing period. Table 901. 64-1: Cold Weather Concrete Surface Temperature Requirements Minimum Section Size Dimension (ft) <1 >1, but ≤3 >3, but ≤6 >6 Minimum temperature of concrete during curing period 57°F 54°F 50°F 50°F Maximum allowable temperature drop in any 24 -hour period after end of curing 50°F 40°F 30°F 20°F The mixing water and/or aggregates may be heated (prior to cement being added) by approved methods so that the temperature of the aggregates and water mixture is not less than 70°F nor more than 140°F. The temperature of the concrete shall not be less than 60°F nor more than 90°F at the time of placing it in the forms. The heating shall be done in a manner to preclude the occurrence of overheated areas that might result in damage to the materials. Any material containing frost or lumps of hardened material shall not be used. Insulation shall be approved blanket, batt or board insulation with a thermal conductivity of less than 0.25 BTU per hour per square foot for a thermal gradient of 1°F/in. Insulation shall be applied II.467 202 4 Edition to the forms in an approved manner. Insulation with breaks or tears shall be rejected unless satisfactorily repaired. Openings for thermometers shall be provided where ordered. Where it may be expected that considerable heat will be generated by the hydration of the concrete, and in some cases where heat is not rapidly dissipated, suitable coverings shall be used to protect concrete. Heavy footings in which the concrete is placed at a concrete temperature of 70°F where protection is provided by the surrounding earth, except on top, shall be protected by a tarpaulin placed over the top with an air space between the concrete and the tarpaulin and sufficient added artificial heat shall be provided to maintain the minimum required concrete surface temperature. Mass concrete, when concrete as such is so specified on the plans or so defined by the Engineer, placed at a concrete temperature of 70°F, shall be protected by enclosure with tight wooden forms at least ⅝ in. in thickness except at corners and edges and sufficient added artificial heat shall be provided to maintain the minimum required concrete surface temperature. Double sheathing, insulation board or tarpaulins with a dead air space between the covering and the forms shall be placed to equally protect such corners and edges. Supplemental enclosures and added artificial heat will be utilized when required to maintain the minimum concrete surface temperature. As much as possible, any enclosure for protection shall be in place before depositing of any concrete and the remainder shall be installed as rapidly as possible in order to reduce heat losses to a minimum. Heating within the enclosure shall be attained by such means of artificial heat as will maintain the temperatures specified continuously and with a reasonable degree of uniformity in all parts of the enclosures. All exposed surfaces of concrete within the enclosure shall be kept sufficiently moist to pre vent any drying of the surface concrete with possible resulting damage to the concrete in place. Heating appliances shall not be placed in such a manner as to endanger the enclosure, forms or supports, or expose any area of concrete to drying out or other injury due to excessive temperatures.
901.65: Finishing and Curing
The requirements of this subsection shall be considered applicable to all concrete placements with the exception of bridge deck, bridge sidewalk, bridge safety curb, and bridge median concrete placements. Refer to the requirements specified under 901.66: Placement, Finishing and Curing of Concrete Bridge Decks for bridge deck, bridge sidewalk, bridge safety curb, and bridge median concrete placements.
The external surface of all concrete shall be thoroughly vibrated and spaded during the operation of depositing the concrete by means of tools of an approved type. The vibrating and spading shall be such as to force all coarse aggregate away from the surface and slowly work the mortar against the forms to produce a smooth finish free from water, air pockets, and honeycombing. The use of mortar, cement water mixture, or neat cement for plastering over any concrete surface will not be permitted. The final finish required on particular concrete shall be as follows:
Immediately after forms have been removed and form ties cut back from the face of the concrete, all voids and cavities shall be filled with a stiff mortar of the same composition and air -entrainment as II.468 202 4 Edition the mortar in the original concrete mix. The mortar for filling shall have been mixed and let set for 30 minutes and then remixed before placing in the work. In case the operation of filling is delayed, the surface of the concrete shall be thoroughly cleaned and washed with water, if necessary, before the mortar is applied.
Within 48 hours after the forms have been removed and form ties cut back from the face of the concrete, all fins, projections and irregularities shall be carefully removed and all voids and cavities shall be carefully and completely filled with a stiff mortar of the same composition and air - entrainment as the mortar in the original concrete mix. The same brand and color of cement, and the same kind and color of aggregate as was used in the original concrete mix shall be used in this mortar. The mortar for filling sha ll have been mixed and let set for 30 minutes and then remixed before placing in the work. The surface film of all such pointed surfaces shall be carefully removed before setting of the mortar occurs. If the Engineer determines these surfaces as prepared do not present a uniformly smooth, clean surface of even texture and appearance, the surface shall be treated and rubbed to obtain a satisfactory finish. The Engineer shall be the sole judge of the amou nt of rubbing which will be required. If rubbing is required, the rubbing will start with 48 hours of notification that rubbing is required, the surface should be wetted with clean water and rubbed with a No. 16 carborundum brick or other abrasive of equal quality until even and smooth and of uniform appearance, without applying any cement or other coating. If additional finishing is necessary, it shall be obtained by a thorough rubbing with a No. 10 carborundum brick or other abrasive of equal quality. Subject to approval by the Engineer, rubbing may be performed by use of satisfactory power equipment and tools, providing that the operational procedures shall be the same as those outlined above for hand rubbing. Rubbing will be kept to a minimum found necessary to produce smooth, even surfaces of uniform appearance. Rubbing will not be required to fill very small surface air bubble holes, to remove a uniform wood grain pattern left by forms, nor to remove inconspi cuous lines or marking between form panels. Patches required for form ties, if carefully and properly done, may not necessitate rubbing. If however, this work is done in such a manner that these patches are conspicuous, the entire exposed face on which they occur shall be rubbed. After the final rubbing is completed, and the mortar has set up, the surface shall be thoroughly drenched and kept wet with clean water for a period of 5 days. No rubbing will be permitted when the air temperature is below 40°F.
Bridge seat bearing areas shall be considered to be those areas of the concrete bridge seats of the abutments, piers, and pedestals that support the bridge bearing devices. The limits of the bridge II.469 202 4 Edition seat bearing area shall extend 3 in . outside of the perimeter of the bearing device component that is in contact with the bridge seat. Bearing devices shall not be placed upon bridge seat bearing areas that are improperly finished, deformed or irregular. Bearing devices shall be set to the required grade in the exact positions called for on the plans and shall have full and even bearing upon the bridge seat cement concrete. Satisfactory drainage shall be provided as called for on the plans and where necessary to prevent water accumulation at the bridge seat bearing areas.
The bridge seat concrete as cast shall be finished to the exact final required elevation and to the roadway profile grade slope in the direction parallel to the centerline of construction and to the cross slope set by the bridge seat elevations in the direction parallel to the centerline of bearings.
The surface of the concrete within the limits of the bridge seat bearing area shall be cast a minimum of ¼ in. higher than the required finished elevation. This additional concrete shall be cast monolithically with the rest of the bridge seat concrete and shall be sound and free of voids and laitance. After the concrete has been cured and thoroughly hardened, thes e areas shall be machine dressed down using approved methods to provide a true even surface at the following elevations and grades:
onto the as -finished bridge seat concrete surface, the surface of the bridge seat bearing area shall be dressed down to the exact final required elevation. For bearing devices that utilize a metal masonry plate, the metal masonry plate shall be set on a system of either rubber -cotton duck bearing pads or molded fabric bearing pads and the surface of the concrete shall be dressed down sufficiently below the required finished elevation so that the rubber -cotton duck or molded fabric bearing pad will bring the bottom of the masonry plate to the exact final required elevation.
level in the direction parallel to the centerline of construction and shall be finished to follow the cross slope set by the bridge seat elevations in the direction parallel to the centerline of bearings .
After concrete is placed, the top surface shall be struck off to the proper crown and longitudinal profile with an approved template. Satisfactory supports, furnished by the Contractor, shall be set and maintained in place for proper operation of the template so that the surface shall be furnished to the required elevations. These supports shall be carefully removed from the concrete before any set of the concrete occurs, and the spaces left by such removal shall be immediately filled and finished to the le vel of the adjacent surfaces. The surface shall be checked, by means of an approved straightedge, not less than 10 ft in length, furnished by the Contractor, as the Engineer may direct. II.470 202 4 Edition Any irregularities, measuring more than ¼ in. vertically, shall be corrected and the whole surface shall be made smooth and even. No load of any kind shall be placed on the concrete after setting of the concrete has begun, and any work on the concrete then required shall be performed from approved bridges furnished by the Contractor, which will not rest on the new concrete in any manner.
All concrete shall be kept fully saturated and protected against any drying action by methods of curing specified herein or as otherwise approved by the Engineer for not less than 7 days after placing cement concrete. All surfaces of concrete which are to receive a rubbed surface finish or on which bitumen is to be placed, and concrete at construction joints shall be cured in accordance with requirements below for water curing. All other concrete may be cured in accordance with requirements below for water curing or waterproof membrane curing.
Cement concrete placements where all volumetric dimensions of the placement are 4 ft or greater shall be considered mass cement concrete. Mass cement concrete shall also include cement concrete placements of other dimensions where measures must be taken to mitigate potential cracking caused by heat of hydration when such placements are sp ecifically designated as mass cement concrete on the plans. The Contractor shall perform the following to prevent cracking in mass cement concrete placements: • Limit the temperature differential between the internal (hottest) and external (coolest) temperature of the cement concrete to 38°F and limit the maximum concrete temperature to 154°F. Heat control shall be accomplished through a combination of proper cement concrete ingredient selection to minimize heat generated, pre -placement cement concrete ingredient cooling, post -placement cooling, cement concrete placement rate control, cement concrete surface insulation to minimize heat loss, and providing supplemen tal heat to prevent heat loss. • Submit for review and approval by the Engineer at least 30 days prior to the date of intended cement concrete placement, along with each mix design, a cement concrete heat of hydration analysis and a detailed plan indicating how temperature differential restrictions for mass cement concrete are to be achieved, methods of observing and recording cement concrete temperatures, and methods of applying immediate corrective action should the temperature differential approach 38°F so as to limit the temperature differential to 38°F. • Measure and record concrete and ambient air temperatures on an hourly basis. Install 2 sets of 3 temperature sensors (thermocouples) prior to placement of concrete. Thermocouples shall be installed so that one is located 2 in . from the top of flat placements or side of vertical placements, one is located 2 in . from the bottom of flat placements or other side of vertical placements, and the third is located midway between the first and second thermocouples. The thermocouples shall be aligned vertically for f lat placements or aligned horizontally for vertical placements. For flat placements, one thermocouple set shall be placed in the center of the plan location of the placement and the second set shall be placed in the plan center of one of the quadrants. For vertical placements, one sensor set shall be located at the mid -height of the placement and the other sensor set shall be located at a quarter point. An additional thermocouple shall be placed in a sheltered area that is out II.471 202 4 Edition of direct sunlight, is protected from weather, and shall be used to monitor the air temperature. The thermocouples shall operate in a minimum temperature range of -22°F to 212°F with an accuracy of 1.8°F. The Contractor shall furnish a temperature logger that records the temperatures automatically at intervals not to exceed once per hour, performs digital temperature storage, and prints temperature data to a paper tape. The thermocouples shall be connected to the recording device using Teflon -sheathed wire or shall use wireless technology. The measuring tips of the thermocouples shall be located as far away from the reinforcing steel as is practical. The thermocouple tips shall be supported with wood or plastic dowels. Thermocouple wire, if used, shall be tied to reinforcing steel bars with plastic zip ties. The thermocouple wire, if used, shall be prot ected from abrasion and concrete tools by securing the wire to the undersides of reinforcing steel. Temperature data shall be furnished to the Engineer as required, with a minimum frequency of once per day.
Curing of concrete shall begin by fog spraying immediately upon the disappearance of free bleed water on concrete surfaces not protected by forms. Fog spraying shall continue until the burlap cover has been placed. The amount of fog spray shall be strictly controlled, so that accumulations of standing or flowing water on the surface of concrete shall not occur. Should atmospheric conditions render the use of fog spray impractical, the Contractor shall use plastic covers of suitable weight and securely weighed down, but not directly in contact with the concrete. The covers shall be used only until the initial set has taken place. The burlap covers shall be placed immediately thereafter. On the windward side of the panel being cured, the Contractor shall erect canvas barriers of suitable height when necessary to protect the curing concrete from the direct force of the wind. The area of concrete to be cured shall be covered by wet burlap blankets placed as soon after concrete finishing as the Engineer determines will not cause damage to the concrete surface. However, in no case will the foregoing time period exceed 1 hour after placing of concrete. Fog spray or covers shall be used continuously during this period. The burlap shall be completely saturated over its entire area by being submerged in water for at least 8 hours before the scheduled start of the placement. The burlap shall be drained of excess water prior to application. The burlap shall be free from cuts, tears, uneven weaving and contaminants. The burlap shall be placed such that the edges are lapped a minimum of 6 in. Burlap shall be kept continuously wet and protected from displacement for the entire curing period in a manner acceptable to the Engineer. The materials for the coverings shall conform to the pertinent requirements for the same provided under M9.06.3: Burlap. The coverings shall be kept thoroughly wet by sprinkling with a fine spray of water until they may be removed. Wooden forms without liners, if left in place longer than 2 days after the placing of the concrete, shall be thoroughly wet down at least once each day for the remainder of the required curing period. Formed surfaces shall, after the removal of forms, be cured in like manner for the remainder of the required period, the entire surface of the concrete being thoroughly drenched with water and covered immediately after the forms are removed. Portions of the covering material may be removed temporarily when and as necessitated by any required finishing or waterproofing operation. II.472 202 4 Edition 3. Impervious Liquid Membrane Curing. Immediately after the free bleed water has disappeared on surfaces not protected by forms and immediately after the removal of forms, if such are removed before the end of the required curing period, the concrete shall be sealed by spraying as a fine mist a uniform application of the membrane curing material in a manner as to provide a continuous uniform, water impermeable film without marring or otherwise damaging the concrete. The impervious liquid membrane material used shall conform to the requirements for the same provided under M9.06.5: Impervious Liquid Membrane except that only ASTM C 1315, Type I shall be permitted. The membrane curing shall be applied in one or more separate coats at the rate recommended by the manufacturer. If, in the Engineer’s judgment, discontinuities or pinholes exist or if rain falls on the newly coated surface before the film has dried sufficiently to resist damage, an additional coat of the material shall be applied immediately to those affected areas at the specified rate. If a slight delay in application shall occur, which permits the concrete surface to dry, the surface of the concrete shall be thoroughly moistened with water, immediately prior to the application of the membrane curing material. Application of membrane curing may be delayed for 12 hours if the concrete surface is protected and kept moist by the use of wetted burlap. The membrane compound shall be thoroughly agitated immediately before application. The liquid shall be applied under pressure by means of an approved pressure spray which shall be held not more than 2 ft away from the concrete surface and the spray protected from any wind by suitable means as may be necessary, so as to apply the material directly onto the concrete surface. The sprayed surface film shall be protected from abrasion or damage for the duration of the required curing period. The placing of materials or unnecessary walking on the surface will not be allowed until the film is at least 2 days old; and then only if no damage is caused to the surface film during the required curing time.
used entirely in accordance with the provisions for such under 476.71: Curing , except that the length of time for the curing period shall be as specified herein.
prior to any use in the work.
901.66: Placement, Finishing and Curing of Concrete Bridge Decks
This work shall consist of the placement of concrete bridge decks by using self -propelled finishing machines, all as indicated on the Plans and in accordance with these Specifications.
At least 30 days prior to the proposed start of placing the concrete bridge deck, the Contractor shall submit to the Engineer for approval a Placement and Curing Plan that will specify all of the steps, methods, equipment and personnel that Contractor shall use to construct the concrete deck in compliance with these specifications. Approval of this plan will not relieve the Contractor of the II.473 202 4 Edition responsibility for the satisfactory performance of his/her methods and equipment. The Placement and Curing Plan shall, at a minimum, specify:
deck where it will be placed. This will also include the conveyance equipment, rate of concrete placement and the estimated time for the completion of all concrete p lacement, consolidation and finishing operations up to the start of curing.
the rails and operating the finishing machine. This will include proof of the following minimum operator qualifications for the bridge deck finishing machine:
proposed.
Or, as a substitute for a. and b.:
to approve the setup of the machine and rail system, and the representative shall be present for the entire duration of the placement of the deck concrete using the bridge deck finishing machine.
location of the wet burlap at the work site, the means for conveying the wet burlap to the work bridges and the amount of wet burlap that will be required to completely cover the deck. It shall also include a letter certifying that the fogging equipment produces atomized water droplets with an average droplet diameter of 0.003 in . or less that are uniformly distributed at a rate of at least 0.10 gallons/square foot/hour .
II.474 202 4 Edition A pre -placement meeting shall be held between the Contractor and the Engineer at least 2 weeks prior to the start of any concrete placement for the deck slab. The Contractor and the Engineer shall review all aspects of the approved Placement and Curing Pla n. Twenty four hours before the scheduled start of concrete placement, the Engineer shall verify that all equipment and materials identified in the Placement and Curing Plan are onsite and have been tested to insure that they are in working order and are func tioning as required. Upon the successful completion of this verification, the Engineer shall allow the concrete placement to proceed. If any equipment or material such as burlap is missing or equipment is malfunctioning, the concrete placement operationss hall be canceled and shall not be re -scheduled until such time as the missing equipment or material is delivered to the site or the equipment has been repaired and is demonstrated to be in working order and functioning as required. The Contractor shall be responsible for any costs associated with the cancellation and rescheduling of the concrete placement operation that is due to missing equipment or material or malfunctioning equipment.
The requirements of 901.64: Protection from Adverse Weather, shall be satisfied in addition to the requirement of this section. Cement concrete for bridge decks shall not be placed when the ambient air temperature exceeds 85 ℉ or is expected to exceed 85 ℉ during the placement of the deck. The evaporation rate of the exposed concrete surface shall not exceed 0.15 psf per hour. The deck surface evaporation rate shall be determined in accordance with Figure 901.66 -1, obtained from ACI 305R -10. The contractor shall determine the evaporation rate by measuring the ambient air temperature, relative humidity of the air at the construction site and concrete temperature prior to the placement of concrete and every hour thereafter until the end of the concrete placement, consolidation and finishing operation. Concrete temperature will be taken from the same sample used for slump and air content tests. To document the readings, Form 901.66 Bridge Deck Placement Environment will be provided by the Engineer and shall be filled out by the Contractor and returned to the Engineer. The Contractor must provide suitable equipment and take appropriate actions as approved by the Engineer to maintain limit the evaporation rate to 0.15 psf per hr or less including one or more of the following actions:
portable pressure washers, not attached to the finishing machine, and manually operated by personnel dedicated to performing fogging until the curing cover is applied. Water that drips from the nozzles shall not be allowed to fall onto the concrete that is being cured. The water mist shall be distributed at a rate of at least 0.10 gal/ ft ²/hr. For example, on a deck that is 30 ft wide, the system must be able to apply at least 3.0 gal of water per linear foot per hr. The nozzles must produce an atomized fog mist that will maintain a sheen of moisture on the concrete surface without ponding. The atomized water droplets shall have an average droplet diameter of 0.003 i n. or less. The area of coverage from each nozzle shall overlap all adjacent coverage areas by at least 12 in. II.475 202 4 Edition 2. Construct windscreens or enclosures to effectively reduce the wind velocity throughout the area of placement. If the use of windscreens is required, the windscreens shall consist of canvas barriers of suitable height erected on the windward side of the concrete placement.
such as at night or during early morning hours. Figure 901.65- 1: Deck Surface Evaporation Rate
II.476 202 4 Edition C. Placement. Concrete placement shall take place during daylight and shall not begin unless the Contractor is certain that the placement can be completed and finished, to the satisfaction of the Engineer, during daylight hours. The Engineer may waive this requirement if adequate and approved lighting facilities are provided by the Contractor prior to the start of the deck placement. Before concrete placement operations begin substantial bulkheads or headers shall be shaped to the required deck surface cross -section. In the event of unforeseen circumstances should the concrete placement be forced to cease, sufficient bulkheads shall be installed at locations determined by the Engineer and the concrete placement shall be discontinued. All concrete in place beyond the bulkh ead shall be removed. Concrete placement will recommence only with the approval of the Engineer. The concrete shall be placed as a monolithic unit in a continuous operation between joints. A minimum rate of placement of 35 yd ³ per hour shall be maintained at each finishing machine.
The concrete shall be consolidated by means of approved high frequency internal vibrators (9,000 to 12,500 vibrations per minute in concrete) that shall be applied in a manner to ensure the consolidation of the concrete throughout the full depth of the dec k in advance of the finishing machine. The Contractor shall use rubber vibrator heads or take other approved preventive measures to ensure that the vibrators will not damage the epoxy coated reinforcement. The Contractor shall have approved vibrators in se rvice for each placement operation in accordance with Table 901.66 -1. The backup vibrator shall be fully functional and shall be on site and available in case of equipment failure. Table 901.66- 1: Minimum Number of Internal Concrete Vibrators Required Concrete Placement Rate Number of Vibrators Required to be In Service Total Number of Vibrators Required Including Backup 35 yd3 to 60 yd³ per hr 3 4 Greater than 60 yd³ per hr 4 5 These vibrators shall be in operation in addition to the surface vibratory action from the vibrating pan(s) of the finishing machine. Consolidation by the vibrators shall leave the concrete free from voids and insure a dense surface texture, but the vibration of the concrete shall not be continued so long as to cause segregation or bleeding. A small uniform quantity of concrete shall be maintained ahead of the screed on each pass. At no time shall the quantity of concrete carried ahead of the screed be so g reat as to cause slipping or lifting.
Methods, procedures, and equipment shall be used which will insure a uniform riding surface without over -vibration or segregation of the components of the concrete. The leading edge of freshly placed concrete shall at all times be maintained approximately parallel to the finishing machine. The weight of the finishing machine(s) shall not cause unaccounted deflection of the bridge members or falsework. The machine shall travel on steel rails, pipe or other approved grade II.477 202 4 Edition control, which shall be supported by vertical supports securely fastened in place at a maximum spacing of 2 ft to prevent any appreciable deflection between rail supports. Screed rail supports may be located inside or outside of the placement width. Prior to placing the concrete, screed rails shall be completely in place, and accurately set to insure finishing of the concrete deck surface to the elevations shown on the Plans. The supports for the rails, if embedded in the deck concrete, shall be of the type that can be removed without disturbing the concrete. Screed rails shall be set entirely above the finished surface of the concrete and shall be supported in a manner approved by the Engineer. Where stud type shear connectors are available, welding to the studs will be permitted. Where no studs are available, other means of attaching the screed rail supports shall be provided. No welding will be permitted directly on stringer or girder flanges or cover plates in tension areas, nor in areas subject to stress reversal, for attaching either screed rail supports o f any type. Any welding in compression areas shall be approved by the Engineer. Screed rail supports set in the concrete shall be so designed that they may be removed to at least 2 in. below the surface of the concrete. Voids created by removal of the upper part of the screed rail supports shall be filled with mortar having the same proportions of sand and cement as that of the slab or wearing surface. The mortar shall contain an approved additive in sufficient proportions to produce non -shrink or slightly expansive characteristics. Screed rail supports shall not be treated with parting compound to facilitate their removal. Rails for finishing machines shall extend beyond both ends of the scheduled length for concrete placement. The extended length shall be of sufficient distance to allow finishing machine(s) to clear the concrete to be placed.
For concrete deck placements specified to be less than or equal to 15 ft in width, or less than or equal to 50 ft in total bridge length, the finishing machine shall be a lightweight vibrating screed with the following features:
the rate of travel can be increased, decreased, or stopped.
The finishing machine shall be operated over the full length of the bridge segment to be finished prior to beginning of concrete placement operations. The test run of the self- propelled finishing machine shall be performed in the presence of the Engineer at least 24 hours in advance of the concrete placement with the screed adjusted to its finishing position. During the test run, checks shall be made of the deflection due to the finishing machine, adjustment of guide rails and required covers for slab reinf orcement. The required concrete cover over the top bars shall be checked by riding the screed over the bars and measuring the cover over the slab reinforcement. Discrepancies so found, which are in excess of the tolerances shall be rectified to secure the required concrete cover. All necessary corrections shall be made before concrete placement is begun. II.478 202 4 Edition The rate of concrete placement shall be coordinated with the initial strike -off so that the initial strike -off is never more than 10 ft behind the concrete placement. Sufficient depth checks shall be made behind the machine(s) and along the full length of the span to insure achievement of the required section and reinforcement cover. Improper adjustment or operation of the finishing machine(s) that results in inadequate reinforcement cover or smoothness shall be corrected immediately. Unsatisfactory performance, particularly with respect to the surface smoothness attained, shall be cause for rejection of the equipment and cement concrete placed.
Than 50 Ft. An approved bridge deck finishing machine(s) complying with the following requirements shall be used for consolidating, striking off, and finishing the concrete deck surface for concrete placements greater than 15 ft in width and bridge lengths greater than 50 ft . The finishing machine(s) shall have the necessary adjustments, built in by the manufacturer, to produce the required profile grade, cross -section, and surface smoothness. The supporting frame shall span the section being cast in a transverse direction without intermediate support. The finishing machine(s) shall be self -propelled and capable of forward and reverse movement under positive control. Provisions shall be made for raising all screeds to clear the screeded surface for traveling in reverse. The screed device shall be provided with positive control of the vertical position. The finishing machine(s) shall be self -propelled with two or more rotating cylinder screeds. The rotating cylinder screeds shall rotate in a transverse direction while also traveling in the same direction and shall be operated transversely in overlappings trips in the longitudinal direction not to exceed 6 in. One or more powered augers shall be operated in advance of the screed(s) and a drag (pan type) float shall follow the screed(s). The surface of bridge decks that are to be left exposed without bitumin ous or cement concrete overlays shall receive an artificial turf drag made of molded polyethylene with synthetic turf blades that are approximately 0.5 in. long and with approximately 6,000 blades per ft ² of drag. The artificial turf drag mat shall be removed and replaced with a clean artificial turf drag mat every 10 ft measured along the bridge centerline. The transversely operated rotating cylinders of the finishing machine(s) shall be rotated such that the direction of the rotation of the cylinders at t he surface of the concrete is in accordance with the manufacturer's recommendations. The finishing machine(s) shall be operated over the full length of the bridge segment to be finished prior to beginning of concrete placement operations. The test run of the self- propelled finishing machine shall be performed in the presence of the Engineer at least 24 hours in advance of the concrete placement with the screed adjusted to its finishing position. During the test run, checks shall be made of the deflection due to the finishing machine, adjustment of guide rails and required covers for slab re inforcement. The required concrete cover over the top bars shall be checked by riding the screed over the bars and measuring the cover over the slab reinforcement. Discrepancies so found, which are in excess of the tolerances shall be rectified to secure t he required concrete cover. All necessary corrections shall be made before concrete placement is begun. The rate of concrete placement shall be coordinated with the initial strike -off so that the initial strike -off is never more than 10 ft behind the concrete placement. II.479 202 4 Edition Concrete immediately in front of the power auger(s) of bridge deck finishing machine(s) shall be placed or cut to a depth no higher than the center of the rotating auger(s). The concrete shall be consolidated just prior to the auger strike off. In the case where the vibratory action of the finishing machine does not provide sufficient consolidation in accordance with the rate of placement, the Contractor shall utilize approved high frequency internal vibrators (9,000 to 13,500 vibrations per minute in concr ete) that shall be applied in a manner to secure maximum consolidation of the concrete. Consolidation shall leave the concrete free from voids, but shall not be continued so long as to cause segregation or bleeding. The advance auger(s) shall strike off th e concrete to approximately ¼ in. above the final grade and then the concrete shall be finished to final grade. Improper adjustment or operation of the finishing machine(s) that results in inadequate reinforcement cover or smoothness shall be corrected immediately. Unsatisfactory performance, particularly with respect to the surface smoothness attained, shall be cause for rejection of the equipment and cement concrete placed.
Work bridges supported on the screed rails shall be provided by the Contractor in order to permit access to the surface of the deck for the purpose of finishing, straight -edging, making corrections, and setting curing materials. The Contractor shall furnis h a minimum of two work bridges behind the bridge deck finishing machine, capable of spanning the entire width of the deck and supporting at least a 500-lb load without deflection to the concrete surface. These working bridges shall be available to the Eng ineer for inspection purposes. Workmen will not be permitted to walk in the fresh concrete after it has been screeded. All finishing work, including application of the fog spray and placement of curing mats, shall be performed from bridges supported above the deck surface.
Verification that the completed surface of the deck has been constructed in accordance with the grades and cross slopes specified on the contract drawings shall be made immediately after finishing and again after the deck has been cured. The Contractor shall check the surface of the concrete with a 10 -ft-long metal straightedge operated parallel and perpendicular to the centerline of the bridge. Deck surfaces that are not to be overlaid with 1 in. or more of wearing surface material shall show no deviation in excess of ¼ in. from the testing edge of the straightedge. For deck surfaces to be overlaid with 1 in . or more of wearing surface material, such deviation shall not exceed ⅜ in. The checking operation shall progress by overlapping the straightedge at least one half of the length of the preceding straightedge pass. Any area that requires finishing to correct surface irregularities shall be re -textured which may be performed with a hand -operated texture mat wrapped in a roll or attached to a round or curve d shaped base. In the event that the tolerance is not met when tested after the concrete has hardened, variance in excess of ¼ in. in 10 ft deck surfaces not to be overlaid with 1 in . or more of wearing surface material or ⅜ in. for deck surfaces to be overlaid 1 in . or more of wearing surface material shall be marked and corrected at the Contractor's expense in a manner satisfactory to the Engineer. The Contractor shall correct out of tolerance hardened concrete surface irregularities by the use of concret e planing or grinding equipment that does not damage the remaining concrete or violate minimum cover requirements on steel reinforcement. II.480 202 4 Edition The straightedges shall be furnished and maintained by the Contractor. They shall be fitted with a handle and all parts shall be made of aluminum or other lightweight metal. The straightedges shall be made available for use by the Engineer when requested.
All concrete bridge decks shall be kept wet with clean fresh water for a curing period of at least 14 days after placing of concrete. Curing shall begin by fog spraying during the placing and finishing operations. Fogging shall continue and shall be applied continuously, rather than intermittently, after the finishing operation until wet covering material has been placed over the concrete surface. All bridge decks, medians, sidewalks, and safety curbs shall be water cured only and shall be kept continuously wet for the entire curing period by covering with one of the following systems:
Curing protection shall be applied within 15 minutes after the concrete is deposited and before the surface of the concrete has lost its surface “wetness” or “sheen” appearance. The burlap shall be completely saturated over its entire area by being submerged in water for at least 8 hours before the scheduled start of the placement. The burlap shall be drained of excess water prior to application. The burlap shall be free from cuts, tears, uneven weaving and contaminants. The burlap shall be placed such that the edges are lapped a minimum of 6 in. Continuous burlap wetting shall commence 10 minutes from the time it is placed and shall be kept continuously wet and protected from displacement for the entire curing period in a manner acceptable to the Engineer. The covering of bridge decks, medians, sidewalks, and safety curbs shall be kept continuously wet for the entire curing period by the use of soaker hoses. The soaker hoses shall circulate water continuously and shall be located to insure a completely wet s urface for the entire curing period. The Contractor shall make sure that adequate personnel are available at the site to carry out the placement, screeding, finishing, fogging and curing operations simultaneously. To overcome shrinkage problems, the use of wind screens and sun shades shall be used as conditions require. The application of impervious liquid membrane curing compounds shall not be considered a substitute for achieving the curing of the concrete required by these Specifications. Only in the event of an unavoidable delay during concrete placement shall two coats of an approved curing compound be sprayed on to the concrete that has been deposited and not screeded. The curing compound shall conform to the requirements provided under M9.06.5: Impervious Liquid Membrane , except that only ASTM C 1315, Type I shall be permitted. This curing compound shall later be mixed into the concrete by the finishing machine. Curing compounds shall not be applied to the screeded surfaces of bridge decks. The Contractor shall limit the maximum concrete temperature to 154°F, and control the temperature of the concrete to ensure that it does not fall below 57°F. Heat control shall be accomplished through a combination of proper cement concrete ingredient sele ction to minimize heat generated, pre -placement cement concrete ingredient cooling, post -placement cooling, cement II.481 202 4 Edition concrete placement rate control, cement concrete surface insulation to minimize heat loss, and providing supplemental heat to prevent heat loss. The Contractor shall submit for review and approval by the Engineer at least 30 days prior to the date of intended cement concrete placement, along with each mix design, a plan indicating methods of observing and recording cement concrete temperatures. The Contractor shall measure and record concrete and ambient air temperatures on an hourly basis for at least the first 72 hours after placement or longer during hot or cold weather conditions. The Contractor shall furnish temperature log records of the temperatures that are recorded at a maximum frequency of once per hour. Temperature data shall be furnished to the Engineer as required, with a minimum frequency of once per day.
Cold weather is defined as any time during the concrete placement or curing period the ambient temperature at the work site drops below 40°F or the ambient temperature at the site drops below 50°F for a period of 12 hours or more. When cold weather is reas onably expected or has occurred within 7 days of anticipated concrete placement, the Contractor shall include in their Placement and Curing Plan detailed procedures for the production, transporting, placing, protecting, curing, and temperature monitoring o f concrete during cold weather. Procedures for accommodating abrupt changes in weather conditions shall be included. Placement of concrete shall not commence until the plan is accepted by the Engineer. Acceptance of the plan will take at least one day. All material and equipment required for cold weather placement and curing protection shall be available at the project site before commencing concrete placement. All snow, ice, and frost shall be removed from the surfaces, including reinforcement, against whi ch the concrete is to be placed. The temperature of any surface that will come into contact with fresh concrete shall be at least 35°F and shall be maintained at a temperature of 35°F or above during the placement of concrete. During the curing period, the Contractor shall provide suitable measures to maintain the concrete surface temperature between 57°F and 85°F which shall be monitored by continuously recording surface temperature measuring devices that are accurate within 1.8°F. At least one temperature measuring device shall be randomly placed in an accessible location for every 1,500 ft ² of concrete deck surface area being cured. The minimum concrete surface temperature requirement shall be continuously maintained for the entire 14 -day wet curing period. Any day during which the minimum concrete surface temperature requirement of 57°F is not continuously maintained shall not count as a day contributing to the curing period. If the concrete surface temperature falls below 45°F during the curing period, the structure shall be enclosed, and external heat shall be provided as directed by the Engineer. If external heat is required, the following shall apply:
and then reduced gradually such that the uniform change in temperature does not exceed 5°F in one hour or 18°F in any 24 -hour period. II.482 202 4 Edition If at any time during the curing period the concrete surface temperature falls below 35°F (2°C), the concrete will be inspected by the Engineer for possible damage due to exposure to freezing temperatures. Concrete determined by the Engineer to be damaged due to exposure to freezing temperatures will be considered as being unsatisfactory and rejected. Adequate precautions shall be taken to protect the concrete deck from any damages resulting from severe weather conditions during the curing process.
The final finish required shall be as follows:
shall be smooth without any projections that could puncture the membrane waterproofing or depressions that could retain water.
propelled sawcutting equipment. Transverse grooves shall be sawcut no sooner t han completion of the 14 -day wet curing operation provided that the concrete has reached a compressive strength of 3,300 psi. The grooves shall be rectangular in shape, ⅛ in. wide (+ ¹⁄₁₆ in., -0 in.) and ³⁄₁₆ in. deep (± ¹⁄₁₆ in.). The grooves shall be cu t at a variable spacing measured from the centerline of grooves as follows: ¾ in. , 1 ⅛ in. , ⅝ in. , 1 in., ⅝ in. , 1 ⅛ in. , and ¾ in. in 6-in. repetitions across the width to be grooved in one pass of the mechanical saw device. One 6 -in. sequence may be adjusted by one- quarter sequence increments to accommodate various cutting head widths provided the general pattern is carried out. The tolerance for the spacing of the grooves is ± ¹⁄₁₆ in. The groove sawcutting equipment shall have a depth control device that will detect variations in the surface profile and adjust the cutting head height to maintain the depth of groove specified. The groove sawcutting equipment shall be provided with devices to control the alignment. Flailing type grooving that is uncontrolled and erratic shall not be permitted. Grooves shall be cut continuously across the roadway, perpendicular to the centerline of the roadway, and shall stop 1 f t from the curb line. Grooves shall be continuous across construction joints. At skewed metal bridge deck expansion joints and at the skewed ends of bridge decks, the groove cutting shall be adjusted by using narrow width cutting heads so that all grooves end within 6 in . of the edge of deck joint measured normal to the centerline of joint or end of deck. No un -grooved deck surface greater than 6 in. in width shall remain. A minimum clearance of 1 in . shall exist between the first groove and the end of deck or edge of metal bridge dec k expansion joint. No overlapping or repeating of grooving in the same location by the grooving machine shall be permitted. The pattern of grooving shall be discussed and agreed upon with the Engineer before grooving begins. Debris and residue from the grooving operation shall be continuously removed and disposed of offsite. Residue from grooving operations shall not be permitted to flow into gutters or drainage facilities. The surface of exposed concrete decks shall be left in a washed clean condition that is free from all slipperiness from the sawcutting slurry. A 1-ft wide margin shall be finished adjacent to curbs with a magnesium float. II.483 202 4 Edition I. Sidewalks and Medians on Bridges. After being placed, the horizontal concrete surfaces shall be properly screeded and finished to true grade and surface. The finish shall be with an approved float, followed by light brushing with a fine brush but without the addition of any water to remove the cement film, leaving a fine grained, smooth but sanded texture. The surfaces shall then be cured as specified herein.
901.67: Removal of Forms, Falsework and Loading on Structures
The terms falsework and centering, as used herein, shall include all supports of the actual forms enclosing and supporting the concrete. No external loads of any kind, except as provided for herein, shall be allowed until the members reach at least the designated strengths.
The forms, falsework, and centering for any portion of the structure shall not be removed until the concrete is strong enough, as determined by the Engineer, to avoid possible injury from such removal. Forms, falsework, and centering shall not be removed o r disturbed without the prior approval of the Engineer. Forms, falsework, and centering shall be removed in such a manner as to permit the concrete to uniformly and gradually take the stresses due to its own weight. When test cylinders are taken from the concrete in the members of a structure for the purpose of controlling the timing of form removal operations, the forms shall be left in place until the concrete has attained the minimum percentage of the specified design strength and, regardless of the strength attained, for the minimum period of time with test cylinder testing as designated in the following table. If test cylinders are cast for this purpose, 3 concrete cylinders shall be cast, field cured, and tested by the Contractor at an independent testing laboratory that is certified under the AAP, all at no additional cost to the project. When test cylinders are not taken from the concrete in the members of a structure for the purpose of controlling form removal operations, the minimum days without test cylinder testing designated in the following table shall be used as a guide. The number of days counted shall be measured from the time of the last placement of concrete in the forms or falsework supports and shall exclude days when the surrounding temperature is below 40°F for a total of 4 hours or more. The complete curing process shall be continued after removal of forms, falsework, or centering as required. In order to facilitate any particular finishing operations, side forms carrying no load may be removed 24 hours to 72 hours (depending on weather conditions and type of concrete) after the placing of the concrete has been completed, subject to the approval of the Engineer and with the complete curing process t o be continued as required. II.484 202 4 Edition Table 901. 67-1: Minimum Design Compressive Strengths Structural Member Minimum Percentage of Specified Design Compressive Strength (𝒇𝒇𝒄𝒄) Minimum Days with Test Cylinder Testing Minimum Days without Test Cylinder Testing Free standing walls, columns, and piers 40% 3 days 5 to 7 days Arches 80% 10 days 14 to 28 days Beams, pier cap beams, slabs, and girders with under 20 ft clear span between supports 80% 10 days 14 to 28 days Beams, pier cap beams, slabs, and girders with 20 ft or greater clear span between supports 90% 14 days 21 to 28 days Cantilevered beams, slabs, and girders 90% 14 days 21 to 28 days Where continuous span structures are involved, the forms or falsework shall remain in place until the concrete in every span of the entire group of continuous spans has attained the minimum percentage of the specified design compressive strength. Any defective work discovered after the forms have been removed shall be immediately removed and replaced. If the surface of the concrete is bulged, uneven or show excessive voids or form joint marks that cannot be repaired satisfactorily, the entire secti on shall be removed and replaced. All repairs and renewals due to defective work shall be done at the expense of the Contractor. Any proposal by the Contractor to remove forms, falsework, and centering prior to the concrete attaining the specified minimum percentage of the design compressive strength must satisfy each of the following requirements: The Engineer has reviewed and approved the Contractor’s justifying calculations. The calculations must be based upon the concrete strength from the time of the proposed early removal until the concrete has attained its design strength. The calculations sha ll demonstrate that the capacity of the structure shall not be exceeded by computing the loads, resultant stresses, and deformations to which the concrete and reinforcing steel will be subject to at the time of the proposed removal. The Contractor has had 3 field cured concrete cylinders tested by an independent testing laboratory immediately prior to the start of removal of forms, falsework, and centering, and all of the test results equal or exceed the anticipated strength used in the Contractor’s calculations. The Engineer must accept the field curing of the 3 test cylinders as being representative of the field curing of the production concrete in order for this approval to occur.
Loads shall not be applied to concrete structures until the concrete has, as determined by the Engineer, attained sufficient strength so that damage will not occur. II.485 202 4 Edition Nothing, except for curing materials and related curing equipment and devices, may be carried on bridge decks until the entire 14 -day wet curing operation is completed. A live load not exceeding 5,500 lb, operated at a speed not to exceed 5 mph , may be allowed on bridge deck concrete no sooner than completion of the 14 -day wet curing operation provided that the concrete has reached a compressive strength of 3,300 psi . Full traffic loading shall not be allowed on bridge deck concrete until completion of the 14- day wet curing operation and until the concrete has reached its specified strength. Precast concrete or steel beams or girders shall not be placed on substructure elements until the substructure concrete has attained 70% of its specified strength. When the placement of backfill will cause flexural stresses in the concrete, the placement shall not begin until the concrete has reached not less than 80% of its specified strength.
901.68: Joints
Construction joints not shown on the plans shall not be permitted except in case of emergency as specified in Paragraph D hereinafter. Concrete in structures shall be placed in such a manner that all construction joints shall be exactly horizontal or vertical, as the case may be, and that they shall be straight and as inconspicuous as possible. All concrete placed between construction joints shall be placed in a continuous operation. In order to allow for initial shrinkage, concrete shall not be placed against the second side of the construction joint for at least 3 days after that on the first side has been placed. When making a horizontal construction joint, care shall be taken to have the concrete below the joint as dry as possible and any excess water or creamy material shall be removed before the concrete sets. Within 12 hours after the concrete below the joint has been placed, the top surface shall be thoroughly cleaned by the use of pressurized water blast and wire brushes and all laitance and loose material removed so as to expose clean, solid concrete. Care must be taken not to loosen any of the course aggregate in the concrete. If for any reason this laitance is not removed before the concrete has hardened in place, it shall be removed using such tools and methods as may be necessary to secure the results specified above. Immediately before placing concrete above the joint, the surface of the concrete below the joint that has been cleaned as specified above shall be thoroughly pre -wetted for a minimum duration of 12 hours. On all exposed surfaces, the line of the proposed joint shall be made truly straight by t acking a temporary horizontal straight edge on the inside of the form with its lower edge on the line of the joint and then placing the concrete sufficiently higher than this edge to allow for settlement. Immediately before placing the new concrete, the forms shall be drawn tightly against the concrete already in place. In construction joints, approved waterstops of plastic material shall be placed not less than 3 in . from the face of concrete and shall extend a minimum of 2 .5 in. into the concrete. Prior to the use of plastic waterstops, the manufacturer’s installation instructions shall be furnished to the Engineer. II.486 202 4 Edition B. Expansion Joints. Expansion joints constructed in bridges, walls and other structures shall be of the thickness shown and as located on the plans. The joint filler shall be cut to the same shape as the area to be covered except that it will be ¼ in. smaller along all surfaces that will be exposed in the finished work. The filler shall be fixed firmly against the surface of the concrete already in place in such a manner that it will not be displaced when the concrete is deposited against it. When nece ssary to use more than one piece to cover any surface, the abutting pieces shall be placed in close contact and the joint between the separate pieces shall be covered with a layer of two -ply roofing felt, one side of which shall be covered with hot asphalt to insure proper adhesio n. The ¼-in. spaces along the edges at exposed faces shall be filled with wooden strips of the same thickness as the joint material. These wooden strips shall be saturated with oil and have sufficient draft to make them readily removable after the concrete is placed. Whatever material is used, the exposed edge of the filler shall be the finished edge as it comes from the fabricator in order to avoid exposure of material roughened by cutting. Each piece of filler shall be fastened to the concrete on one side of the joint with a single line of No. 10 gauge insulation nails 3 in. long and 12 in . on centers. Immediately after forms are removed, the expansion joint shall be carefully inspected and any concrete or mortar that has sealed across the joint shall be cut neatly and removed. The outer edge of the joint shall be straight, parallel and satisfactory in appearance. In expansion joints, approved waterstops of plastic material shall be placed not less than 3 in . from the face of the concrete and shall extend a minimum of 4 .5 in. (115 mm) into the concrete, measured from the center line of the joint. Prior to the use of plastic waterstops, the manufacturer’s installation instructions shall be furnished to the Engineer. All surfaces to which sealants are to be applied shall be thoroughly cleaned to remove all loose concrete, dirt, oil, grease, paint, lacquer, rust, scales, bituminous or other foreign materials. Projections of concrete into joint space shall be removed. St eel surfaces shall be sandblasted or mechanically brushed to obtain a bright, clean, metal surface. Loose particles or dirt shall be removed, and the joint shall be dried before application of primer and/or sealer. A bond breaker shall be used so that the joint sealer shall not be placed in direct contact with bituminous material or bituminous filler. A primer shall be used, when so designated in the manufacturer’s instructions. The sealant shall be mixed and applied in accordance with the manufacturer’s instructions. Application shall be made only when air temperature is 50°F or over. The sealant shall be installed in a neat and workmanlike manner to the depth specified on the plans. The sealant surface shall be either flush with, or be not more than, ⅛ in. above adjacent joint surfaces. Any material that does not adhere or bond to the applied surface, or fails to set up properly, will be removed and replaced at the expense of the Contractor. Any material improperly mixed or which sets up before placement will likewise be rejected and be replaced at the expense of the Contractor. Bonded closed cell joints shall consist of a watertight wear resistant joint system located within the joint gap as shown on the plans. The joint system shall be installed after the adjacent concrete II.487 202 4 Edition structures have cured for a minimum of 14 days. The joint seal shall be installed in widths which are 20% to 25% wider than the joint gap defined on the plans. The joint seal shall be uncoiled from the shipping packaging and shall be allowed to reach a rel axed condition prior to installation. The following installation procedure shall be followed:
one minute, and letting the spliced section remain undisturbed for one hour prior to installation;
with the manufacturer’s recommendations;
at the proper depth.
In bonding new concrete to concrete already set, the surface of the concrete shall be thoroughly cleaned, roughened, wetted with clean water, and then flushed with a mortar composed of equal parts of the cement and sand specified for the new concrete, before new concrete is placed adjacent thereto. New concrete shall be placed before mortar has taken initial set. In lieu of the mortar, an epoxy adhesive suitable for bonding fresh concrete to hardened concrete for load bearing applications may be used. The epoxy adhesive shall conform to AASHTO M 235 M/M 235 Type V and shall be applied in accordance with the manufacturer’s recommendations.
When the work of placing concrete is unexpectedly interrupted by breakdowns, storms or other causes and the concrete as placed would produce an improper construction joint, the Contractor shall construct a construction joint to the approval of the Engineer at no additional expense to the project. When such a joint occurs at a section on which there are shearing or flexural stresses, the Contractor shall provide an adequate mechanical bond across the joint by forming a key, inserting reinforcing steel or by some other satisfactory means, which will prevent a plane of weakness.
901.69: Weep Holes and Drains
Weep holes shall be provided through all structures as indicated on the plans and as directed. Ends of weep holes that are to be covered by filling material shall be protected by ¼- in. mesh galvanized wire screen 23 gauge and not less than 1 yd³ of screened gravel or crushed stone conforming to M2.01.1. II.488 202 4 Edition Drains shall be provided for bridge superstructures as indicated on the plans.
901.70: Protection of Pipes and Conduits
The Contractor shall care for and protect from injury all pipes, wires and conduits encountered in the work by furnishing and maintaining suitable supports, including steel bars, where directed on the bridge during construction. The Contractor shall provide suitable openings in the abutments, walls, piers, and superstructures as shown on the plans and as may be directed. If required, the opening shall be filled with brick masonry in a satisfactory manner.
901.71: Date, Seal, Bench Marks and Ornaments
The Contractor shall place a date on bridges as shown on the plans or as directed. The date used shall be the latest year of contract completion as of the date placement. The same date shall be used when placed at multiple locations on a given bridge. The date shall be cast or cut in masonry as directed. Detail drawings of the date will be furnished by the Department upon the request of the Contractor.
If indicated on the plans, the Contractor shall place a bronze replica of the State Seal on Bridges, as directed by the Engineer. The seal will be furnished by the Department.
Concrete ornaments shall be furnished and placed by the Contractor on bridges when indicated on the plans. The ornamental castings may be either cast in place or precast.
901.72: Concrete Penetrant/Sealer
Concrete penetrant/sealer shall be applied to cement concrete surfaces if shown on the plans. This work shall consist of furnishing all necessary labor, materials and equipment to treat concrete surfaces, including surface preparation and application. The concrete penetrant/sealer shall conform to M9.15.0: Liquid Penetrant/Sealant. Clear concrete penetrant/sealers, after complete application, shall not stain or discolor the concrete. Application of the penetrant/sealer shall not alter the surface texture and shall be compatible with the use of surface finish coatings and/or caulkin gs. The surface shall dry to a tack free condition. Application of the penetrant/sealer shall be in accordance with the manufacturer’s recommendations, including condition and preparation of surfaces to be treated and safety precautions. The preparation process shall not cause any damage to the concrete surface, remove or alter the existing surface finish, or expose the coarse aggregate of the concrete. The Engineer shall approve the prepared surface prior to application of the penetrant/sealer. The Contractor shall prevent the penetrant/sealer from coming in contact with any joint sealers. II.489 202 4 Edition COMPENSATION
901.80: Method of Measurement
Cement Concrete will be measured by the cubic yard and the quantity shall be determined in accordance with dimensions shown on the plans and such alteration of the plans as are specifically ordered by the Engineer in writing. No deduction shall be made in bridges for rustications, chamfered corners of dimensions less than 4 in . on the square sides, or for the volume of pipes less than 18 in . in diameter, drainage inlets, or for anchor bolts or reinforcing bars. The volume occupied by pipe culverts in headwalls shall be deducted. Underwater Foundation Inspection shall be measured by the Unit Day of Underwater Foundation Inspection ordered by the Engineer and actually performed at the work site by each Diver that is a Professional Engineer registered in the Commonwealth of Massachusetts. Each 8- hour period for which Underwater Foundation Inspection is performed as described above shall be measured as one Unit Day. Underwater Foundation Inspection that is performed as described above for less than 4 hours on a given work day shall be measured as one half of one Unit Day. Underwater Foundation Inspection that is performed as described above for more than 4 hours, but less than 8 hours, on a given work day shall be measured as one Unit Day. Underwater Foundation Inspection that is performed as described above for more than 8 hours on a given work day shall be measured by the quantity of Unit Days determined by the actual number of hours during which Underwater Foundation Inspection is performed divided by 8 hours for each Unit Day. Reinforcement for Cement Concrete structures shall be measured by the pound. The weight of bars shall be the product of the length as shown on the approved shop drawings and schedules and the standard weight per foot of length as adopted by the Concrete Reinforcing Steel Institute. Mechanical splicers will be measured by the product of the weight per foot of the bar being joined and the length of an AASHTO Class C lap splice. Wire, metal clips, metal chairs or other fastening and supporting devices used for keeping the reinforcement continuous and in correct position will not be considered reinforcement and the Contractor will receive no additional compensation for their use. The weight of wire mesh (incorporated in the structure) shall be the computed weight in accordance with the plans based on the standard weight accepted by the trade for the unit area of the particular mesh.
901.81: Basis of Payment
Cement Concrete will be paid for at the contract unit price per cubic yard under the particular item of Cement Concrete of the Class required, as shown on the plans or as directed, complete in place and accepted. The Contractor shall have no claims for special allowances for extra cement or apparent shrinkage due to inaccurate proportioning or control, bulging of forms, spilling, waste or for any other project conditions within their control. Payment for additional cement required to be used in proportioning by volume and in placing of concrete under water shall be included in the contract unit price paid for the particular designation of Cement Concrete specified or directed. II.490 202 4 Edition Underwater Foundation Inspection shall be paid at the contract unit price per unit day of Underwater Foundation Inspection ordered by the Engineer and performed by a Professional Engineer registered in the Commonwealth of Massachusetts. Written records, final reports, recommendations, travel time, and photographic documentation shall be considered incidental to Underwater Foundation Inspection and shall not be measured for payment. Steel reinforcement including wire mesh will be paid at the contract unit price per pound complete in place including mechanical splicers, lap splices and proper coating of the bars and splices. Fastening devices and supports for keeping the reinforcement in the correct position are considered incidental to the steel reinforcement and shall not be measured for payment. Galvanized steel curb bars and steel dowels will be paid for at the contract unit price per pound under the item for Steel Reinforcement for Structures. The work specified under 901.69: Weep Holes and Drains , 901.70: Protection of Pipes and Conduits , 901.71: Date, Seal, Bench Marks and Ornaments , and 901.72: Concrete Penetrant/Sealer , shall be done without extra compensation except when openings for pipes, wires and conduits are required to be blocked up, the brick masonry will be paid for at the contract unit price per cubic foot of the kind of masonry in which the opening occurs. Holes for dowels shall be drilled by the Contractor without extra compensation.
901.82: Payment Items
901. 4,000 psi 1.5- inch, 565 Cement Concrete .......................................................... Cubic Yard 901.3 4,000 psi 1.5- inch, 565 Cement Concrete for Post Foundations .............. Cubic Yard 902. 3,500 psi 1.5 -inch, 520 Cement Concrete .......................................................... Cubic Yard 903. 3,000 psi 1.5 -inch, 470 Cement Concrete .......................................................... Cubic Yard 904. 4,000 psi ¾-inch, 610 Cement Concrete ............................................................ Cubic Yard 904.1 5,000 psi, ¾-inch, 705 Cement Concrete ........................................................... Cubic Yard 904.3 5,000 psi, ¾-inch, 685 HP Cement Concrete .................................................... Cubic Yard 904.4 4,000 psi ¾ -inch, 585 HP Cement Concrete ..................................................... Cubic Yard 905. 4,000 psi, ⅜ -inch, 660 Cement Concrete ........................................................... Cubic Yard 905.2 5,000 psi, ⅜ -inch, 710 HP Cement Concrete .................................................... Cubic Yard 906. 5,000 psi, 1.5 -inch, 660 Cement Concrete ......................................................... Cubic Yard
909.9Underwater Foundation Inspection ..................................................................... Unit Day
910. Steel Reinforcement for Structures ...................................................................... Pound
910.1Steel Reinforcement for Structures - Epoxy Coated ...................................... Pound
910.2Steel Reinforcement for Structures – Coated ................................................... Pound
910.3Steel Reinforcement for Structures – Galvanized ........................................... Pound
II.491 202 4 Edition SUBSECTION 940: DRIVEN PILES DESCRIPTION
940.20: General
This work shall consist of furnishing and driving piles to the required bearing capacity in accordance with these specifications and in close conformity with the lines and grades shown on the plans established by the Engineer. The Contractor will be responsible for furnishing piling of sufficient length to obtain the penetration and bearing value required.
940.21: Pile Schedule
The Contractor shall submit to the Engineer, for approval, a schedule of the length of piles they propose to order, and the schedule shall designate the respective location of the piles. The scheduled length shall comprise the length expected to be left in the structure plus the length that might be necessary to provide fresh heading. When test piles and load tests are required, the data obtained from driving test piles and making test loads shall be used in conjunction with other available info rmation to d etermine the lengths of piles to be furnished.
940.22: Precast -Prestressed Concrete Piles
The Contractor shall submit to the Engineer, shop drawings and design calculations which demonstrate the pile complies with the Contract documents. The drawings shall include a schedule of pile lengths, all structural, reinforcing and prestressing details, pickup points, and splice designs. All designs shall be in accordance with the latest AASHTO Standard Specifications for Highway Bridges .
Piles driven to bed rock, into dense stratum or through strata with obstructions shall be equipped with embedded steel H sections or equivalent type protection to minimize damage to the pile tip.
Extensions on precast -prestressed piles shall be in accordance with details shown in the Contract Documents. The final cutting shall be perpendicular to the axis of pile at such an elevation that at least 40 diameters of reinforcing steel are exposed. The final cutting shall not cause undue spalling of the pile adjacent to the cut. Steel reinforcing and concrete for the extensions shall be of the same strength and quality as that used for the original pile. MATERIALS
940.40: General
Piles shall meet the requirements specified in the following Subsection of Division III : II.492 202 4 Edition A. Materials Untreated Timber Pile ............................................................................................................... M9.05.6 Treated Timber Pile .................................................................................................................... M9.05.6 Steel Pile ................................ .......................................................................................................... M8.05.1 Steel Pipe Piles .............................................................................................................................. M8.05.5 Cast -in-Place Pile ......................................................................................................................... M8.05.2 Precast -Prestressed Concrete Pile ........................................................................................ M8.05.6 4,000 psi , ¾-inch, 610 Cement Concrete ........................................................................... M4.02.00 Steel Reinforcement ................................................................................................................... M8.01.0 Mortar ............................................................................................................................................... M4.02.15
When the proposed length is:
or of furnishing each pile in 2 pieces , approximately equal in length, to make up the required length.
piece or splicing 2 pieces approximately equal in length.
Special care shall be used in the storage and handling of piles to avoid damage. The method of handling of precast -prestressed concrete piling shall prevent cracking or fracture by impact or induced bending stresses. At the discretion of the Engineer, cracked or fractured piling shall be either rejected or repaired with epoxy. Fine cracks, which do not extend to the reinforcing steel as determined by the Engineer, will neither require repair or be cause for rejection. The Contractors proposed method for repair with epoxy or the like shall be submitted to the Engineer for approval.
Pile shoes of the type and dimensions specified shall be provided and installed when shown on the contract documents. Timber pile shoes shall be metal and be fastened securely to the pile. Timber pile tips shall be carefully shaped to secure an even uniform bearing on the pile shoes. Steel pile shoes shall be fabricated from cast steel conforming to ASTM A27. II.493 202 4 Edition CONSTRUCTION METHODS
940.50: Equipment for Driving Piles
940.51: Hammers
Piles shall be driven by approved impact hammers or by a combination of jetting and impact hammers. Impact hammers include single, double and differential acting air or steam hammers, and open or closed -end diesel hammers. Drop (Gravity) hammers may be used with the written permission of the Engineer to d rive timber piles. Valve mechanisms and other pans of impact hammers shall be maintained in good condition. Hammers shall be capable of delivering the manufacturer's rated energy and shall be operated at the manufacturer's specified maximum blows per minute. Power sources such as steam boilers and air compressors sh all be capable of continuously maintaining the hammer manufacturer's recommended pressure and flow rate at the intake of the hammer. Boilers and Compressors shall be equipped with pressure gauges or other devices, calibrated against the rated hammer energy. When directed by the Engineer, a gauge readable from the ground surface, shall be provided at the hammer intake to determine the actual pressure delivered to the hammer. The Contractor shall equip open- end diesel hammers with a calibrated scale to enable accurate observation of ram stroke from the ground surface. The Contractor shall also provide the Engineer a chart from the hammer manufacturer equating stroke and blows per minute for the open -end diesel hammer to be used. Double acting diesel hammers (closed -end) shall be equipped with a gauge to measure pressure in the bounce chamber. The gauge shall be readable from the ground surface. Alternatively, the gauge can be equipped with a hose sufficiently long to enable reading on the ground surface. The gauge and hose assembly shall be calibrated to allow for losses in the hose. The Contractor shall provide charts relating the throttle setting and/or bounce chamber pressure to rated hammer energy.
Hammers for Timber Piles. Impact hammers shall have a ram weight of not less than 2,000 lb and shall develop not less than 6,000 ft -lb of energy per blow. When driving to final resistance, the total energy to drive the pile the last 6 in . shall not exceed 32,000 ft -lb times the pile tip diameter in inches. Drop (Gravity) Hammers may be used only with the written permission of the Engineer. Such hammers shall weigh between 2,000 and 3,500 lb, but in no case shall the weight of the hammer be less than the combined weight of driving head and pile. The fall shall be so regulated as to avoid damage to the pile and in no case shall exceed 15 ft. To control excessive stress in concrete piling during driving, the Engineer may require:
II.494 202 4 Edition 3. Reduced ram stroke for driving through very soft soil and increased ram stroke as soil resistance increases;
The Contractor shall submit to the Engineer for approval, a description of the proposed driving equipment with manufacturer's specifications. The equipment description shall include hammer type, hammer cushion, drivehead, and pile cushion, etc. as contained in the “Pile and Driving Equipment Data Form” included in the contract documents or supplied by the Engineer.
Impact hammers shall have an energy rating that will provide the required pile capacity with a penetration resistance between 3 and 15 blows per in ch (BPI). The energy required for these rates shall be determined by the formula given in 940.61: Driven Pile Capacity , Paragraph A for piles with a required capacity less than 50 tons. For piles with required capacity over 50 tons, or as directed by the Engineer, the Contractor shall submit to the Engineer the results of a Wave Equation Analysis performed in accordance with 940.61: Driven Pile Capacity , Paragraph B for the proposed driving equipment. The analysis shall evaluate the acceptability of the driving equipment with regard to energy transfer to the pile top and the potential for impending pile damage due to induced driving stresses. The pile stresses which are indicated by the wave equation to be generated by the driving equipment shall not exceed the values where pile damage impends, if the equipment is to be acceptable. That value is determined by the magnitude of the induced compressive stresses. The point of impending damage in steel piles is defined herein as a compressive driving stress of 90% of the yield point of the pile material. For concrete piles, tensile stresses shall not exceed 3 multiplied by the square root of the concrete compressive strength ( 𝑜𝑜 𝑃𝑃) plus the effective prestress value, ( 3 ×�𝑜𝑜𝑃𝑃+𝑝𝑝𝑝𝑝𝐴𝐴𝑔𝑔𝑗𝑗𝑝𝑝𝐴𝐴𝑔𝑔𝑔𝑔 ) and compressive stresses shall not exceed 85 % of the compressive strength minus the effective prestress value ( 0.85×𝑜𝑜𝑃𝑃−𝑝𝑝𝑝𝑝𝐴𝐴𝑔𝑔𝑗𝑗𝑝𝑝𝐴𝐴𝑔𝑔𝑔𝑔 ). For timber piles, the compressive driving stress shall not exceed three times the allowable static design strength listed on the plans. These criteria will be used in evaluating wave equation results to determine acceptability of the Contractor's proposed driving system. The results of the analysis, including input parameters, shall be subject to the review and approval of the Engineer prior to any pile installations. The Contractor will be notified of the acceptance or rejection of the driving system within 14 calendar days of the Engineer's receipt of the “ Pile and Driving Equipment Data Form. ” If the wave equation analyses show that either pile damage or inability to drive the pile with a reasonable blow count to the desired ultimate capacity will result from the Contractor's proposed equipment or methods, the Contractor shall modify or replace the proposed methods or equipment until subsequent wave equation analyses indicate the piles can be reasonably driven to the desired ultimate capacity, without damage. II.495 202 4 Edition Approval of the equipment by the Engineer will not relieve the Contractor of their responsibility to provide and install piles capable of supporting the design loads given on the contract documents.
940.52: Driving Appurt enances
Piles driven with impact hammers require an adequate helmet to distribute the hammer blow to the pile head . The helmet shall be axially aligned with the hammer and the pile. The helmet should be guided by the leads and not be free- swinging. The helmet should fit around the head in such a manner as to prevent transfer of torsional forces during driving while maintaining proper alignment of hammer and pile.
recommended by the hammer manufacturer, be provided to hold the axis of the pile in line with the axis of the hammer.
perpendicular to the longitudinal axis of the pile to prevent eccentric impacts.
provided in accordance with the manufacturer's recommendations so that the piles may be driven without damage.
Collars, bands, or other devices, to protect timber piles against splitting and brooming, shall be provided by the Contractor.
All pile driving equipment shall be equipped with a suitable thickness of hammer cushion material to prevent damage to the hammer or pile and to insure uniform driving behavior. Hammer cushions shall be made of durable, manufactured materials, provided in accordance with the hammer manufacturer's guidelines except that all wood, wire rope, and asbestos hammer cushions are specifically disallowed and shall not be used. A striker plate as recommended by the hammer manufacturer shall be placed on the hammer cu shion to insure uniform compression of the cushion material. The hammer cushion shall be inspected in the presence of the Engineer when beginning pile driving at each substructure element or after each 100 hours of pile driving, whichever is less. Any redu ction of hammer cushion thickness shall be replaced by the Contractor before driving is permitted to continue.
The heads of concrete piles shall be protected by a pile cushion made of plywood or other similar material approved by the Engineer. The minimum plywood thickness placed on the pile head prior to driving shall not be less than 4 in. A new pile cushion shall be provided for each pile. In addition, during the driving of each pile, the pile cushion shall be replaced if during the driving the cushion is either compressed more than one half the original thickness or begins to burn. The pile cushion dimensions sh all match the cross -sectional area of the pile top. II.496 202 4 Edition E. Leads. The pile driver shall be equipped with fixed leads that are an integral part of the machine. The pile driving hammer shall ride in the ways of the leads. Fixed leads shall be used for driving all piles unless written approval is obtained from the Engineer.
Followers shall only be used when approved in writing by the Engineer, or when specifically stated in the contract documents. The follower shall be of such material and dimensions to permit the piles to be driven to the length determined necessary from the driving of the full -length piles. The final position and alignment of the first two piles installed with followers in each substructure unit shall be verified to be in accordance with the location tolerances in this specification before additional piles a re installed.
Jetting shall only be permitted if approved in writing by the Engineer or when specifically stated in the contract documents. Jetting will not be allowed when driving through newly placed embankment. The use of water jets will be permitted only when excess of water will not affect adjacent structures. In general, jetting will not be permitted near railroad tracks. When jetting is permitted, the Contractor shall determine the number of jets and the volume and pressure of water at the jet nozzles necessary to freel y erode the material adjacent to the pile without affecting the lateral stability of the final in -place pile. The Contractor shall control, treat if necessary, and dispose of all jet water such as to meet environmental considerations. The Contractor shall be responsible for all damage to the site caused by jetting operations. The jetting plant shall have sufficient capacity to deliver at all times a pressure equivalent to at least 100 psi at two ¾-in. jet nozzles. J et pipes shall be removed when the pile tip is a minimum of 5 ft above prescribed tip elevation and the pile shall be driven to the required bearing capacity with an impact hammer.
Preaugering shall only be permitted if approved in writing by the Engineer or when specifically stated in the Contract documents. When permitted, the Contractor shall provide the necessary equipment such as augers, well drilling machines. etc. to preauger holes at pile locations and to the depths required by the Engineer. PILE INSTALLATION
940.60: Preparation for Driving
When piles are located in an area where excavation is to be made or in an area where embankment is to be placed , the piles shall not be driven until the excavation has been made or the embankment has been placed. For either of the foregoing , the grade shall be brought to such an elevation as to compensate for possible uplift or subsidence of the surrounding earth. Adjustments in the grade II.497 202 4 Edition shall be made after all the piles at the location have been driven. Additional excavation or embankment will be considered as part of the process of pile driving and will not be included in the payment for either excavation or borrow.
Where timber, cast -in place, precast -prestressed concrete piles, or steel piles are to be driven through an embankment, and the depth of the embankment at the pile location is in excess of 5 ft , the Contractor shall make a hole for the full depth of the embankment for each pile with an auger or by other approved methods. The hole shall have a diameter of not less than the bun diameter of the pile. After driving, the annular space around the pile shall be filled to the ground surface with dry sand, fine grav el or pea stone. Material resulting from drilling holes shall be disposed of in accordance with Subsection 120: Excavation .
940.61: Driven Pile Capacity
For piles with proposed capacities greater than 50 tons, the Ultimate Pile Capacity shall be determined by a Wave Equation Analysis conducted by a Registered Professional Engineer experienced in the method of analysis, at the expense of the Contractor. For piles wit h proposed capacities not greater than 50 tons, the Ultimate Pile Capacity may be determined by the following formula.
𝑅𝑅 𝑢𝑢= 1. 75√𝐸𝐸 𝐴𝐴𝐴𝐴𝐿𝐿(10𝑁𝑁 )−100 Where: 𝑅𝑅𝑢𝑢=𝑈𝑈𝐴𝐴𝑗𝑗𝑖𝑖𝑁𝑁𝐴𝐴𝑗𝑗𝐴𝐴 𝑃𝑃𝑖𝑖𝐴𝐴𝐴𝐴 𝐶𝐶𝐴𝐴𝑝𝑝𝐴𝐴𝑖𝑖𝑖𝑖𝑗𝑗𝑄𝑄 (𝐿𝐿𝑖𝑖𝑝𝑝𝑔𝑔 ) 𝐸𝐸=𝑀𝑀𝐴𝐴𝑖𝑖𝑜𝑜𝑜𝑜𝐴𝐴𝑖𝑖𝑗𝑗𝑜𝑜𝑝𝑝𝐴𝐴𝑝𝑝𝑔𝑔 𝑝𝑝𝐴𝐴𝑗𝑗𝐴𝐴𝑑𝑑 𝐴𝐴𝑖𝑖𝐴𝐴𝑝𝑝𝐿𝐿𝑄𝑄 𝐴𝐴𝑜𝑜 𝑗𝑗ℎ𝐴𝐴 ℎ𝐴𝐴𝑁𝑁𝑁𝑁𝐴𝐴𝑝𝑝 ,𝐴𝐴𝑗𝑗 𝑔𝑔𝑗𝑗𝑝𝑝𝐴𝐴𝐿𝐿𝐴𝐴 𝐴𝐴𝐴𝐴𝑔𝑔𝐴𝐴𝑝𝑝𝐴𝐴𝐴𝐴𝑑𝑑 𝑖𝑖𝑖𝑖 𝑜𝑜𝑖𝑖𝐴𝐴𝐴𝐴𝑑𝑑 ,𝑖𝑖𝑖𝑖 𝑜𝑜𝐴𝐴𝐴𝐴𝑗𝑗−𝑝𝑝𝐴𝐴𝑜𝑜𝑖𝑖𝑑𝑑𝑔𝑔 𝐴𝐴𝐴𝐴𝐿𝐿(10𝑁𝑁 )=𝐿𝐿𝐴𝐴𝐿𝐿𝐴𝐴𝑝𝑝𝑖𝑖𝑗𝑗ℎ𝑁𝑁 𝑗𝑗𝐴𝐴 𝑗𝑗ℎ𝐴𝐴 𝐴𝐴𝐴𝐴𝑔𝑔𝐴𝐴 10 𝐴𝐴𝑜𝑜 𝑗𝑗ℎ𝐴𝐴 𝑠𝑠𝑜𝑜𝐴𝐴𝑖𝑖𝑗𝑗𝑖𝑖𝑗𝑗𝑄𝑄 10 𝑁𝑁𝑜𝑜𝐴𝐴𝑗𝑗𝑖𝑖𝑝𝑝𝐴𝐴𝑖𝑖𝐴𝐴𝑑𝑑 𝐴𝐴𝑄𝑄 𝑁𝑁, 𝑗𝑗ℎ𝐴𝐴 𝑖𝑖𝑜𝑜𝑁𝑁𝐴𝐴𝐴𝐴𝑝𝑝 𝐴𝐴𝑜𝑜 ℎ𝐴𝐴𝑁𝑁𝑁𝑁𝐴𝐴𝑝𝑝 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝑔𝑔 𝑝𝑝𝐴𝐴𝑝𝑝 𝑖𝑖𝑖𝑖𝑖𝑖ℎ 𝐴𝐴𝑗𝑗 𝑜𝑜𝑖𝑖𝑖𝑖𝐴𝐴𝐴𝐴 𝑝𝑝𝐴𝐴𝑖𝑖𝐴𝐴𝑗𝑗𝑝𝑝𝐴𝐴𝑗𝑗𝑖𝑖𝐴𝐴𝑖𝑖 (𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝑔𝑔 𝑝𝑝𝐴𝐴𝑝𝑝 𝑖𝑖𝑖𝑖𝑖𝑖ℎ). The above formula is applicable only when:
On projects designed using the Service Load Design Method (Allowable Stress Design), a Design Safety Factor of 3.5 is to be used when using this formula to determine the required Ultimate Pile Capacity. For example, if a Design Capacity of 50 tons is required, then an Ultimate Pile Capacity of 175 tons should be used in the formula to determine the necessary hammer blow count. On projects designed using the Strength Design Method (Load Factor Design), the Performance Factor and Factored Design Capacity specified on the plans shall be used when using this formula to determine the required Ultimate Pile Capacity. For example, if a Factored Design Capacity of 35 tons is required and the Performance Factor specified on the plans is 0.35, then an Ultimate Pile Capacity of 100 tons should be used in the formula to determine the necessary hammer blow count. The above formula may be modified by the Engineer if they deem it necessary on the basis of information obtained from a loading test or dynamic field measurements during pile driving. II.498 202 4 Edition B. Wave Equation Method. When required in the contract documents, the ultimate pile resistance shall be determined by the Engineer based on a wave equation analysis. Piles shall be driven with the approved driving equipment to the ordered length or other lengths necessary to obtain the required ultimate pile resistance. Jetting, preaugering or other methods to facilitate pile penetration, shall not be used unless specifically permitted either in the contract documents or approved by the Engineer after a revised driving resistance is established from the wave equation analysis. Adequate pile penetration shall be considered to be obtained when the specified wave equation resistance criteria is achieved within 5 ft of the tip elevation based on ordered length. Piles not achieving the specified resistance within these limits shall be driven to penetrations established by the Engineer. The Contractor is required to perform a wave equation analysis upon each pile type, each pile size, at each significant variation in soil profile, and at each pile driven for the static load test as shown on the plans. When dynamic load tests are required than a wave equation analysis must be performed for each pile to be dynamic load tested by the “Pile Driving Analyzer” (PDA) as determined by the Department. The wave equation analysis shall be made as outlined in the FHWA publication Design and Construction of Driven Pile Foundations . If more than one driving system is proposed by the Contractor, a wave equation analysis shall also be made for each driving system. The driving system, as detailed on the “ Pile Driving and Equipment Data Form, ” shall be completed by the Contractor and furnished for use as wave equation input data. No change in driving equipment will be permitted after an evaluation by the Wave Equation Method without prior approval of the Engineer and a revaluation of the driving system. The Engineer may modify the results from the Wave Equation Analysis, if they deem it necessary on the basis of information obtained from loading tests or dynamic field measurement. The wave equation analysis wi ll be performed by an engineer, registered with the Commonwealth of Massachusetts as a Professional Engineer and experienced in such work. The Contractor's engineer shall be experienced in the performance of the wave equation analysis and its function as related to pile capacity determination. The Contractor's engineer conducting the wave equation analysis shall be thoroughly familiar with the Geotechnical report for the project, the subsurface conditions at the site, and with t he proposed foundation design. The Contractor shall submit a written report with a summary of each wave equation analysis to the Department at least 2 weeks prior to pile driving. That submission shall include a copy of the entire Wave Equation Analysis Program (WEAP) in the form specified in Design and Construction of Driven Pile Foundations . The summary in the report will contain the plotted curves (3) of ultimate resistance vs. blowcount and compressive stresses vs. blowcount and tensile stresses vs. blowcount for each WEAP output for each embedded length and for several stroke -lengths if a variable stroke
The Contractor's engineer conducting the wave equation analysis shall also be the same engineer to conduct the dynamic load tests with the PDA when the Contractor is required to perform such dynamic load tests. II.499 202 4 Edition 940.62: Pile Load Tests
The piles to be tested shall be driven in accordance with the requirements under the item for the type of pile to be used on the project. These tests shall be made before driving production piles. Each pile to be tested shall be driven to the design load as determined by either the Formula in
: Driven Pile Capacity , Paragraph A, or a Wave Equation Analysis in accordance with 940.61:
Driven Pile Capacity , Paragraph B and, at the discretion of the Engineer, by dynamic pile measurements in accordance with 940.62: Pile Load Tests , Paragraph C.
Static pile load tests shall be conducted in accordance with ASTM D1143, “Standard Method of Testing Piles under Static Axial Compressive Load,” except as modified herein.
The top elevation of the test pile shall be determined immediately after driving and again just before load testing to check for heave. Any pile which heaves more than ¼ in. shall be redriven or jacked to the original elevation prior to testing. A minimum 3 day waiting period shall be observed between the driving of any anchor piles or the load test pile and the commencement of the load test. Tell- tales shall be installed in all test piles to determine the percent of the applied test load being transferred to the bearing stratum. Number and location of tell- tales shall be as shown on the plans. The Department will furnish levels and the personnel necessary to make all evaluations. All measuring devices and gauges that will be required, other than levels, shall be furnished by the Contractor. Readings of settlement and rebound shall be referred to a fixed benchmark and shall be made using at least 2 -micrometer dial extensometers graduated to 0.001 in. and located 90° apart along the axis of the exposed portion of the pile. Readings shall be taken at intervals specified in Sections 4, 5, or 6, Test Procedures. Readings shall be taken from gauges mounted on a reference beam supported at each end by reliable supports located at least 10 ft from the center of the test pile. In addition to these readings, elevations to the nearest one -thousandth of a foot by use of an Engineers’ level and rod shall be recorded. The entire measuring installation shall be protected from direct sunlight, frost action and other disturbances that might affect its reliability. The head of each test pile shall be cut -off level or shall be capped in such a manner as to produce a plane, horizontal bearing surface. All records obtained during the test shall be the property of the Department. Furnishing and driving the piles, complete in place, will be paid for under the item for the type of piles on which the test is made. Before starting the work, the Contractor shall submit to the Engineer, for approval, a written description of the equipment and method which the Contractor intends to use. The method must be of an approved type and shall be altered as necessary to meet the approval of the Engineer. II.500 202 4 Edition 2. Load Application. The method of applying the load to the pile will be at the option of the Contractor, provided the method is adaptable to accurate measuring of the applied load, and the method avoids eccentric loading on the pile. The first increment of load shall include allowance for weight of the equipment. Hydraulic Jacks shall be of an approved type and capable of supplying a minimum jacking capacity equal to the maximum test load plus 20%. The Contractor shall provide a load cell, subject to the approval of the Engineer, which is capable of determining load transfer to the test pile. The load cell shall have a capacity equal to the jack capacity and shall be calibrated by a certified testing laboratory. In addition, the Contractor shall provide a calibration certificat e from a certified testing laboratory relating pressure gauge reading to jack load. The Contractor shall submit to the Engineer both calibration certificates prior to load testing.
The total reaction load shall be not less than 250% of the design load for both the short duration and maintained load tests and 400% of the design load for the quick load test method. Any one of the following devices for applying the vertical loads may be used:
pile to be tested. The construction of the box and the application of the loads shall be such that no lateral forces will be applied to the top of the pile and no impact will occur as the loads ar e placed. In cases where the test pile is in an excavation below the natural ground surface, an extension column of structural steel or steel pile may be used to extend from the pile head up to the test box.
material. A hydraulic jack with a recently calibrated pressure gauge shall be interposed between the pile head and the load box and load applied to the pile by operating the jack.
test pile. A girder of sufficient strength to act as a reaction beam shal l be fastened to the upper ends of the anchor piles. A hydraulic jack with a recently calibrated pressure gauge shall be interposed between the head of the test pile and the underside of the reaction beam and the test load applied to the pile by operating th e jack.
Load Test .” The application of the test load shall not begin sooner than 72 hours after placing concrete in Cast- in-place and Steel pipe piles and no sooner than 48 hours after other type piles are driven. A single pile shall be load -tested to not less than twice the design load. When 2 or more piles are to be tested as a group, the total load shall be not less than 1.5 times the design load for the group.
The load sequence shall be as follows: II.501 202 4 Edition a. Apply 25% of the design load every one -half hour up to the greater of the following: 200% of design load; to an applied load which transfers 100% of design load to the bearing strata as determined from tell -tale measurements but not greater than 90% of the reaction load. Longer time increments may be used, but each time increment should be the same.
15-minute and at 15 -minute intervals thereafter. Provided that the design load does not exceed one hundred percent (100%) of the load transferred to the bearing stratum at the maximum test load , the design load from this test type shall be the greater of the following:
settlement at the pile cutoff grade equal to the sum of: a) the theoretical elastic compression of the pile in inches, assuming all the load on the butt is transmitted to the tip, plus b) 0.15 in ., plus c) one hundred twentieth of the pile tip diameter or pile width in inches, i.e., 𝐿𝐿 𝑓𝑓=𝐿𝐿+�0.15+𝑁𝑁120� � Where: 𝐿𝐿𝑓𝑓=𝐿𝐿𝐴𝐴𝑗𝑗𝑗𝑗𝐴𝐴𝐴𝐴𝑁𝑁𝐴𝐴𝑖𝑖𝑗𝑗 𝐴𝐴𝑗𝑗 𝑜𝑜𝐴𝐴𝑖𝑖𝐴𝐴𝑜𝑜𝑝𝑝𝐴𝐴 ,𝑖𝑖𝑖𝑖 𝑖𝑖𝑖𝑖𝑖𝑖ℎ𝐴𝐴𝑔𝑔 𝑁𝑁=𝑃𝑃𝑖𝑖𝐴𝐴𝐴𝐴 𝑑𝑑𝑖𝑖𝐴𝐴𝑁𝑁𝐴𝐴𝑗𝑗𝐴𝐴𝑝𝑝 𝐴𝐴𝑜𝑜 𝐴𝐴𝑖𝑖𝑑𝑑𝑗𝑗ℎ ,𝑖𝑖𝑖𝑖 𝑖𝑖𝑖𝑖𝑖𝑖ℎ𝐴𝐴𝑔𝑔 𝐿𝐿=𝐸𝐸𝐴𝐴𝐴𝐴𝑔𝑔𝑗𝑗𝑖𝑖𝑖𝑖 𝑑𝑑𝐴𝐴𝑜𝑜𝐴𝐴𝑝𝑝𝑁𝑁𝐴𝐴𝑗𝑗𝑖𝑖𝐴𝐴𝑖𝑖 𝐴𝐴𝑜𝑜 𝑝𝑝𝑖𝑖𝐴𝐴𝐴𝐴 𝐴𝐴𝐴𝐴𝑖𝑖𝐿𝐿𝑗𝑗ℎ,𝑖𝑖𝑖𝑖 𝑖𝑖𝑖𝑖𝑖𝑖ℎ𝐴𝐴𝑔𝑔
𝐿𝐿𝑓𝑓=𝐿𝐿+𝑁𝑁30� If the settlement is so small that the load- settlement curve does not intersect the failure criterion , the maximum test load shall be taken as the failure load.
50% of the applied test load which results in a net settlement of the top of the pile of ½ in., after rebound for a minimum of one hour at zero load.
The test loads shall be applied in at least five increments equal to 50, 100, 150, 175 and 200% of the design load. All intermediate load steps shall be maintained constant for a period of two hours. During the loading cycle, the contemplated design load and twice the design load, shall be maintained constant until settlement does not exceed 0.02 in . in 12 consecutive hours, or until the II.502 202 4 Edition pile has failed as determined by the Engineer. The loading period for twice the design load shall be no less than 24 hours. The total test load shall be removed in decrements not exceeding 25% of the total test load. Each step of unloading shall be maintained constant for a period of 4 hours. During loading, record readings of time, load, and movement at intervals not exceeding 10 minutes during the first one -half hour, 30 -minute intervals up to 2 hours at 1 -hour intervals up to 12 hours and 2 -hour intervals thereafter. During unloading, take readings at intervals not exceeding 20 minutes for the first hour and I hour intervals thereafter. Take a final rebound reading 4 hours after all load has been removed. The design load shall be determined in accordance with the procedures specified in the Short Duration Load Test.
This load test shall be performed on individual piles only. The load shall be applied in increments of 5 to 10 tons and shall not exceed 10% of the design load. The time interval between readings shall be 2.5 minutes or as otherwise specified. Add load increments until continuous jacking is required to maintain the test load or until the capacity of either the loading apparatus or reaction load is reached. Hold the failure load or maximum applied load for not less than 5 minutes. Unload the pile in no less than four equal increments. Record time, load, and movements immediately, before and after the application or removal of each load increment. Take a final rebound reading 15 minutes after removing all loads. The design load shall be determined in accordance with the procedures specified in the Short Duration Load Test.
This load test can apply to a compression test, tension test, or both, on a pile and provide the ultimate capacity of the pile. The load test is carried out in four “loading -unloading” cycles, at a constant loading rate, conducted continuously without allowing for settlement stabilization. The loading frame should be designed to handle at least two times the estimated ultimate pile capacity. The displacement and load readings from the top of the pile are to be taken continually by a data acquisition system. The load sequence shall be as follows:
until failure is observed and an additional settlement equal to 0.1 in . is achieved with total pile settlement equal or exceeding 1 in. A failure is defined when displacement increases without an increase in the pile’s load at or below the ratio of 0.1 kips/0.1 in ./ft pile embedment for all compression tests. Unload the pile at a constant rate between 60 to 80 kips/minute until zero load. Carry out additional three load -unload cycles to the maximum load that was achieved in the first cycle.
60 kips/minute. Failure is defined when displacement increases without an increase in the pile’s load at or below the ratio of 0.05 kips/0.1 in ./ft pile embedment for all tension tests. II.503 202 4 Edition c) For all tests, pile top load and displacement are measured at intervals of loads equal to 1 0% of the estimated ultimate pile capacity but no more than 20 kips for a compression test and 10 kips for a tension test. The readings need to allow for accurate definition of the load - unload interception. The use of electronic data acquisition is recommended. If dial gages are used, the gages should not be adjusted at the end of the first cycle and the zero load reading at the end of the first cycle (first zero reading of the second cycle) will be subtracted from the readings of the second cycle. The pile design load on this test is based on the measured ultimate capacity of the pile. The ultimate capacity of the pile is defined as the average of the three intersection points formed by the load - unload curves.
Dynamic measurements will be taken by the Engineer during driving piles designated as Dynamic Load Test (DLT) piles. Prior to placement in the leads, the Contractor shall make each designated concrete and/or timber pile available for taking of wave speed measurements and for predrilling the required instrument attachment holes. When wave speed measurements are made, the piling shall be in a horizontal position and not in contact with other piling. The Engineer shall furnish the equipment, materials, and labor necessary for drilling holes in the piles for mounting the instruments. The instruments will be attached near the head of the pile with bolts placed in masonry anchors for the co ncrete piles or through drilled holes on the steel piles. The Contractor shall provide the Engineer reasonable means of access to the pile for attaching instruments after the pile is placed in the leads. If, in the opinion of the Engineer, the instruments cannot be installed before pile is placed in the leads, th en a platform with minimum size of 4 ft x 4 ft (16 ft²) designed to be raised to the top of the pile while the pile is located in the leads shall be provided by the Contractor. It is estimated that the Engineer will need approximately 1 hour per pile to in stall the dynamic load test equipment. The Contractor shall furnish electric power for the dynamic load test equipment. The power supply at the outlet shall be 10 amp, 115VAC, 55 to 60 Hz, only. Field generators used as the power source shall be equipped with functioning meters for monitoring v oltage and frequency levels. The Contractor shall furnish a shelter to protect the dynamic load test equipment from the elements. The shelter shall have a minimum floor size of 8 ft x 8 ft (64 ft²) and minimum roof height of 7 ft . The inside temperature of the shelter shall be maintained above 45°F. The shelter shall be located within 50 ft of the test location. The pile shall be driven to the depth at which the dynamic analyzer indicates that the ultimate pile resistance shown in the contract plans has been achieved . The stresses in the piles will be monitored during driving with the dynamic analyzer to ensure that the pile stresses determined do not exceed the values which would cause pile damage. The point of impending damage in steel piles is defined herein as a compressive driving stress of 90% of the yield point of the pile material. For concrete piles, tensile stresses shall not exceed 3 multiplied by II.504 202 4 Edition the square root of the concrete compressive strength, 𝑜𝑜 𝑃𝑃, plus the effective prestress value, (3�𝑜𝑜𝑃𝑃+𝑝𝑝𝑝𝑝𝐴𝐴𝑔𝑔𝑗𝑗𝑝𝑝𝐴𝐴𝑔𝑔𝑔𝑔 ) and compressive stresses shall not exceed 85% of the compressive strength minus the effective prestress value ( 0.85×𝑜𝑜𝑃𝑃−𝑝𝑝𝑝𝑝𝐴𝐴𝑔𝑔𝑗𝑗𝑝𝑝𝐴𝐴𝑔𝑔𝑔𝑔 ). For timber piles, the compressive driving stress shall not exceed three times the allowable static design strength listed on the plans. If necessary, the Contractor shall reduce the driving energy output of the hammer in order to maintain stresses below these values. If non -axial driving is indicated by dynamic analyzer measurements, the Contractor shall immediately realign the driving system. When directed by the Engineer, the Contractor shall wait 12 to 24 hours and then after the instruments are reattached, retap the dynamic load test pile. It is estimated that the Engineer will require approximately 0.5 hours to reattach the instruments. A cold hammer shall not be used for the redrive. The hammer shall be warmed up before redrive begins by applying at least 20 blows to another pile. The maximum amount of penetration required during redrive will be 6 in . or the maximum total number of hammer blows required will be 50, whichever occurs first. After retapping, the Engineer will either provide the cut -off elevation or specify additional pile penetration and testing.
When directed in the Contract documents, dynamic measurements will be taken by the Contractor during pile driving and shall be subject to the Department's field review. Those piles to be tested will be designated as dynamic load test piles or “DLT” on the plans and shall be located by the Department. Preliminary location of piles to be tested are subject to revision by the Engineer. The piles to be static load tested and approximately 10% of the remaining driven piles will be tested by this method. The dynamic tests are to be made by the Contractor's engineer who shall be registered with the Commonwealth of Massachusetts as a Professional Engineer. The same Contractor's Engineer conducting the wave equation analysis shall perform the dynamic load tests. Each dynamic test shall also include a “CAP -WAP” analysis in order to closely model actual field conditions. The damping, quake and soil resistance distribution values will be provided by the Contractor's Engineer. The Contractor's Engineer shall be experienced in the use of the Pile Driving Analyzer (PDA) and its purpose as related to pile capability determination. The Contractor's Engineer will also be proficient in the interpretation of the PDA and “CAP -WAP” data and shall determine the tested pile's capacity based upon this data. The Contractor shall submit to the Department a written report with a summary of results upon completion of each PDA test including “CAP -WAP” analysis. A copy of the entire PDA and “CAP- WAP” analysis output will be submitted to the Department for reviewal ong with the Contractor's report of each PDA and “CAP -WAP” test. The PDA and “CAP- WAP” output will not substitute for a written report which includes a summary of the results but will be submitted with such a report. The Contractor shall submit evidence of the engineer's proficiency to the Department at least 2 weeks in advance of the work to allow the Department adequate time for review and approval or comments. No pile driving will be allowed until written approval h as been received from the Engineer. II.505 202 4 Edition A. PDA Equipment. The equipment to perform the dynamic tests shall be a Mode GC pile driving analyzer by Goble, Rausche, Likins and Associates, Inc., 4423 Emery Industrial Parkway, Cleveland, Ohio 44128, phone (216) 831 -6131, or approved equal. The equipment shall be complete with all pertinent peripheral equipment necessary to complete and record the test data and complete the analysis of pile capacity.
At least 2 weeks prior to initiating the pile driving operation , the Contractor shall submit a “pile testing program” outline to the Department for review and approval. The following procedure is suggested as an example of a pile testing program which incorporates the wave equation analysis and the dynamic pile driving analysis including the “CAP -WAP” portion of the dynamic testing. The testing should be performed by experienced engineers. The scope and sequence of testing services is suggested as follows:
capacity, and pile driving equipment to be utilized. See the previously referenced FHWA Manual for examples of the WEAP analysis procedure from static analysis to parameter selection. Submit written report of each wave equation analysis with complete print -out to the Department for review.
Restrike testing is considered essential for service load capacity determinations if they are to include setup/relaxation effects since the analyzer gives the pile capacity at the time of testing.
Engineer. Other than these tests, the Engineer will determine if further dynamic tests should be made when the hammer system is replaced or modified, etc.
“CAP- WAP” on all of the piles tested to verify and refine field results, and upon restrike testing.
addition to a copy of the actual print -outs. This report will show all pertinent information, upon completion of the PDA testing and “CAP -WAP” analysis of each pile.
II.506 202 4 Edition c. Pile structural damage/integrity
Judgements are to be made, even during the testing program by the Contractor's experienced engineer performing the test as to deletions or additions to a “standard” program which will result in the most benefit to the foundation design.
940.63: Test Piles (Indicator Piles)
Test piles shall be driven when shown on the plans at the locations and to the lengths specified by the Engineer. All test piles shall be driven with impact hammers. In general, the specified length of test piles will be greater than the estimated length of production piles in order to provide for variation in soil conditions. The driving equipment used for driving test piles shall be identical to that which the Contractor proposes to use on the production piling. Approval of driving equipment shall conform with the requirements of these specifications. The Contractor shall excavate the ground at each test pile to the elevation of the bottom of the footing before the pile is driven. In the absence of a wave equation analysis, test piles shall be driven to a penetration of 0.5 in. or less after 10 consecutive hammer blows unless the Engineer provides a hammer blow count established by wave equation analysis within a range of tip elevations or unless the driving criteria is established by the dynamic formula. Test piles which do not attain the bearing value specified above at a depth of 1 ft above the estimated tip elevation shown on the plans shall be allowed to “set up” for 12 to 24 hours as directed by the Engineer before being redriven. A cold hammer shall not be used for redrive. The hammer shall be warmed up before driving by applying at least 20 blows to another pile. If the bearing value is not attained on redriving, the Engineer may direct the Contractor to drive a portion or all of the remaining test p ile length and repeat the “set up” redrive procedure. Test piles driven to plan grade and not having the bearing required, shall be spliced and driven until the required bearing is obtained. A record of driving of test piles will be prepared by the Contractor which includes the number of hammer blows per foot for the entire driven length , the as driven length of test pile, cutoff elevation, penetration in ground, and any other pe rtinent information requested by the Engineer. The Contractor shall provide the information listed in the “Pile Driving and Equipment Form ” to the Engineer for inclusion in the record. If redrive is necessary, the Engineer shall record the number of hammer blows per in . of pile movement for the first foot of redrive. The Contractor shall not order piling to be used in the permanent structure until test pile data has been reviewed and pile lengths are authorized by the Engineer.
940.64: Determinations of Required Pile Driving Resistance and Depth of Penetration
Practical Refusal. Practical refusal will be considered attained when ten blows of an adequate hammer, operating at the number of blows per minute for which the hammer is rated by the manufacturer, are required to produce a total penetration of ½ in. Driving should then cease, provided that the pile has not hit an obstruction and has been driven to the depth at which the borings indicate refusal material or bedrock. II.507 202 4 Edition When piles are not either required or directed to be driven to bedrock or refusal, the Engineer shall determine the required driving resistance for safe bearing values and shall establish minimum tip elevations or acceptable bearing stratum depending on su bsurface condition. The required driving resistance will be established as described in 940.61: Driven Pile Capacity . When determining the final driving resistance of the pile, the hammer shall be operated at a speed not less than 90% of the maximum blows per minute specified by the manufacturer. The final driving resistance shall be appropriately adjusted to the actual hammer energy delivered as specified by the manufacturer for the operating speed. When directed by the Engineer, the Contractor shall make dynamic field measurements to demonstrate the percentage of the hammers rated energy is transferred to the pile head.
940.65: Procedure for Driving
No piles shall be driven except in the presence of the Engineer. Where practicable, piles shall be driven continuously to the required penetration and bearing capacity. When the continuous installation of a pile has been stopped for any reason, the pile advancement shall be started in a manner which will not damage the pile. Any pile which cannot be advanced or which is damaged in the process, shall be rejected and either cut -off and repaired or replaced at the discretion of the Engineer. Rejected piles shall be replaced or repaired at no cost to the Department. A ny pile restarted shall be advanced no less than 3 in . before determining the final driving resistance. The order of placing individual piles in pile groups shall be either starting from the center of the group and proceeding outwards in both directions or starting at the outside row and proceeding progressively across the group. If any driven pile is raised more than ½ in. by the subsequent driving of adjacent piles, it shall be redriven to the required final resistance to penetration with no compensation for the additional driving. Cast -in-place and steel pipe piles shall not be filled with concrete until all piles within a footing have been checked for uplift and redriven where necessary. All piles shall be driven a minimum of 10 ft into original ground.
The tops of piles at cut -off elevation shall be within 6 in . of plan locations. No pile shall be nearer than 4 inches from any edge of the cap. Any increase in size of cap to meet this edge distance requirement shall be at the Contractor's expense. Piles shall be installed so that the axial alignment of the top 10 ft of the pile is within 4% of the specified alignment. For piles that cannot be inspected internally after installation, an alignment check shall be made before installing the last 5 ft of pile or after installation is completed provided the exposed portion of the pile is not less than 5 ft in length. The Engineer may require that driving be stopped in order to check the pile alignment. If the location and/or alignment tolerances specified are exceeded, the extent of overloading shall be investigated and if, in the judgement of the Engineer, corrective measures are necessary, suitable measures shall be designed and II.508 202 4 Edition constructed by the Contractor at no cost to the Department. Pulling laterally on piles to correct misalignment shall not be permitted.
If conditions during driving indicate that the pile is hitting an obstruction and the obstruction is not in embankment that has been placed under the contract the following shall apply:
bottom of the footing, the Contractor shall drive through the obstruction or shall use whatever means are necessary to remove or circumvent the obstruction without any additional compensation.
bottom of the footing, the Contractor shall use a combination of water jet and hammer to drive through the obstruction without any additional compensation.
the approximate size of the obstruction;
obstruction in place.
paid for the work of removing the obstruction under Subsection 9.03: Payment for Extra Work.
and Suspension of Work will be allowed for the above. 940. 66: Splices
Full length piles shall always be used where practical.
Splicing of timber piles will not be permitted.
Where these piles have to be extended, the spliced connection shall be a continuous full penetration butt -weld. The butt -welding shall be made to develop the full strength of the pile, both in bearing and in bending. Welding shall conform to the applicable provisions of 940.61: Driven Pile Capacity . Butt -weld splicing of piles other than as shown on the plans will not be permitted without express written consent of the Engineer. Welded splice connections for pipe piles shall be made with a welding or backup ring. Preheat requirements for the welding of pipe piles shall be as specified for ASTM A36 steel. II.509 202 4 Edition D. Precast -Prestressed Concrete Piles. Splices shall develop 100% of the pile strength both in direct stress and in bending. Splices for concrete piles shall be made by the cement -dowel method. Details of the cement- dowel splice shall be shown in the plans. Mechanical splices for concrete or st eel piles may be approved by the Engineer if the splice can transfer the full pile strength in compression, tension and bending. Piles shall have only 1 splice per pile. Splices in the lower 40 ft of the pile will not be permitted.
940.67: Defective Piles
The procedure incident to the driving of piles shall not subject them to excessive and undue abuse, producing: injurious splitting, splintering and brooming of the wood; deformation of steel; breakage and cracking in precast- prestressed concrete piles. Manipulation of piles to force them into proper position will not be permitted when considered to be excessive by the Engineer. Piles damaged by reason of internal defects, by improper handling, driving, defective welds or piles driven out of proper location, shall be corrected at the Contractor's expense by one of the following methods approved by the Engineer for the piles in question.
Damaged steel piles may be spliced at some point such that the completed pile shall be satisfactory. After the shells for cast- in-place piles and pipe for pipe piles have been driven, they shall be inspected and will be classified defective if any of the following are discovered:
elevation from the design alignment.
points of the ends of the casing. This requirement shall be taken as satisfied if some segment of the bottom of the casing is visible. If the bottom of the casing is out of sight, the shape and alignment of the casing shall be surveyed with a suitable instrument supplied by the Contractor and approved by the Engineer.
The Contractor shall provide sufficient lights and other equipment necessary to inspect each shell throughout its length. Precast -prestressed concrete piles which break within 10 ft of ground shall be, at the discretion of the Engineer, either replaced or cut -off and spliced at no cost to the Department. Piles which break below 10 ft from ground surface shall be rejected and replaced by the Contractor at no cost to the Department. The Engineer may elect to use dynamic measurements to aid in evaluating pile integrity. II.510 202 4 Edition 940.68: Cutoffs
The tops of piles shall be sawed off to a true plane at the grades shown on the plans. All cuts and abrasions on treated piles shall be repaired in accordance with AWPA Standard M4. Nail holes shall be filled by driving galvanized nails flush with the surface of the pile.
After driving has been completed the steel or cast -in-place -piles shall be cut off at the directed grade. Cutting of piles shall not be done until it is certain that further operations will have no effect on the previously driven piles. Temporary capping devices shall be provided for cast -in-place and steel pipe piles immediately upon cutoff to prevent soil and water from entering driven piles prior to placing concrete.
Precast -prestressed concrete piles shall be cut -off at the grades specified in the contract documents. Piles shall not be cut -off until it is certain that further pile driving operations will have no effect on the driven piles.
940.69: Placing and Protecting Concrete Filled Piles
No concrete shall be placed in a shell or pipe until all piles within a footing have been satisfactorily driven, inspected and approved by the Engineer. No concrete shall be placed except in the presence of the Engineer. Prior to placing concrete in each pile, 1 ft³ of mortar, having a slump of not more than 3 in. , shall be deposited in the bottom of the pile. Concrete shall then be deposited in the casing through a funnel having a neck not more than 1.5 ft long and not more than 7 in. in diameter. The funnel shall be provided with supports at the neck to permit air to escape during the concrete placing operation. Placing of concrete in each pile shall be continuous and in a manner which will assure complete filling of the casing. The slump of the concrete shall be from 3 to 5 in . Special care shall be exercised in filling the casing to prevent honeycomb and air pockets from forming. Internal vibrators and other means shall be used to the maximum depth practicable, as determined by the Engineer, to consolidate the concrete. During cold weather the pile heads and surrounding ground shall be covered by straw or other suitable protection to prevent frost from damaging the concrete itself or heaving the ground. During the hot weather pile heads shall be protected by suitable covering material. II.511 202 4 Edition COMPENSATION
940.80: Method of Measurement
The length of piles to be paid for shall be the total length in place, measured from the tip of the pile to the plane of the plan cut- off elevation. Timber pile cut -offs will be measured by the foot and the length to be paid for will be the difference between the length of piles approved by the Engineer on the schedule submitted by the Contractor and the length of piles in place, but will not include a ny lengths cut -off for correction of damaged ends or for piles rejected by the Engineer. Precast -prestressed piles will be measured by the foot from the tip of the pile including any steel extension installed for protection (to the plan cut -off elevation) and any extensions required to reach the cutoff elevation.
940.81: Basis of Payment
Timber piles will be paid for at the contract unit price per foot under the item for Untreated Treated Timber Piles, left in place, or under the item for Treated Timber Pile, left in place. If timber piles furnished according to the approved schedule of length prove inadequate to sustain the required load, the Engineer may in writing make changes in the schedule previously approved by them and the piles ordered and driven according to the revised schedule will be paid for at the contract unit price per foot. If as a result of the revised schedule or as a result of timber pile cutoff being used as piles, any of the timber piles which have been purchased by the Contractor in accordance with the approved schedule, cannot be used elsewhere on the project, such piles not used will be paid for under the provisions of Subsection 9.03: Payment for Extra Work , except that no profit or overhead will be allowed and subject to an allowance for their fair salvage value of the piles. In no case will payment for these piles e xceed 50% of the bid price per foot of either treated timber piles or untreated timber piles. Payment for cut -off allowance on treated and untreated timber piles will be made at 50% of the respective bid price per foot. The cut -off shall become the Contractor's property. Timber test piles, whether used in the structure or driven outside the structure, will be paid for at the contract unit price for each pile driven under the item for Timber Test Pile. When the test pile is not used in the structure, the price shall also in clude full compensation for the removal of the test pile or cutting off 2 ft below finished grade of ground and backfilling the hole with suitable material. Steel piles will be paid for at the contract unit price per foot under the item for Steel Piles, complete in place. Cast -in-place concrete and steel pipe piles will be paid for at the contract unit price per foot under the items Cast -in-Place Concrete Piles and Steel Pipe Piles, complete in place, including the concrete and steel reinforced cement. Piles driven as Test Piles or for Load Tests, if incorporated in structures, will be paid at the contract unit price for the length in place under the item for the type of pile. II.512 202 4 Edition No payment will be made for the cut- off of precast -prestressed or steel piles. Pile shoes will be paid per each on piles accepted for payment by the Engineer. All costs for splicing piles shall be included in the contract unit price per foot for the respective pile item, which price shall also include full compensation for delays incurred by splicing of piles or by any other operations in connection with the wor k on piles. Pile loading tests will be paid for at the contract unit price for each pile tested under the item for a specific load sequence. The contract price shall also include full compensation for any interruptions to pile driving or other operations in the vicinity of the pile loading tests. The test at each pile shall be considered completed when all materials and equipment used in the test have been removed. If a pile load test is applied to a steel pipe pile, cast -in-place concrete pile, or precast- prestressed concrete pile, then the contract price for a load test shall also include full compensation for cutting the pile to the grade necessary to properly inc orporate the pile in the structure or, if it is not to be incorporated in the structure, for cutting the pile to the grade necessary to avoid its interference with the proposed construction. The cost of performing Wave Equation Analysis shall be included in the contract unit price per foot of pile. Payment for initial and restrike dynamic pile measurements will be at the contract unit price per pile tested. The price shall include costs for all sensory and wiring devices, monitoring equipment; the setting up and checking of equipment, monitoring pers onnel; costs associated with Contractor's down time during regular working hours while setting -up equipment and making dynamic measurements. II.513 202 4 Edition 940.82: Payment Items 940. Untreated Timber Piles ............................................................................................. Foot 941. Treated Timber Piles .................................................................................................. Foot 942 .* Steel Pile, HP __x__ ........................................................................................................ Foot 943 .* Steel Pipe Pile __ -inch OD .......................................................................................... Foot 945. Cast -in-Place Concrete Piles .................................................................................... Foot
946.12Precast -Prestressed Concrete Pile - 12 Inch ..................................................... Foot
946.14Precast -Prestressed Concrete Pile - 14 Inch ..................................................... Foot
946.16Precast -Prestressed Concrete Pile - 16 Inch ..................................................... Foot
946.18Precast -Prestressed Concrete Pile - 18 Inch ..................................................... Foot
946.20Precast -Prestressed Concrete Pile - 20 Inch ..................................................... Foot
947.1Timber Test Pile ........................................................................................................... Each
948.1Short Duration Load Test ......................................................................................... Each
948.2Maintained Load Test ................................................................................................. Each
948.3Quick Load Test ............................................................................................................ Each
948.31Static -Cyclic (Express) Load Test .......................................................................... Each
948.4Dynamic Load Test Preparation ............................................................................ Each
948.41Dynamic Load Test by Contractor ......................................................................... Each
948.5Pile Shoes ......................................................................................................................... Each
999.9401 Untreated Timber Pile Cut -off ................................................................................ Foot
11 Treated Timber Pile Cut -off ..................................................................................... Foot
*Designation by size and weight. 1Not a bid item. SUBSECTION 945: DRILLED SHAFTS DESCRIPTION
945.20: General
This work shall consist of excavating and constructing drilled, cast -in-place reinforced concrete shafts installed in accordance with these specifications and the details and dimensions shown on the plans. Drilled shafts shall consist of reinforced concrete sections that are cast -in-place against in situ soil or rock or a casing. Permanent casings are designed as part of the drilled shaft and shall remain in place after concrete placement is completed. Tempo rary casings shall be installed to facilitate drilled shaft construction and removed during or after concrete placement. The embedment length of the drilled shafts may be modified by the Engineer, pending results of any subsurface investigation taken and/o r load testing performed as an initial part of the work, as approved by the Engineer. II.514 202 4 Edition MATERIALS
945.40: General
Materials shall meet the requirements specified in the following Subsections of Division III, Materials: Cement Concrete .......................................................................................................................... M4.02.00 Reinforcing Steel .......................................................................................................................... M8.01.0 Epoxy Coated Reinforcing Bars ............................................................................................. M8.01.7 Galvanized Reinforcing Bars ................................................................................................... M8.01.8 Mechanical Reinforcing Bar Splicer ..................................................................................... M8.01.9 Steel Casings .................................................................................................................................. M8.05.6 Cross Hole Sonic Testing Access Pipes ............................................................................... M8.22.0 Drilling Slurry ................................................................................................................................ M9.40.0
CONSTRUCTION METHODS
945.50: Personnel Qualifications
Drilled shaft construction personnel must be experienced in this type of work. Experience shall be relevant to anticipated subsurface materials, water conditions, shaft size, and special construction techniques required. Prior to the Preconstruction Conference, the Contractor shall submit the following information to verify the firm’s experience and the qualifications of personnel scheduled to perform the drilled shaft construction:
drilled shaft construction. Include a brief description and reference for each project listed.
for the Project. On -site supervisors shall have at least 2 years of experience in drilled shaft construction, and drill operators shall have at least 1 year of experience.
subsurface information including any soil or rock samples made available in the contract documents. Work on any drilled shafts shall not begin until the qualifications have been approved. The Engineer may suspend the drilled shaft construction if the Contractor substitutes unapproved personnel during construction. Requests for substitution of field personnel shall be submitted to the Engineer for approval. Additional costs resulting from the suspension of work will be the Contractor’s responsibility, and no extension in contract completion date resulting from the suspension of work will be allowed. The Contractor shall have on site during all drilled shaft construction activity a minimum of one person who has fulfilled the qualifications required for drilled shaft field inspector certification. The representative will be responsible for the Contracto r's QC of the drilled shafts during all phases of construction. The Contractor's QC representative shall have proof of certification as a Drilled Shafts Inspector by the NETTCP or an equivalent certification program approved by the Department. II.515 202 4 Edition 945.51: Drilled Shaft Installation Plan The Contractor shall submit a drilled shaft installation plan for review and approval of the Engineer at least 30 days prior to the anticipated date of beginning drilled shaft work. This plan shall provide the following:
overall construction plan and the sequence of shaft construction in bents or groups .
concrete expelled from the top of the shaft (if applicable).
and dispose of the slurry (if applicable). Include a discussion of the suitability of the proposed drilling slurry in relation to the anticipated subsurface conditions.
requirements, required tests and test methods to ensure the synthetic slurry performs as intended. Submit to the Engineer the name and current phone number of the synthetic slurry manufacturer’s representative who will provide techn ical assistance during construction.
centering and lifting methods and the method for supporting the reinforcement on the bottom of the shaft excavation. Include details for ensuring the reinforcing cage position is maintained during construction. Include details for attaching the crosshole sonic logging test access tubes to the reinforcing cage.
completed (if applicable). II.516 202 4 Edition 12. Detailed procedures for permanent casing installation and temporary casing installation and removal, including casing dimensions.
Engineer. These manuals shall become the property of the Department. The Engineer shall approve or reject the drilled shaft installation plan after receipt of all submissions. The Contractor shall provide any additional information and submit a revised plan, if requested, for review and approval. All procedural approvals gi ven by the Engineer will be subject to trial in the field and will not relieve the Contractor of the responsibility to satisfactorily complete the work. The Contractor shall submit requests for modification of adopted procedures to the Engineer. All portions of proposed construction shall be described on shop drawings and submitted to the Engineer for approval. No work shall commence prior to receiving the written approval of the proposed methods and equipment by the Engineer. This approval shall be considered in no way as relieving the Contractor of the responsibility to satisfactorily complete the work in accordance with the Plans and Specifications. A Preconstruction Meeting shall be conducted when so requested by the Engineer. Such meeting is held among the Department, the Contractor and the Drilled Shaft Subcontractor to review special requirements for the drilled shaft work, including installation plans, acceptance and rejection criteria, and project documentation.
945.52: Borings
When required in the contract documents, soil borings and/or rock cores shall be conducted at the specified locations and to the indicated size and depth, as approved by the Engineer. The boring logs shall be reviewed by the Contractor and shall be submitted to the Engineer for approval prior to mobilizing drilled shaft equipment. All work shall be performed in accordance with Subsection 190: Borings .
945.53: Trial Drilled Shaft
When required in the contract documents, a trial shaft shall be constructed by the Contractor. A trial shaft may be required on projects where unusual and variable subsurface conditions exist, when the dry method of construction is proposed, and/or when excavations are performed in open water areas. The Contractor shall demonstrate the adequacy of their methods, techniques and equipment by successfully constructing a trial shaft in accordance with the plans and these requirements. This trial shaft shall be drilled to the maximum depth of any production shaft and away from production shafts as shown on the plans or as directed by the Engineer. Failure by the Contractor to demonstrate the adequacy of methods and equipment shall be reason for the Engineer to require modifications in equipment and/or method by the Contractor to eliminate unsatisfactory results. Any additional trial holes required to demonstrate the adequacy of altered methods or equipment shall be at the Contractor’s expense. The same methods and equipment used to construct the approved trial shaft shall be used to construct the production shafts. II.517 202 4 Edition The trial shaft holes shall be filled with unreinforced concrete in the same manner that production shafts will be constructed and shall be cut off 2 ft below finished grade and left in place. The disturbed areas at these shafts shall be restored as nearly as practical to their original condition.
945.54: Protection of Existing Structures
The Contractor shall control their operations to prevent damage to existing structures and utilities. Preventive measures shall include, but are not limited to, selecting construction methods and procedures that will prevent caving of the shaft excavation, monitoring and controlling the vibrations from construction activities such as the driving of casing or sheeting, drilling of the shaft, or from blasting, if permitted. The Contractor shall be responsible for selecting and using equipment and procedures that keep deformations of adjacent structures within acceptable levels as determined by the Engineer.
945.55: General Methods and Equipment
The Contractor’s methods and equipment shall have adequate capacity including power, torque and down thrust to excavate a hole of both the maximum diameter and to a depth of 25% beyond the depths shown on the plans. The permanent casing method shall be used only at locations shown on the plans or when authorized in writing by the Engineer. The Contractor shall provide all equipment and tools as necessary to construct the shaft excavation to the size and depth required. Drilling tools should contain vents to stabilize hydrostatic pressure above and below the tool during insertion and extraction.
The dry method shall be used only at sites where conditions are suitable to permit construction of the shaft in a relatively dry excavation and where the sides and bottom of the shaft can be visually inspected by the Engineer during the excavation and prio r to placing the concrete. The dry method shall only be approved when a trial shaft excavation demonstrates that: less than 6 in. of water accumulates above the base over a one- hour period without pumping; the sides and bottom of the hole remain stable wit hout caving and sloughing over a 4- hour period following completion of excavation; any loose material or water can be removed prior to inspection and concrete placement.
The wet method consists of using water or slurry (mineral or polymer) to maintain stability of the drilled hole while advancing the excavation to final depth, placing the reinforcing cage, and concreting the shaft. Slurry should be introduced when the depth of the drilled hole is still above the piezometric level and not after the inflow of water is detected and/or sloughing has begun. This method may involve desanding and cleaning the slurry and final cleaning of th e excavation by means of bailing bucket, air lift, submersible pump or other approved devices. The wet method may also be used in combination with the casing method. II.518 202 4 Edition C. Casing Method. The casing method may be used at sites where the dry or wet methods are inadequate to prevent hole caving or excessive deformation of the hole. The casing may be either placed in a predrilled hole or advanced through the ground by twisting, driving, or vibration before being cleaned out. When the casing is placed in a predrilled borehole, the temporary stability of the hole may need to be assured by using drilling slurry. The rising column of fluid concrete must force the slurry that is trapped in the annular space behind the casing out as the casing is being pulled. The casing method may not be permitted at specified depths that are designated for mobilization of side resistance.
945.56: Drilled Shaft Excavation
The Contractor shall use excavation techniques that are technically adequate and cost effective to meet the geologic conditions encountered at the site. Excavation for drilled shafts shall be made so that the sidewalls of the hole are stable at all times. Drilled shafts shall be excavated to the dimensions and elevations shown or as directed. Materials removed from the shaft excavations and slurry shall be disposed of according to the applicable federal, state and local regulations and shall not be discharged into any stream, waterway, or storm water drainage system. If approved by the Engineer, a partially excavated shaft may be left open overnight, provided that the excavation: • Is stabilized at the bottom, sides and surface to prevent soil caving or swelling or a reduction of soil strength ; and • Is covered at the surface to protect the public. Excavation shall not commence immediately adjacent to a concreted drilled shaft for a minimum of 24 hours after completing the shaft concrete pour. The Contractor shall extend the drilled shaft tip elevations when so indicated by the results of the load test and/or the Engineer determines that the material encountered during excavation is unsuitable or differs from that anticipated in the design of the drilled shaft. Drilled shaft excavation is excavation accomplished with conventional tools such as earth augers, casing twisters, drilling buckets, and overreaming (belling) buckets attached to drilling equipment of the size, power, torque, and down thrust (crowd) approved for use by the Engineer. Should the Engineer have reason to believe that the drilled shaft excavation techniques or workmanship have been deficient, so that the integrity of any excavation is in question, work on that drilled shaft shall be stopped. Drilled shaft excavation will not be allowed to resume until the deficient excavation techniques or workmanship have been changed to the satisfaction of the Engineer. II.519 202 4 Edition B. Clean Out. Appropriate means, such as a cleanout bucket or air lift, shall be employed to clean the bottom of the drilled shaft excavations. No more than 1 in. of loose or disturbed material will be allowed at the bottom of the excavation for end -bearing drilled shafts. No more than 3 in . of loose or disturbed material will be allowed at the bottom of the excavation for skin friction drilled shafts. All drilled shafts shall be assumed to be end- bearing shafts. Shaft cleanliness will be determined by the Engineer. The Engineer shall be notified of completion of each drilled shaft excavation to permit inspection before proceeding with construction. The drilled shaft dimensions and alignment shall be verified with approved methods. Final shaft depths shall be measured with a suitable weighted tape or other approved method after final cleaning. The drilled shaft excavation may be extended if the Engineer determines that the subsurface materials encountered are not capable of providing the required bearing capacity or differ from those anticipated in the design of the drilled shafts. If caving occurs during any construction procedure, the construction operation shall be stopped, the Engineer shall be notified, and the shaft excavation shall be stabilized by approved methods.
Rock socket excavation is excavation that requires rock -specific tools and/or procedures to accomplish hole advancement, such as rock augers and core barrels. All excavation performed below the depth where rock socket excavation is authorized shall be considered rock socket excavation regardless of the density, strength, hardness, or changes in type or character of materials encountered.
Obstructions are defined as impenetrable objects that cannot be removed or excavated using conventional rock or soil augers, drilling buckets, casing twisters, and cause a significant decrease in the rate of excavation advancement as compared to before the obstruction was encountered or shafts in close proximity advanced using the same techniques and equipment. The Engineer will consider the equipment, techniques, and level of effort by the Contractor and shall be the sole judge of the significance of any r educed rate of shaft advancement and the classification of obstruction excavation. Special procedures/tools needed to remove obstructions may include: core barrels, chisels, boulder breakers, downhole hammers, hand excavation, temporary casing, and increasing the hole diameter. Blasting shall not be permitted. The Contractor shall specifically log the depth and rate of removal of the obstruction. Those obstructions located within 5 ft of the top level of the ground surface during shaft drilling at shaft locations shall be removed at the expense of the Contractor. Such obstructions may include man -made materials such as old foundations, utilities, tunnels, and natural materials such as boulders and wood. Drilling tools that are lost in the excavation shall not be considered obstructions and shall be promptly removed by the contractor without compensation. All costs due to lost tool removal shall II.520 202 4 Edition be borne by the Contractor including but not limited to, costs associated with the repair of hole degradation due to removal operations or an excessive time that the hole remains open. The rate of occurrence of obstruction encounters during the excavation and construction of drilled shafts may vary considerably from what is inferred from the boring logs due to sampling limitations of the boring(s), sampling bias due to the diameter differences between the drilled shaft and the boring(s), and spatial variability of the soil deposit. The Engineer shall be present to evaluate the occurrence of obstructions, to authorize, and to approve the designation of such. Sloping bedrock and/or higher than anticipated bedrock, as inferred from the borings, shall not be considered obstruction excavation.
Casings shall be steel, clean, watertight, and of ample strength to withstand handling and installation induced stresses and the pressure from both concrete and surrounding earth materials. The outside diameter (O.D.) of casings shall not be less than the specified size of shaft. Casings may be either placed in a predrilled hole or advanced through the ground by twisting, driving or vibration before being cleaned out. Permanent casings shall be used only at locations shown on the plans or upon approval by the Engineer. The casing shall be continuous between top and bottom elevations. Temporary casings shall be provided to aid shaft alignment and position, to prevent sloughing of the shaft excavation, and to prevent excessive deformation around the hole. As the temporary casing is withdrawn, the level of concrete (and drilling fluid/slurry, if used) shall be maintained with a sufficient head to prevent any water and/or other extraneous materials from entering the drilled shaft. In addition to the foregoing , the level of concrete in the temporary casing shall be maintained a minimum of 5 ft from the bottom of the casing. As the casing is withdrawn, care shall be exercised to maintain an adequate level of concrete within the casing so that fluid trapped behin d the casing is displaced upward and discharged at the ground surface without contaminating or displacing the shaft concrete.
If synthetic drilling slurry is selected, a manufacturer’s representative shall be available to provide technical assistance at the site prior to use of the slurry. The manufacturer’s representative shall remain available during construction to adjust the slurry mix for the specific site subsurface conditions. All in -hole drilling slurry shall meet the required Specifications prior to concrete placement. The slurry shall be cleaned, re -circulated, de -sanded or replaced to maintain the required slurry properties. The level of slurry in the excavation shall be maintained at not less than 5 ft above the groundwater level for all slurries. The slurry level shall be maintained a sufficient distance above all unstable zones to prevent bottom heave, caving or sloughing. Slurry shall feed continuously into the shaft excavation as drilling progresses so that a stable excavation is maintained. A self -priming pump shall be used to reclaim the slurry. A functioning standby pump shall be kept on- site and available during the dr illing operation. II.521 202 4 Edition G. Drilling Slurry Inspection and Testing. All drilling slurries shall be mixed and kept thoroughly hydrated in an appropriate storage facility. Sample sets shall be collected from the storage facility and tests shall be performed to ensure the slurry conforms to the specified material properties b efore introduction into the drilled shaft excavation. A sample set shall be composed of samples taken at mid -depth and within 24 in. of the bottom of the storage facility. All slurry shall be sampled and tested in the presence of the Engineer. Final cleani ng of the excavation and placement of concrete will not be allowed until the test results indicate the slurry properties are as specified. A minimum of two sets of slurry tests shall be performed per eight -hour work shift, the first test being done at the beginning of the shift. Field conditions may require more frequent testing to ensure acceptable slurry properties. Copies of all slurry tes t results shall be provided to the Engineer on request.
945.57: Construction Quality Control
Drilled Shafts shall be located and staked by the Contractor who shall maintain and be responsible of all location and elevation stakes. The Contractor shall maintain a construction method log during shaft excavation and concreting of each drilled shaft. This record shall be available for the Engineer’s inspection as directed. The log shall contain for each shaft the following information: • Shaft number, date and time of installation. • Description and approximate top and bottom elevation of each soil or rock material, and final tip elevation. • Level and variation of the piezometric surface. • Excavation procedures and method used to stabilize the sides of shaft and any seepage of groundwater. • Quantity, type of obstruction material, and drilling rate. • Diameter of the as -built shafts. • Plumbness and deviation of shaft location. • Type, diameter, and length of any casing left in place. • Time, method, and duration of placement of concrete. • A chart showing quantity of concrete placed versus depth or elevation of top of concrete in shaft during placement. • Other pertinent data relative to the installation.
The Contractor shall provide to the Engineer access and equipment for checking the dimensions and alignment of each permanent shaft excavation. After excavation is complete, the bottom of the shaft shall be measured and sounded with a steel rod (AW) and/or a weighted tape. A check of the bearing surface by sounding shall be made in the presence of the Engineer, who shall determine if the drilled shaft excavation is acceptable. The bearing surface shall be sounded again immediately before placing concrete. II.522 202 4 Edition No more than 1 in. of loose or disturbed material will be allowed at the bottom of the excavation for drilled shafts designated as end- bearing and no more than 3 in. of loose or disturbed material will be allowed at the bottom of the excavation for drilled shafts designated as deriving their capacity from skin friction. Shaft cleanliness will be determined by the Engineer, based on visual inspection for dry shafts and other methods deemed appropriate for wet shafts. In addition, for dry excavations the maximum depth of water shall not exceed 3 in. prior to concrete placement.
The following construction tolerances apply to drilled shafts:
elevation for the top of the shaft.
within 2 in . of the plan top of shaft elevation.
per foot of shaft diameter.
vertical, and elevation tolerances shall meet the structural column or cap requirements. Drilled shaft excavations constructed in such a manner that the concrete shaft cannot be completed within the required tolerances are unacceptable. Correction methods shall be submitted by the Contractor for the Engineer’s review and approval before continuing with any drilled shaft construction. Correction procedures are dependent on analysis of the effect of the degree of misalignment and improper positioning.
Drilled shaft excavation and cement concrete placement shall be scheduled so that each drilled shaft is cast immediately after drilling operations are complete. After the first drilled shaft on a project has been accepted, no significant change in construction methods, equipment, or materials used shall be made in the construction of subsequent shafts. Construction of subsequent shafts shall not proceed until the first drilled shaft has been approved by the Engineer. Drilling may commence on a subsequent sh aft at an approved location provided that the cement concrete placement operation on the previous drilled shaft is in progress and there are sufficient workers present to complete all required operations. For a minimum period of 24 hours after completion of the cement concrete placement operation in a newly constructed shaft, including withdrawal of casing if applicable, none of the following operations shall be permitted within 15 ft of the newly constructed shaft: • Excavation for adjacent shafts; • Construction of footings; • Application of equipment loads; or • Introduction of vibrations with a peak particle velocity of greater than ¼ in. per s econd . II.523 202 4 Edition 945.58: Steel Reinforcement Configuration and Placement Steel reinforcement shall not be placed until the Engineer has approved the results of all borings and load tests for drilled shafts. The clear spacing between bars of the steel reinforcement cage shall be at least 5 times the size of the maximum coarse aggregate size of concrete. Reinforcing steel bars shall be connected together using double wire ties at each intersection of the longitudinal bars and spirals. Hooks at the top of the steel reinforcement cage shall not be bent outward if there is any chance that temporary casing will be used. Similarly, interior h ooks must be designed to permit adequate clearance for a concrete tremie pipe, i.e., 12 in. minimum. The assembled steel reinforcement cage outside diameter must be at least 10 in. smaller than the drilled hole diameter. This clear space is necessary both to permit free flow of concrete up the annular space between the cage and the hole perimeter and to provide adequate concrete cover over the steel reinforcement cage. The steel reinforcement in the shaft shall be tied and supported so that the steel reinforcement will remain within the allowable tolerances given above. Concrete spacers or other non -corrosive durable spacing devices shall be used at sufficient intervals not exceeding 10 ft up the shaft to insure concentric spacing for the entire steel reinforcement cage length. The spacers shall be of adequate dimension to insure a minimum 5 in. annular space between the outside of the steel reinforcement cage and the side of the excavated hole or casing. The spacing of the spirals and/or ties may be adjusted slightly to accommodate the rotation of the centering devices. Cylindrical concrete feet, or approved alternate bottom supports, shall be provided to ensure that the bottom of the cage is maintained 3 in. above the base. The steel reinforcement cage, consisting of longitudinal bars, spirals and/or ties, cage stiffener bars, spacers, centralizers, and other necessary appurtenances, shall be completely assembled and placed as a unit immediately after the shaft excavation is inspected and accepted. The steel reinforcement cage shall be supported by positive methods to prevent its displacement during concrete placement.
945.59: Cement Concrete Placement
Cement concrete placement shall be performed in accordance with the applicable portions of Subsection 901: Cement Concrete and in accordance with the requirements herein. Cement concrete quantities over the theoretical amount required to fill any excavations for the shafts dimensioned on the plans shall be furnished at the Contractor’s expense. The bottom of the shaft shall be sounded immediately before placing concrete. Cement concrete placement for a drilled shaft shall start within 2 hours after the excavation has been completed and approved and the steel reinforcement has been placed and approved. If cement concrete placement is not begun within 2 hours, then the steel reinforcement cage shall be removed and inspected. The Contractor shall remove any caked slurry or soil from the steel reinforcement cage before returning the cage to the shaft, re -clean the bottom, re -circulate, and test the slurry prior to resetting cage. Cement concrete shall be placed in a manner to prevent segregation. Cement concrete placement II.524 202 4 Edition shall be a continuous operation except for the time interval necessary to remove temporary casings, tremie pipe sections, and to change concrete trucks. The cement concrete shall remain in a workable plastic state through the placement period. Prior to cement concrete placement the Contractor shall provide test results of both a trial mix and slump test conducted by an approved testing laboratory to demonstrate that the cement concrete meets the above requirements. If the drilled shaft excavation cannot be pumped free of seepage water at the time of cement concrete placement, the cement concrete shall be placed under water with a tremie pipe or pump hose. Cement concrete placement shall proceed continuously from the bottom of the shaft to the top of shaft elevation shown. Shaft cement concrete may be placed without mechanical vibration in those areas of the drilled shaft that are not formed or are below the ground line or the water surface. If caving occurs during concrete placement, the shaft will be rejected, and a repair plan shall be submitted by the Contractor to the Engineer for approval. Should a delay in cement concrete placement occur because of a delay in cement concrete delivery or other factors, the placement rate shall be reduced to maintain a flow of fresh concrete into the shaft excavation. A maximum of 60 minutes shall be allowed between cement concrete placements. No cement concrete older than 90 minutes from batch time shall be placed. Procedures for cement concrete placement shall ensure that the cement concrete within the shaft becomes a monolithic, homogeneous unit. The expose d top of concrete shall be cured a minimum of 7 days by covering with wet burlap overlain with plastic sheets. The burlap shall be kept continuously wet during the entire 7 -day cement concrete cure period.
Tremies may be used for cement concrete placement in either wet or dry holes. Tremies used to place cement concrete shall consist of a tube of sufficient length, weight, and diameter to discharge cement concrete at the shaft base elevation. The tremie shall not contain aluminum parts that will have contact with the concrete. The tremie inside diameter shall be at least 6 times the maximum size of aggregate used in the cement concrete mix but shall not be less than 8 in. for tremie pipe or 4 in. for pump hos e. The inside and outside surfaces of the tremie shall be clean and smooth to permit both flow of cement concrete and unimpeded withdrawal during concreting. The wall thickness of the tremie shall be adequate to prevent crimping or shear bends that restrict cement concrete placement. An alternate delivery system that can be used in case of failure of the primary delivery system shall be provided. Tremie cement concrete shall be placed so that mixing with groundwater or slurry is avoided. The tremie tube shall be fitted with a valve or plug to prevent the cement concrete placed initially from contacting water before a sufficient head of concrete has been obtained. The bottom of the tremie tube shall be kept a minimum of 5 ft below the top of the in -place concrete at all times once the cement concrete has reached a depth of 5 ft. The initial placement of the tremie pipe shall be within 12 in. from the bottom of the shaft. The tremie used for wet excavation concrete placement shall be watertight. Underwater placement shall not begin until the tremie is placed to the shaft base elevation. Plugs shall either be removed II.525 202 4 Edition from the excavation or be of material approved by the Engineer that will not cause a defect in the shaft if not removed. The discharge end of the tremie shall be constructed to permit the free radial flow of concrete during placement operations. If concrete is placed under water, all displaced water shall be disposed of in an approved manner. When groundwater, the drilling water or slurry in the shaft excavation is to be removed by pumping during concrete placement, a standby pump shall be kept av ailable on -site.
Concrete pumps and lines may be used for concrete placement in either wet or dry excavations. All pump lines shall have a minimum 4 in. diameter and be constructed with watertight joints. Cement concrete placement shall not begin until the pump line discharge orifice is at the shaft base elevation. Cement concrete shall be placed in a continuous operation so that the cement concrete always flows upward within the shaft. The delivery hose or pipe shall be withdrawn slowly as the elevation of the fresh concrete rises in the shaft. The discharge end of the pipe or hose shall be kept at least 5 ft below the surface of the cement concrete after the cement concrete has reached a depth of 5 ft . When lifting the pump line during concreting, the Contractor shall temporarily reduce the line pressure until the o rifice has been repositioned at a higher level in the excavation. During cement concrete placement, markings on the tremie pipe or pump hose or a sounding device or other appropriate method shall be provided and maintained to determine the relative elevati ons of the fresh cement concrete surface and the bottom end of the pipe or hose. For wet excavations, a plug or similar device shall be used to separate the concrete from the fluid in the hole until pumping begins. The plug shall either be removed from the excavation or be of a material, approved by the Engineer, which will not cause a defect in the shaft if not removed. If for any reason, the tremie/pump line is removed during concrete placement, the line must be resealed at the bottom and once again embedded sufficiently below the level of concrete at which the tremie pipe was removed prior to continuation of the pour. C oncrete placement can then be continued until fresh uncontaminated concrete has overflowed the top of the shaft. All contaminated concrete must be removed exposing the clean concrete in the shaft.
The free fall placement of cement concrete shall only be permitted in dry holes. The maximum height of free fall placement shall not exceed 25 ft. Drop chutes shall be used to direct placement of cement concrete to the base of the excavation, where the maximum depth of water shall not exceed 3 in. , without hitting either the steel reinforcement cage or hole sidewall. Drop chutes shall consist of a smooth tube of either one -piece construction or sections that can be added and removed. Cement concrete may be placed through either a hopper at the top of the tube or side openings as the drop chute is retrieved during concrete placement. The drop chute shall be supported so that the free fall of the concrete measured from the bottom of the chute is less than 25 ft at all times. If placement cannot be satisfactorily accomplished by free fall in the opinion of the Engineer, the Contractor shall use either tremie or pumping to accomplish the placement of cement concrete. II.526 202 4 Edition E. Casing Removal. If a temporary casing is used during drilled shaft construction, casing removal shall not start until the level of fresh cement concrete within the casing has reached a depth of 10 ft . As the temporary casing is withdrawn, a minimum 5 ft head of concrete above the bottom of the casing shall be maintained. The elevation of the top of the steel reinforcement cage and the elevation of the top surface of the shaft cement concrete shall be checked before and after temporary casing extraction. Any upward or downward movement of the steel reinforcement cage or any large downward movement of the surface of the concrete during casing extraction shall be cause for rejection of the shaft. A slight downward movement of the casing while exerting downward pressure or hammering or vibrating the casing will be permitted to facilitate extraction. Casing that cannot be extracted during or immediately after the cement concrete placement operation shall also be cause for rejection of the shaft. A repair plan (or a structural evaluation for temporary casing not extracted from the shaft excavation) for all rejected shafts shall be submitted to the Engineer for approval. The tops of permanent casings shall be removed to the top of the drilled shaft or the finished ground line, whichever is lower. The tops of permanent casings for shafts constructed in a permanent body of water shall be removed to the low water elevation.
945.60: Inspection
Nondestructive Evaluation (NDE) tests shall be performed on all completed drilled shafts as directed by the Engineer. Such tests may include cross- hole acoustic tests, sonic echo tests, and other specified NDE tests.
Cross- hole sonic logging (CSL) is a down -hole ultrasonic test method used to evaluate the condition of the concrete within drilled shafts. The test shall meet ASTM D6760 requirements as modified herein. This method involves using a piezo -electric transducer (emitter), to generate a signal that propagates as a sound wave (sonic) within the concrete, and another transducer (receiver) is used to detect the signal. Both transducers are placed into a vertical steel pipe filled with water that acts as a coupling medium between the transducer and the tube. These pipes are attached to the reinforcement cage. The transducers are lowered to the bottom of their respective pipes and placed in the same horizontal plane. The emitter transducer generates a sonic pulse that is detected by the receiver in the opposite pipe. While the pulses are generated, the two trans ducers are simultaneously raised within the pipes until they reach the top of the drilled shaft. This process is repeated for each possible pipe combination. The existence of a flaw or defect (void, soil inclusion, or necking within the shaft) will slow down the signal. The signal arrival times are plotted with depth to generate a log for the particular pipe combination. In addition, the energy of each signal ( integration of the amplitude with time) is also II.527 202 4 Edition plotted with depth. Lower energy or longer arrival times would indicate the occurrence and location of the defects.
Provisions for sonic testing shall be made for all shafts. The testing subcontractor and test method to be used for sonic testing shall be approved by the Engineer. A record of experience of the testing subcontractor shall be submitted to the Engineer alon g with written description of the testing procedures, operation manuals for the testing equipment, and samples of previous test results indicating both sound and defective shaft.
The Contractor shall furnish and install a minimum of four 1.5 -in. to 2-in. internal diameter steel pipes to provide access for sonic testing in each drilled shaft. The pipes shall be installed such that all internal joints are flush. If the number and placement of the pipes are not called out in the construction drawings, then the following guidelines shall be used: Table 945. 60-1: Pipe Requirements Based Upon Shaft Diameter Shaft Diameter ≤5 ft 4 Pipes (Minimum) 5 ft < Shaft Diameter ≤8 ft 6 Pipes (Minimum) Shaft Diameter >8 ft 8 Pipes (Minimum) The steel pipes shall be connected so that the transducers can pass through unobstructed. The tubes shall be clean from any corrosion or dirt to ensure a good bond between the tube and concrete. The pipes shall be watertight (including at joints) and capped at the bottom and the top. The top cap must be removable, i.e., threaded for access of the transducers during testing. The pipes shall be attached to the interior of the reinforcement cage or as specified in the contract documents. However, if the clear spacing between longitudinal bars is less than 5 in ., the pipes shall be offset from the rebar cage by 3 in. toward the center of the shaft. The pipes shall be located in a symmetric pattern depending on the size of the shaft and the number of pipes. Tie wire or spacers shall be used to attach the pipes to the reinforcement cage so that they remain as vertical a nd parallel a s possible during cage installation. The pipes shall extend from 6 in . above the bottom of the shaft to 3 ft above the top of the shaft, or ground surface, whichever is higher. The pipes shall not be placed on the bottom of the shaft. The pipes shall be full of clean water prior to cement concrete placement. The caps must be sealed to prevent debris from entering the pipes after the water is placed. The pipes must be handled with care during installation and capping (i.e. , no twisting or impacting). After completion of CSL testing and upon approval of the Drilled Shaft by the Engineer, the water shall be removed from the pipes to be completely filled with a cement or sand -cement grout.
The Sonic Logging equipment furnished by the Contractor shall consist of the following components: II.528 202 4 Edition • Ultrasonic emitter and receiver probes capable of producing records with good signal amplitude and energy through concrete. • A measurement wheel or other suitable linear measuring device to record the depth of the transducers. • A microprocessor -based system, with data filtering/amplification and synchronized triggering of records with pulses, that is capable of permanent recording of data, display of individual records, and printing of logs. • The Contractor shall also furnish all necessary supplies, support equipment, power, and provide reasonable access to the shaft top for performance of the sonic logging.
Completed drilled shafts shall be tested between 1 and 7 days after placing of cement concrete. Information on the drilled shafts to be provided to the CSL consultant shall include: Shaft bottom and top elevations, pipe lengths and positions, and construction dates including cement concrete placement. Sonic Logging shall be performed between all possible tube combinations. Tests shall be performed in the same horizontal plane in all pairs of pipes directly across from each other. Tests involving different horizontal planes would be conducted if requested by the Engineer or when necessary to further evaluate defects. The probes shall be raised simultaneously from the bottom of the pipes by winch ensuring that all slack is taken out of the cables before the analyzer is switched on. The speed of ascent should be less than 1 ft per second. A depth wheel or similar measuring device shall be used to provide accurate depth measurements. Measurements shall be taken at 0.2 ft intervals or as otherwise directed by the Engineer.
The Contractor shall provide a CSL Report signed by a Professional Engineer providing the results and recommendations for acceptance or correction of each shaft tested. The report shall include the following: • The cross -hole sonic logs with potential defects indicated. • Records of the initial pulse arrival time and energy/amplitude vs. depth for each pipe combination. • Related interpretation and discussion of the results. Defects identified by longer arrival times or lower energy signals shall be promptly reported to the Engineer. Any further tests required by the Engineer to evaluate the extent of the defects shall be duly carried out.
Any indicated drilled shaft defects shall require further integrity testing. The Engineer may require other nondestructive tests upon evaluation of the data. These tests may include cross- hole tomography, Single -hole Sonic Logging, Pulse Echo Method, or others. II.529 202 4 Edition If the additional tests and records are inconclusive, the Engineer may require coreholes of the defective shaft, at the expense of the Contractor. If the cores show defects in the shaft, these defects shall be repaired at the Contractor’s expense by methods acceptable to the Department.
945.61: Drilled Shaft Load Tests
When the contract documents include load testing of shafts, the load test shall be completed before construction of any production drilled shafts. The Contractor shall construct a test shaft in accordance with the provisions of the specifications. The Depa rtment's Geotechnical Engineer shall be notified at least 2 working days prior to the start of the load test. The load test can be performed when 75% of the design compressive strength of the concrete for the drilled shaft is achieved as determined from cylinder breaks. The Contractor shall allow 10 working days for analysis of the load test data by the Engineer before estimated drilled shaft tip elevations are provided for production shafts. Static load tests shall conform to the requirements of ASTM D1143 (vertical load testing -quick test method) and ASTM D3966 (lateral load testing) or as modified herein. Bi-directional load tests shall conform to the requirements of ASTM D8169 or as modified herein. Other types of Load Tests may be included in a project’s Special Provisions. A detailed Testing Plan, in conformance with the specification requirements, shall be submitted to the Engineer for review and approval. The contractor shall supply calibration certificates from a certified testing laboratory for each instrument to measure load or movement during the load testing of the drilled shaft. The number and locations of load tests shall be shown on the plans and/or as designated by the Engineer. The load test shafts shall be loaded to a load equal to 3 times the test shaft design load, or to plunging failure, whichever occurs first. Plunging fa ilure is defined as a deflection of the shaft head equal to 5% of the shaft diameter.
This work shall consist of furnishing all materials and labor necessary for conducting an Osterberg Cell Load Test and reporting the results of the test. The Osterberg Cell, herein called the O -cell, is a calibrated bi -directional loading device capable of applying loads upward and downward, when embedded in a drilled shaft. The drilled shaft used for the load test shall be instrumented by the Manufacturer of the O -cell as directed by the Engineer.
The Contractor shall obtain the services of a licensed Professional Engineer, with O -cell load testing experience, to conduct the test in compliance with these specifications, record all data and furnish reports of the test results to the Engineer. The Manufacturer's Representative from the supplier of the Bi -direction Load cell shall be present on site during the installation of the load cell and other instruments required for testing of the shaft, the placement of the concrete for the test shaft and during initial testing. II.530 202 4 Edition 2. Instrumentation and Materials. The Contractor shall supply all instrumentation and materials required to install the O -cell, conduct the load test and remove the load test instrumentation and apparatus as required. Instrumentation and materials include, but are not limited, to the follo wing:
bottom of the cell. Also, a beam or pipe, as required by the manufacturer, to support its placement in the test shaft.
will be required.
of the shaft, supported at a minimum distance of 3 shaft diameters from the center of the shaft.
gages applied in pairs at approved intervals throughout the shaft length. The instrumentation shall be able to provide the distribution of stresses along the shaftle ngth and to distinguish bottom displacement from top displacement of the tested shaft.
manufacturer's representative, to form the hydraulic fluid pressure used to pressurize the O-cell.
The Contractor shall supply equipment required to install the O -cell, conduct the load test, and remove the load test apparatus. Equipment includes but is not limited to:
equipment, attach pipes, plates and fittings to the O -cell.
cell and during the conducting of the test, including but not limited to a crane or other lifting device(s) for the cell piping, manual labor, and hand tools as required by the manufacturer's representative.
representative. II.531 202 4 Edition 4. Procedures. The O -cell, piping and other attachments will be assembled and made ready for installation under the direction of the manufacturer of the load cell in a suitable area, adjacent to the test shaft, to be provided by the Contractor. When a reinforcing steel cage is required for the test shaft, the O -cell assembly shall be welded to the bottom of the cage in conjunction with the construction of the cage. If a rebar cage is not required, the load cell and piping shall be supported during installation by suitable means such as two channel beams attached on each side. When excavation for the test shaft has been completed, inspected, and accepted by the Engineer, a seating layer of concrete or grout shall be placed, by an approved method, at the base of the shaft. The Contractor shall then install the O- cell under the direction of the manufacturer and the Engineer such that the cell is res ting firmly in the bed of grout or concrete. The Contractor shall use utmost care in handling the test equipment assembly so as not to damage the instrumentation during installation. Alternatively, the O -cell and its support system can be lowered to near -bottom of the shaft and the center pipe from the cell can be used to grout the space between the cell and the bottom of the shaft so as to firmly seat the cell. After installation of the cell, the drilled shaft shall be concreted in a manner specified above. The load sequence shall be as follows:
minute intervals until the maximum capacity of the cell is reached or until the shaft has failed as determined by the Engineer.
a minimum of ½ hour.
1-, 2- and 4 -minute intervals while the load is held constant. During the period required to perform the load test, no drilling or excavation operations on any shaft may be performed. If test apparatus shows signs of negative effects due to other construction activities, such activities shall be halted for the duratio n of the test. After completion of the load test the contractor shall remove any equipment, material, waste, etc., which are not to be part of the finished structure.
The contractor will supply a report in PDF format for each load test detailing the load -movement curves and test data. The report shall be reviewed and approved by the Engineer.
945.62: Defective Drilled Shafts
Defective drilled shafts are defined as exhibiting flaws that result in inadequate performance (deflections criteria) or unsafe performance (capacities criteria) under the shaft design loads, as determined by the Engineer, based on the shaft construction records, NDE, and load test data. II.532 202 4 Edition The Contractor shall submit a plan for remedial action to the Engineer for acceptance. Modifications to the structural integrity and/or load transfer mechanism caused by the remedial action shall require that calculations and working drawings stamped by a Professional Engineer registered in the Commonwealth of Massachusetts for all elements affected, be provided. All labor and materials necessary to complete the remedial work shall be furnished without cost to the Department. COMPENSATION
945.80: Method of Measurement
Drilled shaft excavation will be measured for payment on a length basis by the foot of completed drilled shaft excavation of the diameter shown on the plans measured along the centerline of the shaft from the bottom to the top of the completed shaft excavation or as indicated on the plans , less the measured length of obstruction excavation and less the measured length of rock socket excavation. Measurement shall be to the nearest 0.1 ft . Rock socket excavation will be measured for payment on a length basis by the foot of completed rock socket excavation of the diameter shown on the plans measured from the highest point of encountered rock within the excavation to the bottom of rock socket. Measurement shall be to the nearest 0.1 ft . Obstruction excavation, after designation as obstruction excavation by the Engineer, will be measured for payment on a length basis by the foot of completed obstruction excavation of the shaft diameter indicated on the plans. Measurement shall be to the nearest 0.1 ft. Trial drilled shafts that are accepted, including backfill when required, will be measured for payment by the foot of completed trial drilled shaft of the diameter shown on the plans measured along the centerline of the trial shaft from the bottom of completed trial shaft to the top of the completed trial shaft or as indicated on the plans. Measurement shall be to the nearest 0.1 ft. Drilled shafts, of the cement concrete and steel reinforcement as shown on the plans, will be measured for payment on a length basis by the foot of completed drilled shaft of the diameter shown on the plans measured along the centerline of the shaft from t he bottom of the rock socket or shaft excavation to the top of the completed shaft or as indicated on the plans. Measurement shall be to the nearest 0.1 ft . Permanent casing will be measured for payment on a length basis by the foot of permanent casing of the diameter shown on the plans measured along the centerline of the shaft from the bottom to the top of the permanent casing. Measurement shall be to the nearest 0.1 ft. CSL access pipes will be measured on a length basis by the number of feet of pipes installed and grouted (upon acceptance of testing) regardless of whether sonic testing is performed. CSL sonic testing shall be measured on an each basis per shaft tested. Osterberg load cell axial load testing shall be measured on an each basis per shaft tested. Conventional axial load testing shall be measured on an each basis per shaft tested. II.533 202 4 Edition 945.81: Basis of Payment Drilled shaft excavation will be paid at the contract unit price per foot of completed drilled shaft excavation of the diameter shown on the plans. Payment for drilled shaft excavation shall be considered complete compensation for temporary casing, water c ontrol, removal from the site and disposal of excavated materials, using slurry as necessary, tools and drilling equipment to excavate the shaft, and furnishing all other labor, materials and equipment necessary to complete the drilled shaft excavation. If larger diameter drilled shaft excavation than that specified on the plans is performed at the Contractor’s option, no additional compensation will be provided to perform this oversized drilled shaft excavation. Rock socket excavation will be paid at the contract unit price per foot of completed rock socket excavation of the diameter shown on the plans. Payment for rock socket excavation shall be considered full compensation for water control, removal from the sit e and disposal of excavated materials, drilling equipment, procedures to excavate the rock socket to the required depths, and all labor, materials, equipment, and tools necessary to complete the rock socket excavation. If larger diameter rock socket excavation than that specified on the plans is performed at the Contractor’s option, no additional compensation will be provided to perform this oversized rock socket excavation. Obstruction excavation, after designation as obstruction excavation by the Engineer, will be paid at the contract unit price per foot of completed obstruction excavation of the shaft diameter indicated on the plans. Payment for obstruction excavation shall be considered full compensation for water control, removal from the site and disposal of excavated materials, drilling equipment, procedures to excavate the obstruction to the required depths, and all labor, materials, equipment, and tools necessary to co mplete the obstruction excavation. If larger diameter obstruction excavation than that specified on the plans is performed at the Contractor’s option, no additional compensation will be provided to perform this oversized obstruction excavation. Trial drilled shafts that are accepted will be paid at the contract unit price per foot of completed trial drilled shaft of the diameter shown on the plans. Payment for trial drilled shafts shall be considered full compensation for the excavation of the tr ial shaft hole through whatever materials are encountered to the authorized bottom of trial shaft, including obstructions, temporary casings, backfilling the hole with unreinforced concrete, restoring the site as required, and all other incidentals necessa ry to complete the trial drilled shaft. If larger diameter trial drilled shaft than that specified on the plans is performed at the Contractor’s option, no additional compensation will be provided to perform this oversized trial drilled shaft. Drilled shafts, of the diameter, cement concrete and steel reinforcement as shown on the plans, will be paid at the contract unit price per foot of completed drilled shaft. Payment for drilled shafts shall be considered full compensation for all cement con crete, steel reinforcement, labor, materials, equipment, and all other incidentals necessary to complete the drilled shaft. This payment shall include all cement concrete and steel reinforcement that extends into rock sockets, if any, and all steel reinfor cement that is embedded in the shaft and extends above the top of the shaft to the point where it connects to any steel reinforcement that is not embedded in the drilled shaft. Bracing, centering devices, and support devices for the steel reinforcement cage shall be considered incidental to the work. If a larger diameter drilled shaft than that specified on the plans is II.534 202 4 Edition constructed at the Contractor’s option, no additional compensation will be provided to perform this oversized drilled shaft construction. Permanent casing shall be paid at the contract unit price per foot of permanent casing of the diameter shown on the plans furnished and installed in the drilled shafts. Payment for permanent casing shall be considered full compensation for all labor, materials, equipment, and all other incidentals necessary to complete the permanent casing. CSL access pipes shall be paid at the contract unit price per foot pf access pipe installed. Payment for CSL access pipes shall be considered full compensation for the supply and installation of the pipe and the grouting of the pipes after testing. CSL sonic testing shall be paid at the contract unit price per shaft tested. No payment shall be made for supplementary sonic logging testing required to further evaluate any shaft defects detected by the initial CSL sonic test. Payment for CSL sonic testi ng shall be considered full compensation for the performance of the test, including all labor, equipment, and materials incidental to the test instrumentation, data collection, and report. Osterberg load cell axial load testing shall be paid for at the contract unit price per each Osterberg load cell axial load test completed and accepted. Payment for Osterberg load cell axial load testing shall be considered full compensation for the perfor mance of the load test, including all labor, equipment, and materials incidental to the test instrumentation, data collection and report (and subsequent removal of test apparatus and appurtenances) prepared under the direction of the Contractor’s Testing E ngineer and the Manufacturer's Representative. Conventional axial load testing shall be measured on an each basis per shaft tested.
945.82: Payment Items
945.1 * Drilled Shaft Excavation *Feet Diameter ............................................................ Foot 945.2 * Rock Socket Excavation *Feet Diameter ............................................................ Foot 945.3 * Obstruction Excavation *Feet Diameter ............................................................. Foot 945.4 * Trial Shaft *Feet Diameter ................................ ........................................................ Foot 945.5 * Drilled Shaft *Feet Diameter ........................ ........................................................... Foot 945.6 * Permanent Casing *Feet Diameter ................. ....................................................... Foot
945.71Cross Hole Sonic Testing Access Pipes ................................................................ Foot
945.72Cross Hole Sonic Test .................................... ............................................................ . Each
945.81Osterberg Load Cell Axial Load Test .................................................................... Each
Conventional Axial Load Test ........................ ......................................................... Each
* = as per Department Standard Nomenclature. II.535 202 4 Edition SUBSECTION 950: SHEETING DESCRIPTION
950.20: General
This work shall consist of furnishing and placing lumber, wood or steel sheeting of the kinds and dimensions required, complying with these specifications, where indicated on the plans or where directed. All dimensions specified for lumber are nominal dimensions. MATERIALS
950.40: General
Materials shall meet the requirements specified in the following Subsections of Division III. Materials: Lumber Sheeting .......................................................................................................................... M9.05.0 Wood Sheeting .............................................................................................................................. M9.05.0 Steel Sheeting ................................................................................................................................ M8.05.4 CONSTRUCTION METHODS
950.60: General
Work shall not be sta rted until all materials and equipment necessary for their construction are either on the site of the work or satisfactorily available for immediate use as required. Sufficient labor and equipment shall be employed to insure the completion of the excavation, placing of the concrete and backfilling in the shortest possible time. Where no other direction is given, sheeting shall be driven to such depth that the footing may be lowered at least 2 ft below the elevation shown on the plans without any change in the sheeting as driven. Sheeting that is to be paid as sheeting left in place shal l be driven to a minimum depth of 5 ft below the proposed bottom of the concrete footings. After sufficient progress has been made on the construction the sheeting shall be cut off at the tops of the footings or as otherwise directed.
950.61: Placing of Sheeting
The sheeting shall be securely and satisfactorily braced to withstand all pressures to which it may be subjected and be sufficiently tight to prevent any flow of water or material into the space in which concrete is deposited. The bottom edge of each piece of lumber and wood sheeting shall be so sharpened as to lead the toe of the sheeting away from the excavation. Jetting may be done only with the approval of the Engineer, but it will not be permitted when excess of water may endanger railroad tracks or ot her structures. Where sheeting is to be used as a form for placing concrete the sheeting shall be driven entirely outside the neat lines shown on the plans for the concrete. When, in the Engineer's judgment, the foundations must be altered to such an extent that changes must be made in the depths to which sheeting has been driven, or the area enclosed by the sheeting II.536 202 4 Edition must be changed, the Contractor shall make the directed changes in accordance with the provisions of Subsection 9.03: Payment for Extra Work .
950.62: Cut-Off
The sheeting shall be driven down or cut off to the elevation shown on the plans or directed by the Engineer. No sheeting may be left so as to create a possible hazard to navigation of a stream, safety of the public, obstruction to flow of water, or a hindrance to traffic of any kind.
950.63: Care Near Railroads
When sheeting is driven adjacent to railroad tracks, the Contractor shall keep on the work site, quickly available for use. such equipment and operators needed to immediately burn or cut off any sheeting that cannot be driven into the clear before the arrival of trains.
950.64: Disposal of Cut -off and Waste Materials
No cut -off shall be allowed to float away in a stream or left in such a manner as to obstruct the flow of water. All cut -off will become the property of the Contractor and shall be removed by them from the site. At the option of the Contractor, steel sheeting cut- offs may be used as sheet piling or pans of sheet piling. If welding is used, such welds shall be full butt -welds designed to develop the full strength of the sheet pile, both in bearing and bending, and shall conform with any of the prequalified joints shown in the specification for welded Highway and Railroad Bridges of the American Welding Society.
950.65: Defective Work
The responsibility for the exact satisfactory construction and maintenance of sheeting complete in place shall rest with the Contractor and any work done which in the performance of incidental construction is not acceptable for the intended purpose shall b e either repaired or removed and reconstructed by the Contractor at their expense. COMPENSATION
950.80: Method of Measurement
The items of Lumber Sheeting, Wood Sheeting, or Steel Sheeting will be a pay item only if indicated on the plans or in the Special Provisions to be left in place or when ordered left in place by the Engineer as a permanent part of the foundation. Otherwise the Contractor may remove or abandon the sheeting, but only to the extent permitted by the Engineer. Lumber or Wood Sheeting, when indicated on the plans or in the Special Provisions to be left in place or when ordered by the Engineer to be left in place as a permanent part of the foundation, will be measured by the MBF of lumber or wood sheeting. The quantity to be paid for will be the area of sheeting left in place multiplied by the nominal thickness. Steel sheeting, when indicated on the plans or in the Special Provisions to be left in place or when ordered by the Engineer to be left in place as a permanent pan of the foundation, will be measured by the pound. The weight of the quantity to be paid for shall be calculated on the basis of 22 psf of II.537 202 4 Edition wall in place. No additional compensation will be allowed if a heavier sheeting is used unless such heavier sheeting is specified in the Special Provisions, or shown on the plans.
950.81: Basis of Payment
Steel sheeting, when indicated on the plans, in the Special Provisions, or when ordered by the Engineer, to be left in place as a permanent part of the foundation, will be paid for at the contract unit price per pound under the item for Steel Sheeting. The contract unit price per pound shall also include full compensation for anchors, when required, for the sheeting. Lumber or Wood when indicated on the plans or in the Special Provisions to be left in place or when ordered by the Engineer in writing to be left in place as a permanent part of the foundation will be paid for at the contract unit price per MBF for Lumber Sheeting or Wood Sheeting. No direct payment will be made for any sheeting not indicated on the plans or in the Special Provisions or not ordered in writing by the Engineer to be left in place as a permanent part of the foundation. Such sheeting will be considered as incidental work necessary for the proper prosecution and protection of the work during construction operations and compensation therefor shall be included in the prices bid for the various items of work for which the sheeting was used. If the Contractor elects to leaves uch sheeting in place with the approval of the Engineer, no payment will be made for same as sheeting left in place. For purposes of partial payment, except as noted below, the sheeting item will be considered 90% done when the sheeting has been completely driven and the area within the sheeting is ready for such work as may be required to be done therein. Tile sheeting item will be considered completed when the sheeting has been cut at the required elevation.
950.82: Payment Items
950. Lumber Sheeting .......................................................................................................... MBF 951. Wood Sheeting .............................................................................................................. MBF 952. Steel Sheeting ................................................................................................................ Pound SUBSECTION 955: TREATED TIMBER DESCRIPTION
955.20: General
Treated timber shall be used where indicated on the plans and where directed. MATERIALS
955.40: General
Material shall meet the requirements specified in the following Subsections of Division III, Materials: II.538 202 4 Edition Wood Products ............................................................................................................................. M9.05.1 Wood Preservative ...................................................................................................................... M9.05.5 Fastenings ....................................................................................................................................... M8.01.5 Tar Paper ......................................................................................................................................... M9.06.2 CONSTRUCTION METHODS
955.60: General
Treated timber shall be carefully handled, stored, and fabricated in accordance with AWPA M4 without sudden dropping, breaking of outer fibers, bruising or penetrating the surface with tools. It shall be handled with rope slings. Cant hooks, peaveys, pikes or hooks shall not be used. Borings, cuts, holes and other machining of wood shall be done prior to preservative treatment whenever possible. All cuts, holes, and injuries such as abrasions which occur after preservative treatment shall be field treated in accordance with AWPA M4. The Contractor shall provide the Engineer with a written copy of AWPA M4 Treatment Specification before any field treatment work is performed. A washer, of the size and type specified, shall be used under all bolt heads and nuts which would otherwise come in contact with timber. The nuts of all bolts shall be effectively locked after they have been finally tightened. Fastenings shall conform to M8.01.5: Anchor Bolts, Nuts and Washers for anchoring bridge bearings. Stringers and other members supporting planking shall be capped with tar paper.
955.61: Inspection
All materials will be inspected either at the place of manufacture or upon arrival at the site where it is to be used. All materials not conforming in every detail with the requirements of these specifications will be rejected and removed from the work by the Contractor. COMPENSATION
955.80: Method of Measurement
All treated timber used will be measured by MBF, in place. The quantities will be measured according to the following dimensions: For wheel guards, sleepers, blocking, bracing, isolated timbers and similar lumber, the nominal size of the timber and the actual length in place. For platforms, decks and similar lumber, the nominal thickness of plank and the overall area, with no deduction for directed spaces between planks. No allowance will be made for waste or cut -off.
955.81: Basis of Payment
Treated timber will be paid for at the contract unit price per MBF measure d under the item for Treated Timber complete in place. II.539 202 4 Edition 955.82: Payment Items 955. Treated Timber ............................................................................................................. MBF SUBSECTION 960: STRUCTURAL STEEL AND MISCELLANEOUS METAL PRODUCTS DESCRIPTION
960.20: General
This section shall apply to the furnishing, fabrication, erection and coating of all structural steel and metal work in the contract. MATERIALS
960.40: General
Materials shall meet the requirements specified in the following Subsections of Division III - Materials: Structural Steel ............................................................................................................................. M8.05.0 Stud Shear Connectors .............................................................................................................. M8.04.1 Steel Pins ......................................................................................................................................... M8.04.2 High Strength Bolts ..................................................................................................................... M8.04.3 Bronze Self -Lubricating Bearing Plates .............................................................................. M8.11.0 Iron Casting .................................................................................................................................... M8.03.0 Paints and Protective Coatings .............................................................................................. M7.00.0 Steel Baffles & Drainage Troughs .......................................................................................... M8.05.3 If a Contractor proposes to use steel from sources other than a mill, the source must be approved by the Engineer. The Contractor shall supply the Engineer with a description of the proposed facility along with the method used by the facility to segregate, identify and otherwise assure the Engineer that the supplied material is in conformance with the specifications. All sources must supply the actual mill test reports prior to the start of fabrication. Material shall be identified with the MassDOT contract number, material specification, and heat number. CONSTRUCTION METHODS
960.60: Shop Drawings
After the contract has been awarded, and before any shop work is commenced, the Contractor shall submit complete sets of prints of the shop drawings as specified in Subsection 5.02: Plans and Detail Drawings . On projects that contain more than one bridge, each bridge will be considered separately in submitting shop drawings. Shop work may commence on each bridge when the entire set of shop drawings for that bridge are approved. II.540 202 4 Edition On projects which contain complicated steel structures such as a viaduct, long span bridge, etc., the Contractor shall submit a schedule showing how they intend to divide the steel structure into sections. After this schedule is approved, shop work may commence on each section as the shop drawings for that section are approved. Fabrication shall not begin until the drawings are approved. Work performed prior to shop drawing approval is at the contractor’s risk and may require additional inspection, NDT, or partial disassembly/reassembly to satisfy the Verification Inspector.
960.61: Design, Fabrication and Erection
All structural steel and appurtenant material shall be designed, fabricated, coated and erected in accordance with these specifications, the AASHTO Standard Specifications for Highway Bridges , and the AASHTO/AWS Bridge Welding Code (ANSI/AASHTO/AWS D1.5). All aluminum material shall be designed, fabricated and erected in accordance with these specifications, the AASHTO Standard Specifications for Highway Bridges , and the AWS St ructural Welding Code - Aluminum (ANSI/AWS D1.2). All stainless -steel material sh all be designed, fabricated, and erected in accordance with these specifications, the AASHTO Standard Specifications for Highway Bridges , and the AWS Structural Welding Code – Stainless Steel (ANSI/AWS D1.6). All steel tubular material shall be designed, fabricated, and erected in accordance with these specifications, the AASHTO Standard Specifications for Highway Bridges or the AASHTO Standard Specifications for Highway Signs, luminaries, and Traffic Signals , and the AWS Structural Welding Code - Steel (AN SI/AWS D1.1). FABRICATION. Fabricators . Fabricators shall be approved for work in one or more of the following three categories; Major Bridge Structures, Simple Bridges and Miscellaneous Steel Fabrication, or Poles, Sign Supports, Etcetera. Fabricators approved to perform work in the Major Bridge Structures category are also approved to perform work in the Simple Bridges and Miscellaneous Steel Fabrication category. Fabricators of major bridge structures including rolled beams with coverplates, girders, and more complex work shall meet the requirements of AISC Catego ry Major Steel Bridges with the Fracture Critical Endorsement if applicable. Fabricators of simple bridges and miscellaneous steel, which includes rolled beams without coverplates, steel products such as expansion joints, bridge rail, etcetera shall meet the requirements of AISC Category Simple Steel Bridges. Fabricators of poles and sign supports shall meet the requirements of AISC Category Simple Steel Bridges. A list of approved fabricators may be obtained from the MassDOT website at www.mass.gov/dot. Fabricators wishing to be approved by the Department shall submit the following:
assurance, QC and testing.
II.541 202 4 Edition After receiving the material listed above, the Engineer shall review it and conduct a shop inspection before approval may be granted. The Contractor shall submit a shop schedule to the Engineer. The shop schedule shall be provided sufficiently in advance for the Engineer to determine the level of verification inspection required and to arrange for the inspector’s attendance. The shop sch edule shall include the date fabrication will begin, the approximate date it will be completed, and hours of operation including time and date work is to be performed on all shifts. A revised schedule may be submitted at any time. No material shall be fabricated until the shop schedule has been reviewed. No work shall be performed on second and third shifts unless specifically indicated on the shop schedule. The Contractor will be required to submit to the Department’s Inspector, for approval, three certified copies of the mill test reports for each heat number of steel and aluminum furnished. These certificates shall certify compliance with the specifications and shall give the chemical and physical analysis of the metal. Any cost involved in furnishing the certificates shall be considered incidental to the work. These reports shall be given to the Verification Inspector in advance of shipping so that this inspector has sufficient time to properly review the reports. No material shall be shipped until the reports are reviewed and approved by the Verification Inspector. Written procedures shall be submitted by the Contractor and approved by the Engineer for the following fabrication processes: material traceability; hot bending; welding; cambering and heat curving; shop assembly/laydown; postheat and stress -relieving; sho p installation of fasteners; and blast cleaning and coating. These procedures may be standardized and are not required to be resubmitted for each project. Inspection. QC inspection and testing is the responsibility of the fabricator and shall be performed by a sufficient number of qualified inspectors to guarantee product integrity. QC inspection shall be performed throughout the entire fabrication process from receiving material to shipping the final product. QC Inspectors at the fabricating shop shall be certified by the American Welding Society in accordance with the provisions of the Standard for Qualification and Certification of Welding Inspectors (AWS QC1). At least one inspector on each shift shall be a Certified Welding Inspector (CWI). The Engineer, upon written request from the fabricator, may accept other certifications or experience and training consistent with AWS QC1. Assistant inspectors may be used to perform specific inspections under direct sup ervision of a QC Inspector. For projects requiring greater than 1,500 ft² of steel surface to be painted, the inspector shall have completed, as a minimum, NACE Level I certification or received other formal training acceptable to the Engineer. Verification Inspectors will be employed by, and act on behalf of, the Department. The inspector has the authority to act for the Engineer on matters relating to quality including inspection and testing, within the scope of the contract. Verification Inspectors will be assigned at the discretion of the Engineer. The presence or absence of the Verification Inspector does not relieve the Contractor of QC responsibility. The fabricator shall provide facilities, for the Verification Inspectors, in direct proximity to the work. These facilities shall include a secured office with a desk and chair for each inspector, a file II.542 202 4 Edition cabinet provided with a lock, a plan rack and a table adequate to review plans and drawings. The office shall have a minimal floor area of 120 ft ². The office shall contain a telephone with an outside line suitable for modem communication and a system of heating and cooling that will maintain a temperature of 68°F to 72°F. The fabricator shall also supply ready access to fax and copy machines and adequate parking. The fabricator shall maintain adequate inspection records. Such records shall be signed by the QC Inspector and provided to the Verification Inspector. No material shall be shipped to the job site until the QC Inspector certifies that the material has met all provisions of the Contract. Such certificate shall be endorsed by the Verification Inspector who then shall place their stamp on the material. The Verification Inspector shall affix their stamp only when the material is ready for shipment and properly loaded on trucks or rail cars. Material delivered to the job site without such stamp affixed will be considered rejected and immediately returned to the Contractor. Process. Steel shall be blast cleaned prior to starting fabrication. Fabrication includes, but is not limited to, drilling, cutting, and welding. The blast cleaning shall conform to the SSPC SP10 “ Near -White Blast Cleaning. ” Heat numbers shall be transferred, in the presence of the Verification Inspector, to all pieces that are to be major component parts of a main member. Main members are considered to be all webs, flanges, coverplates, floorbeams, stringers and diaphragms on horizontally curved girders as well as any other members as specified on the drawings. Heat numbers are not required to be transferred to component parts of secondary members or to minor components of a main member, i.e., stiffeners, clip angles, etc. For primary members, the plate components and splice plates shall be cut with the direction of rolling parallel to the direction of primary stresses. For those plates thicker than ⅝ in., plane ³⁄₁₆ in. off sheared edges that remain exposed after fabrication. Welding shall not commence until the welding procedures and welder certifications have been approved by the Engineer. All welding procedures shall conform to the applicable welding code, (i.e., AASHTO/AWS Bridge Welding Code, the AWS Structural Welding Code - Aluminum, AWS Structural Welding Code - Reinforcing Bars, etc.) as determined by the Engineer. Shop welders shall be certified in accordance with the applicable AWS Welding Code as determined by the Engineer. All field welders shall be certified by the Department and possess the Department's Welder Qualification Test Record and the Welder Qualification Certificate. Material fabricated that does not meet the plans and specifications will not be incorporated into the work. Repair procedures, other than those allowed under the Bridge Welding Code, shall be submitted by the Contractor to the Engineer for approval. Structural rolled beams shall be cambered to the amount shown on the plans with a tolerance of -0, +½ in. for beams 50 ft or less. For beams greater than 50 ft, the plus tolerance of ½ in. shall be increased by ⅛ in. for each 10 ft or fraction thereof in excess of 50 ft. Plate girders shall be cambered to the amount shown on the plans with a tolerance as specified in the AASHTO/AWS Bridge Welding Code. II.543 202 4 Edition The beams and girders shall be handled and stored in such a manner that they will have the required camber after erection. When steel beams or girders are to be spliced in the field, they shall be assembled in the no load position in order that the assembly, including camber, alignment, accuracy of punched holes and fit of beam or girder ends may be done in accordance with the requirements of the type of splice. When members are assembled with the webs vertical, they shall be supported at intervals no greater than 20 ft . The requirements of AASHTO for shop assembly shall apply. Reaming of holes shall be performed in accordance with AASHTO. Hand held reamers shall not be used. All detrimental material, such as oil, grease, dirt, slag, etc. shall be removed from unpainted portions of all weathering steels prior to shipping. Fascia beams/girders shall be reblasted to remove staining and heat marks. All structural parts shall be provided with adequate drain holes at points where water could otherwise accumulate. Dimensions indicated at expansion joints and similar construction are determined for a temperature of 50°F. The proper adjustments for temperature must be made by the Contractor when the structure is placed at any other temperature. If steel expansion joint assemblies are used, they must be properly fitted in the shop, after coating, and shipped with a device for maintaining proper spacing and fit as shown on the plans. Bolts on shipping device must be loosened within one hour after concrete is placed, so that movement may take place. The device shall be removed after concrete has set on both sides of the assembly. Storage and Shipping. Fabricated material shall be handled with chain softeners and stored in a manner that protects it from damage, facilitates subsequent inspections, and does not compromise the safety of personnel. Proper consideration shall be given to guard against lateral buckling of unsupported beams and girders. Material shall be stored above the ground on skids or other supports. Fabricated material shall be kept free of dirt, grease and other foreign matter and shall be stored in a way to facilitate drainage when stored outside. Marking and shipping shall conform to AASHTO Division II Section 11. Hold down softeners shall be used to prevent chain marks on the material during shipment. Structural members shall be shipped in the upright position. Structural members shipped on truck beds or supported on dollies shall not cantilever behind same in excess of 25% of their length. Other shipping configurations shall require calculations by a licensed professional engineer that demonstrate that the member will not be overstressed during sh ipment. The calculations shall use a load, including impact, of not less than 300% of the dead load. Connections Using High Strength Bolts. The certification, testing, installation and inspection for all high strength bolts shall conform to the requirements of the current edition of the AASHTO Standard Specifications for Highway Bridges, except as amended herein.
Mill Test Reports shall be furnished for all mill steel used in the manufacture of bolts, nuts or washers. These reports shall indicate the place where the material was melted and manufactured. II.544 202 4 Edition The manufacturer shall furnish Manufacturers Certified Test Reports for the items supplied. These reports shall show the relevant information required. The manufacturer performing the rotational - capacity test shall include in the test report:
The Distributor shall include the Manufacturer’s Certified Test Reports for the various bolt assembly components. The rotational- capacity test may be performed by the distributor (in lieu of the manufacturer) and reported on a Distributor Certified Test Re port. This report shall show all the information required on the Manufacturers Certified Test Report. The Distributor shall certify that the manufacturer's reports are in conformance to this specification and the appropriate AASHTO specifications.
All bolting shall be performed using the calibrated wrench method or the turn of the nut method in accordance with the current edition of AASHTO. Regardless of the tightening method used, particular care should be exercised so that the snug tight condition is achieved. In addition, the rotational -capacity tests described in M8.04.3: High Strength Bolts shall be performed at the job site on each rotational -capacity lot number prior to the start of bolt installation. Hardened washers are required as part of the test even though they may not be required in the actual bolt assembly. A Skidmore -Wilhelm Calibrator or an acceptable equivalent tension measuring device shall be required at each job site during erection. The Contractor shall submit to the Engineer a certification that the calibration device has been checked by qualified personnel acceptable to the Engineer within the previous thirty days. The device must also be checked for accuracy upon completion of the work on the project and proof of this certification must be submitted to the Engineer.
Bolts, nuts and washers from each rotational- capacity lot shall be shipped in the same container. If there is only one production lot number for each size of nut and washer, the nuts and washers may be shipped in separate containers. Each container shall be permanently marked with the rotational - capacity lot number such that identification will be possible at any stage prior to installation. Bolts, nuts and washers shall remain in their original container(s) until installation. If it is necessary to place the bolts in a different container, these new containers shall be labeled with all appropriate information and be shipped with a copy of the original documentation. The new containers shall be stamped by the Verification Inspector prior to shipping to the j ob site. Nondestructive Testing. Personnel performing radiographic, magnetic particle and dye penetrant tests shall be certified by a Level III technician who shall have attained certification by examination. Personnel performing radiographic, magnetic particle and dye penetrant tests shall be qualified in accordance with the II.545 202 4 Edition current edition of the American Society for Nondestructive Testing, Recommended Practice SNT - TC-1A. Only individuals qualified for NDT Level II and certified as noted above may perform these tests. When ultrasonic testing is required, it shall be performed by technicians who meet the Level II qualifications above and who shall be qualified by a written examination and performance test administered by the Engineer. The Engineer, at their discretion, may accept other properly documented certifications and tests. Nondestructive testing shall be performed by the Contractor in accordance with the procedures and standards set forth in the AASHTO/AWS Bridge Welding Code or other applicable code. The Department reserves the right to perform additional testing at its own cost during fabrication and up to final acceptance of the project. All welding must meet acceptable quality standards which are defined by the acceptance criteria for the particular test method. All nondestructive testing shall be witnessed by the Department’s Verification Inspector. Certification that all tests were performed in the presence of the Inspector shall be furnished to the Engineer. In addition to that required by the Bridge Welding Co de, all radiographs shall be identified as to date, bridge number and girder or beam number. All costs for these tests, including necessary rework and repair, shall be at the Contractor’s expense. A copy of all NDT reports shall be given to the Verificatio n Inspector. Heat Cambering and Curving.
The Maximum allowable temperatures when applying heat to the steel is 1 ,200°F for AASHTO M 270M/M 270 Grades 250, 345 and 345W (Grades 36,50 and 50W) steels and 1,100°F for AASHTO M 270M/M 270 Grades HPS345W and HPS485W (HPS50W and HPS70W) steels. Bending and curving may be accelerated by the use of external forces (preload). The stresses induced due to the preload (including loads induced by the member weight) shall be limited to 25 ksi. Calculations showing the maximum external force to apply shall be submitted to and approved by the Engineer. The Contractor shall show the relationship between the maximum allowable external force and the maximum allowable stress. The external force shall be applied before heating and not increased by external means during heating or cooling. Jacks shall not impede contraction during the cooling phase and they shall not produce local buckling. Heat patterns shall be marked on the steel prior to heating. The steel shall be brought to the appropriate temperature as rapidly as possible. Heating torches shall be manipulated to avoid overheating of the steel. Care shall be taken to avoid the buckling of relatively thin, wide plates. The temperature of the steel shall be monitored with temperature sensitive crayons, pyrometers or infrared non -contact thermometers. The temperature shall be measured 5 to 10 seconds after the heating flame leaves the area to be tested. After the steel has cooled to 600°F, rapid cooling with dry compressed air or a water mist is permitted. Care shall be taken to avoid burns when using the water mist. II.546 202 4 Edition The steel shall be cooled to below 250°F before applying another set of heat patterns. When using V-heat patterns, a location may be reheated after applying at least three sets of heating patterns at other locations.
When the radius is less than 1,000 ft, heat curving shall be performed with the web in the horizontal position or preload to induce stress prior to heating when curving with the web in the vertical position. When heating with the web vertical, the member shall be sufficiently supported so that the member will not deflect laterally, overturn or twist. Intermediate safety catch blocks shall be provided to prevent buckling or excessive local deformations.
The member shall be supported when heating with the web in the vertical position. The supports shall be spaced to take maximum advantage of the dead load of the member and shall be placed prior to heating. If the web is in the horizontal position, care shall be taken when applying the external force and safety catch blocks shall be used to prevent sudden spring back of the beam in case the jacks slip. ERECTION. Within sixty days of the date of the Notice to Proceed, the Contractor shall submit an erection procedure. The submitted method of erection is subject to review, comment, and approval by the Engineer. The method must be submitted with a detailed procedure which includes drawings and calculations sufficient to enable the Engineer to determine the adequacy of the proposed method. The method and all submissions shall be prepared under the supervision of a professional engineer, registered in Massachusetts, who is familiar with these Specifications, AASHTO, the work, and experienced in this technical field. All submitted sheets shall be stamped by the supervising Engineer. As a minimum the following information shall be included in the submittal:
crane influence area shall be taken as circular areas with radii matching the boom length and radius points located at the boom pivot point. Crane capacity rating charts and the rated capacity of all lifting and connecting devices shall be clearly shown in the submittal. The 125% or 150% factors of safety are to be used in addition to any factors of safety used by the manufacturer to calculate the rated capacity.
II.547 202 4 Edition 5. The order of lifts, repositioning of equipment and counterweights, and location and method of attaching deadmen.
member (either temporarily or permanently) for erection purposes. The stresses shall be investigated at each stage of erection with allowance for wind pressure determined by Table 960.1. Table 960. 61-1: Wind Pressure Allowances Height of Members Above Ground ( ft)* Wind Pressure ( psf) Beams & Girders Trusses 15 21.0 31.5 30 25.5 38.5 50 28.0 42.0 100 32.0 48.0 300 39.0 58.5 *For heights not given wind pressures shall be interpolated. Curved girders and long span straight girders shall be stabilized with falsework, temporary braces, or holding cranes until a sufficient number of adjacent girders are erected with all diaphragms and cross frames connected to provide necessary lateral stability. All trusses shall be erected on falsework. The falsework shall provide for proper camber and alignment and shall be properly designed, constructed, and maintained for the loads that will be imposed upon it. When erecting trusses, the falsework shall be left in place until all connections are bolted and accepted by the Engineer. Care shall be taken in the use of falsework and other temporary supports to insure that the temporary elevation of structural steel provided by the falsework is consistent with the deflections that will occur as the structure is completed. In instances where falsework is required by the contract or proposed as part of the erection procedure, it shall be properly designed, constructed, and maintained for the loads that it will bear. Plans for falsework along with necessary engineering data shall be submitted to the Engineer for review, comment, and approval under the same guidelines as the erection procedure. Plans, details, and calculations shall be submitted to the Engineer in those instances where changes in an existing structure are necessary to maintain traffic The Contractor shall keep a full record of piles driven for falsework. If the Contractor does not make a pile loading test, the pile bearing formulas of 940.61: Driven Pile Capacity shall be used to determine the bearing values. Erection drawings shall show bolting or welding procedures necessary to complete erection. Procedures shall include sequence and method of connecting main members and secondary members. For stringer and girder spans, the following minimum information shall be included in the notes, modified as necessary to conform to design and erection requirements for each structure: II.548 202 4 Edition 1. Splices and field connections of main stress carrying members shall be made with a minimum of 50% of the holes filled with approved high strength bolts and erection pins before the external support system is released. At least one -half of this percentages hall be bolts, tightened to specification requirements. The bolts and pins shall be installed uniformly throughout the connection except that erection pins shall be used in the extreme corners of all main connections.
tightened to specification requirements before erecting the member.
other temperature. After the erection of beams and girders has been completed, expansion bearing sole plates shall be re-aligned so that they will be centered at 50°F.
960.62: Preparation of Bridge Seats
The bridge seats for the bearing devices shall be prepared in accordance with 901.65: Finishing and Curing , Paragraph A.3: Preparation of Bridge Seat Bearing Areas.
960.63: Painting
General. The paint system used shall be approved by NEPCOAT. Prior to the start of painting, each batch of paint shall be sampled, tested and approved in accordance with Section M7: Paints, Protective Coatings . For contracts requiring greater than 1,500 ft² of painted steel surfaces, the contractor or subcontractor performing surface preparation, and field coating of structural steel in the field must be prequalified by the Department in the Painting (Structural) category. For surface preparation and painting in the shop a current AISC Sophisticated Paint Endorsement (SSPE) or SSPC QP3 certification is required. The prime coat shall be applied in the shop. The remaining coats may be applied in the shop or in the field at the Contractor’s option. Structural steel meeting AASHTO M 270 M/M 270 Grade 345W (50W), Grade 485HPS (70HPS) and other weathering steels shall not be painted except when and where specifically called for on the plans. When weathering steel is painted, the finish coat color shall conform to Federal Standard 595B, “Colors Used in Government Procurement”, color chip no. 30045. All structural steel surfaces excluding the surfaces of weathering steel that is to remain uncoated, shall receive three coats of paint. All surfaces of this steel that come in contact with concrete shall be painted with the prime coat only. If the entire paint system is applied in the shop, the steel surfaces in contact with concrete shall receive all three coats. Surfaces not in contact but inaccessible after assembly erection shall be painted in the shop with the prime coat followed by II.549 202 4 Edition one coat of coal tar epoxy polyamide paint (M7.05.21) having after application a minimum dry film thickness of 8 mils. The flange surfaces to which shear studs are to be field welded shall receive a mist coat of the prime coat, having after application a minimum dry film thickness of 1 to 1.5 mils. The faying surfaces of all field bolted splices and other faying surfaces, except weathering steel in areas where no paint is specified, shall have the faying surfaces painted with the prime coat only. This prime coat shall have a slip coefficient of Class B. Application of organic zinc, epoxy, and urethane systems shall not be done when the relative humidity is above 85% or when the surface temperature of the steel is less than 5°F above the Dew Point. Paint shall not be applied when the surface temperature is below 40°F or when the surface temperature is above 125°F. Paint shall not be applied when, in the Engineer’s judgment, conditions are or will become unsatisfactory for application and proper cure. All changes as to the application parameters other than specified must be the manufacturer’s and presented in writing and approved by the Engineer. Ambient conditions should be closely monitored so that proper cure/drying is achieved prior to recoat. In no case shall a succeeding coat of paint be applied before the previous coat has cured/dried sufficiently for recoat as per manufactured data sheet. Measurement of the ambient conditions shall be done in accordance with ASTM E337 Test Method for “Measuring Humidity with a Psychrometer” (the Measurement of Wet and Dry bulb Temperatures). All coats of paint shall be from the same manufacturer. The colors of the shop coat, second coat, and the top coat shall have a definite color contrast between them. The prime coat shall be tinted red or green so as to contrast with the blast cleaned steel. The application contractor is required to conduct and document QC inspection of the cleaning and painting operations including, at a minimum, measurements of ambient conditions, surface profile, surface cleanliness, coating material acceptability, dry film thicknesses, and visual inspection for coating defects. The data shall be recorded in an applicator log maintained at the painting site and be available for the Owner’s review during working hours. This applies to the application of all three coats. The Contractor shall supply mechanical paint mixers on the job. Paints shall be mixed in clean containers and agitated thoroughly before drawing off paint through a strainer into the painter’s buckets or spray machines. Paint shall be kept thoroughly stirred in spray pots or containers during application and the zinc rich primers shall have continuous agitation. Paints specified are formulated ready for application and if for any reason it is necessary to thin the paint, the method used shall not produce a dry film thickness less than that specified. The method used to thin the paint and the thinner used. The steel shall not be shipped from the shop to the field in less than 2 days after the application of the last coat of paint. Bolts nuts and washers shall be solvent cleaned and dried prior to painting. II.550 202 4 Edition The contractor shall take appropriate precautions to avoid damaging the coating during erection. After erection and after the finish coat of paint has been applied, the date (year, month) of painting and the bridge and BIN numbers shall be stenciled on the bridge as directed by the Engineer. The characters shall be 3 in . in height and be furnished by the Contractor at their expense. Prime Coat. Steel shall not be painted until shop fabrication is complete. All welds shall be cleaned thoroughly in accordance with good practice and shall have a suitable surface to accept the primer. There shall be no evidence of oil, grease, dirt or other foreign m atter on the steel. All surfaces shall be returned to an SSPC SP10 condition. The steel shall have a surface profile of 25 µm (1 mil) minimum and 75 µm (3 mils) maximum measured with a profile depth tape and micrometer. Profile depth tape measurements shall be retained and submitted for the Engineer’s approval. The abrasive cleaning material shall meet the requirements of SSPC -AB 1, “Mineral and Slag Abrasives”, SSPC -AB2, “Cleanliness of Recycled Ferrous Metallic Abrasives”, or SSPC -AB 3, “Newly manufactured or Re - Manufactured Steel Abrasives”, and the condition and cleanliness of the recycled abrasives shall be checked daily or as directed by the Engineer. All sharp corners shall be broken prior to final cleaning (profiling) and prime painting. Sharp corners may usually be removed by a single pass with a grinder. Thermal cut edges (TCE) to be painted shall be ground before final cleaning (profiling). To provide adequate film thickness in areas or places prone to breakdown, edges, corners, bolts, nuts, and welds shall be striped by brush painting. The paint when applied, shall be so manipulated under the brush as to produce a uniform even coating, confo rming to the dry film thickness, as specified by the manufacturer on the surface being painted. Stripe coating of the primer shall be completed prior to the application of the full prime coat. The steel shall then receive one shop coat having after application a minimum dry film thickness of 75 µm (3 mils). Paint shall not be applied to shop contact surfaces. Machined finished surfaces, except abutting joints and base plates, shall be coated with a material suitable to the Engineer. Intermediate and Finish Coat. The steel painted in the shop or field shall receive an intermediate coat having after application a minimum dry film thickness of 100 µm (4 mils). Within 24 hours of the application of the intermediate coat, the steel shall receive the finish coat having after application a minimum dry film thickness of 75 µm (3 mils). The manufacturers’ recommendations for recoating shall be followed. When the erection of the steel is fully complete and the intermediate and finish coats are to be put on in the field, all adhering rust, scale, concrete, dirt, laitance, grease, welding flux and slag, white rust or other foreign matter shall be removed fro m the steel. Immediately after cleaning of the steel has been done to the satisfaction of the Engineer and prior to the application of the first field coat of paint, all steel surfaces that require painting (bolts, welds, etc.); the base metal that has become exposed; or any surface from which the shop coat has become defective shall be thoroughly covered with one coat of the same paint used in the shop. The minimum dry film thickness after application shall be 75 µm (3 mils). When the erection of the steel is fully complete and the intermediate and finish coats were put on in the shop, all adhering rust, scale, concrete, dirt, laitance, grease, and other foreign matter shall be II.551 202 4 Edition removed from the steel. Damaged coating shall be touch -up with the same finish coat that was used in the shop. Exposed steel surfaces including but not limited to bolts and weld metal shall be thoroughly cleaned as stated above and painted in the field wit h the primer, intermediate and finish coats. The minimum dry film thickness shall be 75 µm (3 mils) for the primer. Minor coating defects, handling damage and other occasional nonconformances, and destructive test sites shall be repaired in accordance with SSPC -PA 1 and/or the manufacturer’s recommendations. The applicator shall submit repair procedures for substantial damage, significant defects, or widespread (gross) nonconformances in the coating for the Engineer’s approval. Repairs to the topcoat must result in an acceptable, uniform gloss and color. The Engineer shall have final authority concerning the coating’s uniformity and acceptable appearance. In order to avoid subsequent discoloring or staining due to dripping or running of concrete, the field coats of paint shall not be started until all concrete nearby has been placed and all forms have been removed. Concrete, stone, masonry and other parts of the structure that are not to be painted shall be fully protected by covers during the painting operations. Full protection shall be provided in the field for all private property. Environmental Protection Requirement for Field Painting. The Contractor shall design, install, and maintain a containment system in accordance with 961.67: Containment .
960.64: Galvanizing
The following shall be hot dipped galvanized in accordance with Section M7: Paints, Protective Coatings :
composed of non -weathering steels or weathering steels designated to be coated.
Galvanized members requiring shop fabrication and assembly shall be cut, welded, and/or drilled prior to galvanizing. Members to be milled shall be galvanized prior to milling. A thin layer of a rust inhibitor shall be applied to the milled surface. Galvanized members that are to be welded after galvanizing shall be masked 1 in. (25 mm ) on either side of the weld line prior to galvanizing. After welding, the weld areas shall be cleaned in accordance with the SSPC -SP3 “Power Tool Clean” and coated with “High Zinc Dust Content” paint meeting M7.04.11. The galvanizing shall be repaired in accordance with ASTM A780 “Repair of Hot Dip Galvanizing”. The paint shall be applied such as to achieve a dry film thickness of a minimum of 3 mils (76.2 µm ) and not mo re than 5 mils (127 µm ). Application methods shall be in accordance with the manufacturer’s recommendations.
960.65: Metallized Sole Plates for Sliding Elastomeric Bearings
This work shall consist of surface preparation and the application of thermal sprayed metal coating (metallizing) on structural steel sole plates for sliding elastomeric bearings. The metallizing process shall consist of melting metal and spraying it on to a prepared surface by means of compressed gas. All steel surfaces shall be metallized with the exception of the area over which the stainless -steel II.552 202 4 Edition mating surface is to be welded to the sole plate and the 1 -in. wide strips where the sole plate is to be welded to the flange. The surface preparation shall be accomplished in accordance with the requirements of the SSPC SP1 for Solvent Cleaning and SP10 for Near White Blast Cleaning. The surface preparation shall result in a 50 to 100 µm (2 to 4 mils) blast profile as determined by the Engineer. The average surface profile produced by the contractor’s surface preparation procedures will be determined at the beginning of the work and as required by the Engineer using a profile depth tape and micrometer. Profile depth tape measurements shall be retained and submitted for the Engineer’s approval. Single measurements less than 50 µm (2 mils), or greater than the specified maximum for the metallizing system used will be considered unacceptable. Areas having unacceptable measurements will be further tested to determine the limits of the deficient area. If unacceptable profiles are provided, work will be suspended. The Contractor shall submit a plan for the necessary adjustments to ensure the correct surface profile on all surfaces. The co ntractor shall not resume work until authorized by the Engineer. The abrasives used shall be hard and sharp in order to produce an angular surface profile. Acceptable abrasives include but are not limited to, angular aluminum oxide, angular steel grit and angular crushed slag. Silica sand shall not be used. Steel shot and other abrasives producing a rounded surface profile are not acceptable. However, the steel can be preblasted with shot provided that the entire surface is reblasted with angular abrasives. All metallizing shall occur within 4 hours of completion of blas t cleaning. The thickness of the metallizing shall be 200 to 250 µm (8 to 10 mils), measured as specified by SSPCPA2. All metallizing work shall be performed by a company with at least five years of experience in the field of metallizing structural steel. The spray requirements shall be according to the SSPC CS -Guide 23.00 “Guide for Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their Alloys and Composites for the Corrosion Protection of Steel” and the ANSI/AWS C2.18 “Guide for the Protection of Steel with Thermal Sprayed Coatings of Aluminum and Zinc and their Alloys and Composites .” To produce the required thickness and uniformity, a minimum of two passes are required, overlapping and at right angles to each other. The gun shall be held at such a distance from the work surfaces that the metal is still plastic on impact, 5 to 9 in. The coating shall be firmly adherent and free from uncoated spots, lumps, or blisters, and have a fine sprayed texture. The Contactor is required to provide facilities to protect the finished metallized surface from damage during the blasting and thermal spraying work operations on adjacent areas. All damaged areas shall be properly repaired and remetallized by the contractor. Surfaces not intended to be metallized shall be suitably protected from the effects of cleaning and metallizing operations. To the maximum extent practicable, metallizing shall be applied as a continuous film or uniform thickness free of pores. All thin spots or areas missed in the application shall be remetallized. After field welding the sole plate to the flange the weld shall be cleaned and painted with a high zinc content paint in accordance with 960.64: Galvanizing . II.553 202 4 Edition 960.66 : Stud Shear Connectors General. Welding of stud shear connectors shall conform to the latest edition of the AASHTO/AWS Bridge Welding Code. All stud shear connectors applied to flanges of beams or girders shall be field installed. Workmanship. At the time of welding, the studs shall be free from any rust pits, scale, oil or other deleterious material that would adversely affect the welding. The area of the beams or girders to which the studs are welded shall be free of rust and scale. The arc ferrules shall be kept dry. Any ferrules that show signs of moisture shall be oven dried at 250°F for two hours before use. After welding, the studs shall be free of any discontinuities that would interfere with their intended function. Longitudinal and lateral spacing of studs with respect to each other and to edges of beam or girder flanges may vary a maximum of 1 in. from the location shown on the drawings. The clear distance between studs shall not be less than 4 diameters center to center. The minimum distance from the edge of a stud base to the edge of a flange shall be the diameter of the stud plus ⅛ in., but preferably not less than 1.5 in. Preproduction Testing. Before production welding begins and at the beginning of each shift thereafter, testing shall be performed on the first two studs that are welded for each particular set -up, size and type of stud. All test studs shall be welded in the same position as requ ired in production. The test studs shall be visually examined and shall exhibit a full 360 -degree flash. The test welds shall also be mechanically tested by bending the studs approximately 30 degrees. The weld or stud shall not fail. If either of the above tests fail, two more studs shall be welded to separate material and tested again. Technique. Stud shear connectors shall be welded to steel beams or girders with automatically timed stud welding equipment connected to a suitable power source of direct current electrode negative (DCEN) power. If two or more stud welding guns are to be operated from the same power source, they shall be interlocked so that only one gun can operate at a time and so that the power source has fully recovered from making one weld before another weld is started. The power source shall be adequate to meet the requirements of the size of stud being welded. While in operation the welding gun shall be held in position without movement until the weld metal has solidified. II.554 202 4 Edition When the temperature of the base metal is below 32°F, one stud in each 100 studs welded shall be bent 15 ° in addition to the first two bent. Welding shall not be done when the base metal temperature is below 0°F. Operator Qualification. The equipment operator is qualified by passing the preproduction test. Production Welding. Studs on which a full 360° weld is not obtained may be repaired, at the option of the contractor, by adding the minimum size fillet weld in place of the missing flash. The repair shall extend at least ⅜ in. beyond each end of the discontinuity being repaired. Removal of unacceptable studs in tension areas:
Removal of unacceptable studs in compression areas:
depth of the discontinuity is less than ¹⁄₁₆ in., the discontinuity may be faired by grinding. Base metal shall be preheated to: 50°F for base metal thickness up to and including ¾ in.; 70°F for base metal thickness up to and including 1.5 in .; 150°F for base metal thickness up to and including 2.5 in. If the reduction in the height of the studs as they are welded becomes less than normal, welding shall be stopped immediately and not resumed until the cause has been corrected. Inspection. If visual inspection reveals any stud which does not show a full 360° flash or which has been repaired by welding, such stud shall be bent 15° off the vertical. For studs showing less than a 360° flash, the direction of bending shall be opposite to the lack of weld. Studs that crack either in the weld or shank shall be replaced. Studs that are tested and show no sign of damage may be left in the bent position. The Engineer, at their option, may select additional studs to be subject to the bend test specified above. If during the progress of work, inspection and testing indicate, in the judgment of the Engineer, that the stud shear connectors are not satisfactory, the Contractor will be required at their expense to make such changes in the welding procedure, welding equipment and type of stud as necessary to secure satisfactory results. II.555 202 4 Edition COMPENSATION
960.80: Method of Measurement
Payment will be based only on computed weights (masses) of steel complete in place in the structure. No additional allowance in mass will be made for the shop coat of paint or for any other coat of paint or other protective covering. The weight of the rolled shapes and of the plates, regardless of the width of the plates, shall be computed on the basis of their nominal mass and of their dimensions as shown on the approved shop drawings, deducting for copes and cuts, and for all open ho les that are not to be filled with rivets, bolts or plug welded. Steel for expansion assemblies at the roadway level of bridges and similar structures (whether or not attached to the structural steel of the deck) and bronze or other metal for expansion bearings, drainage troughs and baffles, shall be included in the mass to be paid for as structural steel. Where no separate items are in the contract for galvanized nose angles on piers, or curb plates or angles in bridge curbs, such steel will be paid for by the pound as structural steel, with no additional compensation f or the galvanizing. The computed weights shall not include the weight of welds. The density of the various metals shall be assumed as follows: Steel (Structural, Cast, Galvanized) ...................................................................................... 490 pcf Cast Iron .......................................................................................................................................... 450 pcf Bronze ....................................................................................................................................... ....... 542 pcf The weight of the nuts and heads of bolts shall be included in the computed weight, assuming the weight to be as shown in Table 960.80 -1. Payment for bolt heads and nuts will be made by the pound. Where rivets are used in the permanent construction, the heads of the rivets shall be considered, for purpose of payment, as bolt heads for bolts equal in diameter to the rivets, regardless of the material of which they are composed or the materials to which they fasten. All permanent washers will be paid for by the pound. The shank of a bolt will be considered as part of the material through which it passes and will be paid for as that material. No allowance or payment will be made for that part of a bolt shank that exten ds through and past the nut. Table 960. 80-1 : Assumed Weight of Nuts and Heads of Bolts Diameter of Bolt (in .) Weight per 100 Bolts (Heads & Nuts) ( lb) ½ 4 ⅝ 7 ¾ 12 ⅞ 18 1 26 1 ⅛ 36 1 ¼ 48 II.556 202 4 Edition 960.81: Basis of Payment The furnishing, fabricating, erecting and coating of all structural steel and all metal work for the structure not otherwise provided for, will be paid for at the contract unit price per pound under the item for structural Steel, complete in place. To avoid delay in computation of the weight for partial and final payment, the Contractor shall submit their computations for the steel shown on each of the approved shop drawings as soon as practicable after the sheet has been approved. The computation by the Contractor shall show the weight for each member, except that duplicate members may be grouped together .
960.82: Payment Items
960. Structural Steel ............................................................................................................. Pound
960.1Structural Steel – Coated Steel ................................................................................ Pound
960.11Structural Steel – Uncoated .............................................................................. ....... Pound
960.12Structural Steel - M270 Grade 70HPS & 50HPS .............................................. Pound
999.960 Structural Steel on Hand ........................................................................................... Pound
1Not a bid item. SUBSECTION 961: MAINTENANCE PAINTING OF STEEL BRIDGES DESCRIPTION
961.20: General
This work consists of the surface preparation and painting of all steel, including but not limited to, the beams (girders), bearings, diaphragms, cross frames, hand railings, drainage systems, utility supports and lamp posts. The work also includes environmental protection and waste disposal. The Contractor shall implement and maintain programs and procedures that comply with the requirements of this specification and all applicable standards and regulations. The Contractor shall comply with all applicable regulations even if the regulation is not specifically referenced herein. If a Federal, State or local regulation is more restrictive than the regulation of this specification, follow the more restrictive requirements. Work shall also consist of the removal of all graffiti from concrete surfaces and the removal and disposal of debris on abutments and pier caps. The Contractor shall provide the Engineer safe access and support to all parts of the structure for interim and final inspection of the bridge during cleaning and painting operations. This support shall include the necessary traffic controls, scaffolding, fall protection and lighting. All Contractors and Subcontractors performing lead -based paint removal, containment and collection, surface preparation, and coating of structural steel must be prequalified by the Department in the Painting (Structural) category. II.557 202 4 Edition MATERIALS
961.40: Materials
Coatings systems shall conform to the requirements of M7.02: Structural Paint .
961.41: Inspection Equipment
Prior to the start of any cleaning or painting operations, the contractor shall furnish the following inspection equipment to the Engineer: 4 Wet Film Thickness Gauges (notch type, as specified in ASTM D4414, procedure A) 1 Dry Film Thickness Gauge - type two, with memory and download capabilities (Posi- Tector 6000, Elecometer 345, Quanix or approved equal) 1 Sling Psychrometer with two replacement thermometers (Bacharach, Taylor, Ertco or approved equal) 1 National Weather Bureau psychrometric tables 1 Magnetic Surface Temperature Thermometer, calibrated/certified, range 0 °F to 150 °F 1 Spring loaded micrometer for reading surface profile tape * Course and x -course profile replica tape 1 Surface Profile Comparator, comprised of, 10x flash light magnifier and 1 grit/slag disc or coupon, Keane -Tator, Elcometer, Clemtex or approved equal. * Quantitative soluble contaminates test kit (Bresle, Chlor*Test, or approved equal) 1 Inspection mirror, telescopic with a mirror surface of 10 in. ² * Blotter Paper for compressed air testing 9V lantern 1 High/Low Recording Thermometer (for paint storage area) Incline Manometer Velometer 1 Light Meter 1 SSPC VIS 1 Standards 1 SSPC VIS 3 Standards * A quantity sufficient for required testing. All equipment shall be in usable condition and complete with all necessary components and instructions for the proper calibration and function. Equipment found to be incomplete or unable to be field calibrated, shall be immediately replaced. All equipment shall remain the property of the Contractor upon completion of the project. CONSTRUCTION METHODS
961.60: Surface Precleaning
Pressure washing is required for all surfaces of the structure that are to be painted. Prior to pressure washing, the Contractor shall remove all accumulated debris from abutments, pier caps, girder flanges and other areas of collection. Debris may include but are not limited to, sand, gravel, bituminous materials and bird droppings. The method of removal shall allow for the collection and proper disposal of the debris. All water used for pressure washing shall be potable and supplied by the Contractor. II.558 202 4 Edition Water from pressure washing operations shall be collected, filtered, and tested for toxic metals. Pressure washing shall not be performed more than seven days prior to the start of surface preparation. Prior to the start of surface preparation, the Engineer will inspect the cleaned surface to ensure that it is acceptable. The Contractor shall reclean u nacceptable surfaces in the specified manner. Portable pressure washing equipment shall be operated at a minimum of 3,000 psi, a water temperature of 200°F and a minimum consumption of 6 gallons per minute shall be used to clean all surfaces to be painted of visible and non -visible contaminants. Pressure washers shall be equipped with gauges to ascertain operating pressure and temperature. The use of an oscillating or rotary type nozzle is recommended for all washing. The Contractor shall use a water -based, phosphate free, biodegradable cleaner, which has a pH of 9 to 11. The cleaner shall also be, non -flammable and non- reactive. RMS shall approve all cleaning solutions. Each pressure washing unit shall have a cleaning compound supply tank with the ability to control the amount of solution being supplied to the feed water. Cleaning solutions shall be used in strict accordance with the manufacturer’s written recommendations. All dirt, oil, grease, tar, road salt, bird dropping residue, chalky paint and other dissolvable debris and contaminates shall be removed by pressure washing. Excessive deposits of cleaning liquids remaining on surfaces that will not drain shall be flushed off with clean, fresh water without detergent. In as much as a certain amount of liquid will remain on horizontal surfaces after cleaning, the cleaning process shall be followed through systematically from top to bottom. The last pass on any surface shall be made with clean fresh water without detergent to remove surplus solution. The Contractor shall be solely responsible for damages arising from pressure washing operations. Expansion joints or open areas that will allow debris or water to pass shall be covered or sealed to protect vehicle and/or pedestrian traffic. Under no circumstances will surface preparation or painting be started over cleaned surfaces until the surface is free of standing water and dry to the touch, and then only after the approval of the Engineer.
961.61: Surface Preparation
All equipment, materials and vehicles brought to the site by the Contractor shall be clean and free of debris. A visual assessment of cleanliness shall be made by the Engineer prior to locating equipment at the contract location(s). All portions of the structure that could be damaged by surface preparation, abrasive residue, and painting operations, (e.g., utilities, bearings, machined surfaces, electric motors, wiring, and neoprene pads) shall be protected prior to the start of cleaning and painting operations. Any damage or reduced service life caused by the failure to protect areas or components of the structure shall be repaired or replaced at the Contractor expense. The Contractor shall immediately report to the Engineer any cracks, section loss or other potential problems found during surface preparation. II.559 202 4 Edition After surface preparation all surface imperfections/discontinuities (e.g., sharp fins, sharp edges, weld spatter, burning slag, scabs. slivers, laminations, etc.) that remain shall be completely removed by grinding to the satisfaction of the Engineer. The Contractor shall restore surface profile if degraded by grinding. Alternate methods of surface preparation that will provide the specified surface cleanliness and profile may be submitted to the Engineer for review for approval. Prior to full operation of surface preparation, an acceptance standard for the preparation method(s) shall be prepared by the Contractor and approved by the Engineer. The surface for the standard (or control) should be a flat portion of the surface actuall y to be cleaned and shall be located by the Engineer. The Engineer shall be the final authority in regard to determining whether or not a prepared surface meets the requirements of this specification. To establish this standard, SSPC VIS -1 and VIS -3, shall be used as guides. An area not less than 2 ft x 2 ft shall be prepared to meet the requirements of the surface preparation method(s) to be utilized. After approval and at the option of the Engineer, the prepared standard will be sealed with a clear protective paint to preserve its appearance. Upon completion of the surface preparation and application of the primer, the standard will be re -prepared and coated in accordance with these specifications. All laminar and stratified rust that has formed on the existing steel surfaces shall be removed. Pack rust formed along the perimeter of mating surfaces of connected plates or shapes of structural steel shall be removed to the extent feasible without mechanically detaching the mating surface. Extensive pack rust, buckled plates, and loose or missing bolts shall be brought to the attention of the Engineer before painting. Any pack rust remaining shall be tight and intact when examined after scraping with a d ull putty knife. A best effort with the specified methods of cleaning shall be performed in limited access areas. The equipment being used for the majority of the cleaning may need to be supplemented with other commercially available equipment, such as angle nozzles, to properly clean the limited access areas. The acceptability of the best effort cleaning in these areas is at the sole discretion of the Engineer.
961.62: Surface Cleaning Requirements for Overcoating
All steel except as defined under section entitled “Cleaning of the Bearing Areas” shall be spot cleaned SSPC SP -3 Power Tool Cleaning or SSPC SP -14 Industrial Blast Cleaning, the method of surface preparation shall be chosen by the Contractor. Regardless of the method used for cleaning, remaining old paint shall be feather edged so that the repainted surface will have a reasonably smooth appearance. All steel within the width of the pier caps and abutments and a length from the end of the stringer to a distance 5 ft beyond the centerline of the bearing (from the top of the pier caps and abutments to the bottom of the bridge deck) shall be abrasive blast cleaned to meet the requirements of SSPC SP-10 “Near White Metal Blast. ” This requirement is waived at bearing areas located at intermediate piers where there are no deck joints directly above. II.560 202 4 Edition 961.63 : Surface Cleaning Requirements for Full Removal All surfaces to be painted shall be abrasive blast cleaned to meet the requirements of SSPC SP -10 “Near White Metal Blast” using recyclable steel abrasives.
Abrasive blast cleaned surfaces shall have a uniform profile of 25.4 to 76.2µm (1 to 3 mils). Verification of the profile height will be performed in accordance with ASTM D4417 Method C. If surface profile requirements of the coating manufacturer differ from those specified, the Contractor shall comply with the coating manufacturers requirements. Profile replica tape shall be filed with the project inspection records. The profile shall be measured three times in random locations at least every 500 ft ² of pr epared surface or as directed by the Engineer. The measured profile shall be approved by the Engineer.
All abrasives brought to the site shall be stored in a clean and dry environment. The Contractor shall select the type of abrasive. Expendable abrasives shall be in accordance with SSPC AB- 1, class “A.” Recycled steel grit shall be in accordance with SSPC AB -2, and recyclable steel abrasives shall be in accordance with SSPC AB -3. The selected abrasive shall be sufficient to produce a profile within the range specified. The profile shall be uniform and of sufficient angularity as to be acceptable by the paint manufacturer for the application of primer. The Engineer with the use of a surface profile comparator will randomly inspect angularity of the profile. All abrasives will be maintained clean, dry and uncontaminated. The abrasive shall be tested daily for grease, oil or non- abrasive residue with a “vial test” using the following method: A sealable jar is filled with distilled water, a sample of abrasive taken from the storage hopper or pressure vessel and is then added to the jar. The vial is shaken for one minute and allowed to set for five minutes. The vial is observed. If any oil or grease is floating on the top of the water or a cloudy condition exists, the abrasive will be considered contaminated. Contaminated abrasives will not be used for surface preparation. Abrasive found to be contaminated shall be disposed of or recycled. The use of proprietary additives to water or abrasive to generate a non- hazardous waste is not permitted.
All compressed air sources shall have properly sized and operational oil and moisture separators. Prior to the connection of the air to the blast pot(s), a desiccant filter drying unit or air dryer shall be installed. They shall allow air at the nozzle for blast cleaning, painting, or blow off to be oil free and moisture free. Compressed air shall have sufficient volume and pressure to accomplish the associated work effectively and efficiently. A blotter test will be performed at the start of each day or shift by the Engineer to ensure that compressed air is free of oil and moisture. The Contractor shall supply all blotter paper. The II.561 202 4 Edition compressed air will be tested for contaminants in accordance with ASTM D4285 “Detecting Oil or Water in Compressed Air.”
Upon completion of blast cleaning and prior to inspection, the Contractor shall vacuum and/or blow down under full ventilation and containment all surfaces to be inspected, providing areas for testing and to aid visual inspection of the substrate. The prepared surface will be tested by the Engineer for chloride contamination using the required test kit and the manufacturer’s instructions for extracting and quantifying chloride levels. All test areas will be recorded for re -testing purposes. A minimum of 5 tests per 1,000 ft ² or fraction thereof completed in a given day shall be conducted at project start up. If results greater than 7 µg/cm² are detected, the surface shall be recleaned as specified and retested at the same frequency. If acceptable results are achieved on three consecutive days in which testing is conducted, the test frequency may be reduced to one test per 1,000 ft² providing the preparation method remains unchanged. If unacceptable results are encountered, or the methods of preparation are changed, testing shall resume at a frequency of 5 tests per 1,000 ft ². After testing and approval, the test areas shall be blast cleaned to the specified level of cleanliness and profile.
961.64: Paint
Paints and solvents are hazardous due to their flammability and potential toxicity. Proper safety precautions shall be observed to protect against these recognized hazards. Proper ventilation and handling shall be employed during mixing and application to insure that vapor concentrations do not exceed the published Permissible Exposure Limits (P.E.L.) and the Lower Explosion Limit (L.E.L.). Prior to the application of any coating, all dust and debris shall be removed by vacuuming and/or blowing down under full ventilation and containment. Painting of the approved area will not be allowed until the area has been properly ventilated to remove all airborne dust. Surface preparation and subsequent paint application shall be so programmed that dust and other contaminants from the cleaning process will not fall on surfaces about to receive paint, or on wet, newly painted surfaces. Approved surfaces will not be allowed to stand uncoated longer than eight hours unless some form of protective environmental procedure is utilized, e.g., dehumidification. If substrate is found to have degraded, it will be recleaned in the specified method at the Contractors expense. All surface preparation will be reviewed and approved by the Engineer prior to painting operations. The finish coat shall be Federal Standard Color #14223, green. The colors of the prime, intermediate and finish coats shall have a definite color contrast between them and be subject to the approval of the Engineer. Minimum and maximum dry film thickness shall be in accordance with the latest manufacturer’s data sheet for each product applied. II.562 202 4 Edition A. Storage, Testing and Sampling. The Contractor shall provide a suitable facility for the storage of paint that will be in accordance with the latest requirements of OSHA. This facility must provide protection from the elements and insure that the paint is not subjected to temperatures outside the manufacturer’s recommended extremes. Storage of the paint must be located in reasonable proximity to the painting location. The Contractor’s facility for the storage of paint and its location at the site are subject to the approval of the Engineer. Before the Contractor will be permitted to use any paint, the material provided for application shall have been sampled, tested and approved in accordance with Section M7: Paints, Protective Coatings . RMS requires a minimum of 14 days after the receipt of samples to test and approve.
Before the paint is applied, each component shall be mechanically mixed to ensure complete disbursement of the pigment. Mixing of components shall be accomplished by mechanical mixing or agitation, boxing or hand mixing of components will not be allowed. Any special precautions or requirements for mixing by the manufacturer shall be followed. Paint shall be kept thoroughly mixed in spray pots or containers during application. The pot life shall not be exceeded, or attempts made to extend pot life with the addition of solvent. If it is necessary for any reason to thin paint it will be done in the presence of the Engineer, in accordance with the manufacturer's recommendations. Thinning must be performed using a measuring cup marked in ounces or milliliters. Other methods, such as eyeballing, are not acceptable. Thinner shall be supplied from the same manufacturer as the paint system. For multi -component paints, the mixing of half or partial kits is not allowed. If the need for small quantities of paint is anticipated, the contractor should order materials accordingly.
All necessary precautions shall be taken to protect pedestrians, vehicles, concrete areas, and any other areas not to be painted. All paint overspray, mist and or dust shall be collected and filtered with collection equipment. Prior to the application of any coating material, the Engineer’s approval must be obtained. All surfaces painted prior to the Engineer’s approval, shall require the complete removal of the coating applied. All labor, materials, and associated costs with th e removal of any unapproved coating shall be done at the Contractor’s expense to the satisfaction of the Engineer in accordance with these specifications. Applied coatings shall not exhibit, runs, sags, holidays, wrinkling, pinholes, nap hair, topcoat gloss or color variations, or other film discontinuities. Repair of unacceptable areas that involve removal of the coating system or part of it, shall require surface preparation and coating equal to that specified. Repair procedures used for any unacceptable coating shall be those supplied by the paint manufactu rer and approved by the Engineer. II.563 202 4 Edition Application of full coats of paint shall be accomplished by spray equipment. Spray equipment shall meet the requirements of the coating manufacturer and be in proper working order. Application by brush and roller will be limited to stripe coating, inaccessible areas and the application of the spot coat of primer. Brushes and roller covers recommended by the coating manufacturer shall be used. Areas brushed and rolled will have a unif orm thickness and be free of defects and excessive coating thickness. All coating shall be applied according to the latest manufactures written requirements. The maximum re -coat times of the primer, intermediate and finish coats shall not be exceeded. Application of organic zinc, epoxy, and urethane systems shall not be done when the relative humidity is above 85% or when the surface temperature of the steel is less than 5°F above the Dew Point. Paint shall not be applied when the surface temperature is below 40°F or when the surface temperature is above 125°F. Application of moisture cure urethane systems shall not be done when the relative humidity is above 95% or when the surface temperature of the steel is less than 3°F above the Dew Point and rising. Paint shall not be applied when the surface temperature is below 35°F or when the surface temperature is above 125°F. If requested by the Engineer, the Contractor shall provide written instructions from the coating manufacturer indicating the length of time that each coat must be protected from cold or inclement weather (e.g., exposure to rain) during its curing or drying period. Paint shall not be applied when, in the Engineer’s judgment, conditions are or will become unsatisfactory for application and proper cure. All changes as to the application parameters other than specified must be the manufacturer’s and presented in writing and approved by the Engineer. Ambient conditions should be closely monitored so that proper cure/drying is achieved prior to recoat. In no case shall a succeeding coat of paint be applied before the previous coat has cured/dried sufficiently for recoat as per manufactured data sheet. If required, contaminated surfaces, e.g., bird droppings, road debris shall be cleaned in accordance with SSPC - SP 1 Solvent Cleaning method 4.1.1. Measurement of the ambient conditions shall be done in accordance with ASTM E337 Test Method for “Measuring Humidity with a Psychrometer” (the Measurement of Wet and Dry bulb Temperatures). After Full Removal The primer will be applied at a coverage rate that will result in a minimum dry film thickness recommended by the manufacturer, when measured in accordance with SSPC PA -2. The primer shall not be cleaned of over spray or debris by wire brushing or methods that would burnish the surface. When the primer has cured sufficiently for recoat, all bridge components to be painted shall receive a full intermediate coat. II.564 202 4 Edition To provide adequate film thickness in areas or places prone to breakdown, edges, corners, rivet heads, bolts, nuts, and welds shall be striped by brush painting. Stripe coating of the intermediate coat shall be completed prior to the application of the full intermediate coat. Prior to the application of the finish coat, bearing areas as defined shall receive an additional intermediate coat at 3 mils Dry Film Thickness (DFT), spray applied. The additional coating will be applied from the end of the beam to a distance of 5 ft including all steel between the abutment cap and the bottom of the bridge deck and including end diaphragms. All steel within the width and length of the intermediate pier(s) from the center of the pier to a distance of 5 ft in each direction on the stringers including all steel between the pier cap and the bottom of the bridge deck shall also receive additional second spray applied intermediate coating at 3 mils DFT, with the exception of the intermediate piers where there are no deck joints directly above. When the intermediate coat has cured sufficiently for recoat, all bridge components to be painted shall receive the finish coat by spray application. All prepared surfaces shall receive three full coats of paint (primer, intermediate, finish) and the additional (bearing area) intermediate coat of a system selected from the NEPCOAT “B” list, Protective Coatings for New and 100% Bare Existing Steel for Br idges . All areas prepared by spot cleaning shall be spot primed with the selected systems primer. Spot priming shall be completed by brush and roller to provide complete coverage of irregular or pitted surfaces. Areas spot cleaned in accordance with 961.62: Surface Cleaning Requirements for Overcoating shall be painted with an approved 2 or 3 coat NEPCOAT system selected from the “M” list, Protective Coatings for Previously Painted Existing Steel Bridges. Overcoat - Two Coat Systems When the primer has cured sufficiently for recoat, all bridge components to be painted shall receive a full finish coat by spray application. Overcoat - Three Coat Systems When the primer has cured sufficiently for recoat, all bridge components to be painted shall receive a full intermediate coat by spray application and when sufficiently cured a full finish coat by spray application. Bearing areas cleaned in accordance with 961.62: Surface Cleaning Requirements for Overcoating, Part A., Cleaning of the Bearing Areas shall receive three full coats of paint. Application shall be in accordance with the Full Removal portion of this section. The coating system shall be selected from the NEPCOAT “B” list, Protective Coatings for New and 100% Bare Existing Steel for Bridges. Interface between different paint systems shall be vertically masked during the final coat to provide a neat edge on the fascia girders.
The Engineer will measure wet and dry film thickness with the following methods and standards. II.565 202 4 Edition Wet Film Thickness: Will be measured during application with a notch type wet film thickness gauge every 50 ft², in accordance with, ASTM D4414 Standard Practice for Measurement - Wet Film Thickness by V Notch Gages, procedure A . Dry Film Thickness: Will be measured using a type II gauge. The prime, intermediate and the finish coats, shall be measured in accordance with SSPC PA -2, Measurement of Dry Coating Thickness with Magnetic Gages. The Engineer has the option to measure the dry film thickness of overcoated surfaces with the use of a Tooke gage or similar type instrument. Repair to areas cut to determine the DFT of new coatings will be done at the Contractor’s expense.
After the application of the finish coat of paint, the Contractor shall stencil the 3 -character BIN, completion date (month and year), and the letter “F” to designate full clean and paint or “O” to designate clean and paint (overcoat). The information shall be applied on the steel in black on a white base measuring 30 in. by 5 in., square , utilizing 2-in. numbers, when and as directed by the Engineer.
961.65: Worker Protection
The DEP and EPA regulate coatings containing toxic metals and the residue generated from the removal process as a hazardous waste. The Contractor shall comply with all Federal, State and municipal laws, regulations and ordinances that require the Contractor to provide for a safe and healthful work area for work to be per formed by the Contractor under this Contract. The Massachusetts Department of Labor and Workforce Development, Division of Occupational Safety, and the Federal Occupational Safety and Health Administration (OSHA) regulate the exposure to paint and debris containing toxic metals by workers involved in the removal of bridge coatings. Coatings removed from highway structures that contain toxic metals, has been shown to have serious health effects on workers if regulations and caution are not observed. The existing structure(s) and components may be coated with a lead -based paint. Therefore, the Contractor shall be required to sample the existing coatings to determine the percent of lead and if other toxic metals are present. Within 30 days of the notice to proceed the Contractor shall submit a sampling protocol to the Engineer for approval. Upon approval of the protocol the Contractor shall sample and have analyzed in accordance with 310 CMR 30.155B (EPA SW846 Method 1311) the existing coatings. The results of the testing shall be utilized in the development of the “Compliance Program” to protect workers from lead and toxic metals as required by Federal and State regulations. The remaining portion of this specification focuses on lead but requires the Contractor and the Certified Industrial Hygienist (CIH) to address other toxic metals. The Contractor shall provide the Massachusetts Department of Labor and Workforce Development’s, Division of Occupational Safety, a written notification of the project. The notification shall be received at least ten days prior to the beginning of any contract operations and include: its location, start date and anticipated completion date. The Contractor shall also comply with all registration, license, and permit requirements. II.566 202 4 Edition Equipment noise in excess of 90 decibels or other local ordinances as measured at the closest residential, commercial or recreational area, shall be lowered by the contractor to a maximum of 90 decibels or other local ordinances. The use of sound barriers, mufflers or other equipment and materials used to lower noise levels shall be approved by the Engineer prior to installation and provided and installed at no additional cost to MassDOT.
The Contractor shall develop a written program under the direction and approval of a Certified Industrial Hygienist (CIH) to establish and implement practices and procedures for protecting the health of those employees exposed to lead. The Compliance Progr am shall establish methods for complying with any Federal, State or local regulations.
The Contractor shall provide to not more than three representatives of the MassDOT, all the work place and worker protection requirements that the Contractor is required by law and regulations to provide to their own employees in order to maintain a safe and healthful work place. Without limiting the Contractor’s responsibilities under the prior paragraph, the Contractor shall provide to not less than three representatives of the MassDOT Department the following services:
standards; Hazard Communication training (29 CFR 1926.59), including proper handling and disposal of hazardous waste.
analysis, and medical surveillance as required by OSHA health and safety standards for lead; verify that laboratories that conduct blood analysis meet the qualification requ irements established by OSHA; conduct blood sampling and analysis within one month prior to the start of work and at a minimum of once every 2 months for the first 6 months of exposure, and a 6 months intervals thereafter; conduct blood tests within 5 days of separation and upon completion of the person’s project activities that involve exposure to lead, even if this occurs prior to the completion of the Contractor’s work on the project; supply the Massachusetts Blood Lead Registry (MBLR) and Engineer with the results of all blood tests prior to commencement of work; subsequent blood lead test results shall be supplied to MBLR and the Engineer within ten days of receipt; only certified laboratory copies of test results from OSHA -CDC approved laboratories may be submitted to MassDOT and the Department of Labor and Industries, Division of Occupational Hygiene, with more frequent testing to be done as required, in accordance with this specification and 29 CFR 1926.62; evaluate effectiveness of protection practices whenever a 10 µg/dl blood lead level increases between two results, or a single result in excess of 20 µg/dl.
exposure exceed the PEL or TLV. II.567 202 4 Edition 5. Lavatory and Hand Washing Facility: provide clean lavatory and hand washing facilities in accordance with OSHA sanitation standard 29 CFR 1926.51 and provide showers when the exposure limit exceed the PEL or TLV.
Signs warning that lead paint removal operations are being conducted shall be posted at all approaches to the work areas and in areas where workers will be exposed to concentrations above the PEL. At a minimum, such signs shall include the words: WARNING LEAD WORK AREA POISON NO EATING OR SMOKING AUTHORIZED PERSONNEL ONLY, RESPIRATORS REQUIRED IN THIS AREA The lettering shall be black block, no smaller than 3 in. tall, and on a white, yellow, or orange background. Caution ribbons shall also be used where appropriate. A daily sign in/out log which identifies persons by name, address, and affiliation, or work classification for all employees with the project, and the times of arrival and departure must be maintained at the work site, and submitted to the Engineer on a weekly basis when lead paint removal operations are being performed.
961.66: Environmental Protection and Monitoring
The Contractor shall comply with all Federal, State and municipal laws, regulations and ordinances that require protection of the environment, including laws and regulations whose purpose is to prevent contamination and pollution of the air, water and soil in and surrounding the work site, where lead paint being removed from a bridge under this contract is subject to abatement, containment, transportation and disposal.
Baseline Monitoring Pre-project monitoring shall be performed for a minimum of two days while no paint removal work is underway in order to establish baseline levels. Emissions from the project site will not be penalized by existing baseline levels. If the baseline levels are highly variable, the Engineer may require that periodic or full- time upwind monitoring be conducted. Include provisions for such monitoring in 961.69: Submittals , Paragraph B. High Volume Ambient Air Monitoring High volume ambient air monitoring shall be conducted in strict accordance with the requirements of 40 CFR 50, 310 CMR 7.00, and the equipment manufacturer's instructions. The Contractor shall submit methods and procedures for locating the monitors, calibrating and conducting baseline and project monitoring, and completion of chain of custody forms. Include the name and qualifications of the State- certified laboratory proposed for use, and the test methods that will be utilized for the analysis of the filters. II.568 202 4 Edition Conduct the following monitoring activities under the observation of the Engineer: locating and calibration of the monitors, daily removal and replacement of the filters, and completion of the chain of custody forms. TSP Lead Monitoring The monitoring shall be in accordance with 40 CFR 50 for 5 out of the first 10 days at the beginning of each project location while paint removal, containment movement, and cleanup activities are underway. Monitoring during paint application is not require d, and if performed, will not be counted as one of the 5 days of project monitoring. The monitors shall be placed at the point of maximum environmental impact (usually downwind of the cleaning operation) and other locations of potential public or environmental exposure. Monitors shall be moved to maintain this condition due to shifting wind patterns. For TSP -lead monitoring, emissions in excess of the value attained by the following formula or exceeding 150% of background levels shall be cause to shut down the project until the work activities and/or containment are modified to provide better control o f emissions. 𝑁𝑁𝐴𝐴=(90÷𝑃𝑃𝑁𝑁)× 1.5 µg m 3⁄ Where: 𝑁𝑁𝐴𝐴=𝑗𝑗ℎ𝐴𝐴 𝑁𝑁𝐴𝐴𝑖𝑖𝐴𝐴𝑄𝑄 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝑖𝑖𝑖𝑖𝐴𝐴 𝑖𝑖𝑖𝑖µg m3⁄ 𝑃𝑃𝑁𝑁 =𝑗𝑗ℎ𝐴𝐴 𝑖𝑖𝑜𝑜𝑁𝑁𝐴𝐴𝐴𝐴𝑝𝑝 𝐴𝐴𝑜𝑜 𝑝𝑝𝑝𝑝𝐴𝐴𝑝𝑝𝐴𝐴𝑝𝑝𝐴𝐴𝑗𝑗𝑖𝑖𝐴𝐴𝑖𝑖 𝐴𝐴𝑝𝑝 𝑝𝑝𝐴𝐴𝑖𝑖𝑖𝑖𝑗𝑗 𝑑𝑑𝑖𝑖𝑔𝑔𝑗𝑗𝑜𝑜𝑝𝑝𝐴𝐴𝐴𝐴𝑖𝑖𝑖𝑖𝐴𝐴 𝑑𝑑𝐴𝐴𝑄𝑄𝑔𝑔 𝐴𝐴𝑖𝑖𝑗𝑗𝑖𝑖𝑖𝑖𝑖𝑖𝑝𝑝𝐴𝐴𝑗𝑗𝐴𝐴𝑑𝑑 𝑖𝑖𝑖𝑖 𝐴𝐴 90 𝑑𝑑𝐴𝐴𝑄𝑄 𝑝𝑝𝐴𝐴𝑝𝑝𝑖𝑖𝐴𝐴𝑑𝑑 The above calculation provides an allowance criteria for a 24 -hour period. In order to convert this value to an allowance corresponding to the hours worked, do the following: 𝐴𝐴𝑁𝑁𝐴𝐴 =𝑁𝑁𝐴𝐴×(24÷𝐻𝐻) Where: 𝐴𝐴𝑁𝑁𝐴𝐴 =𝑗𝑗ℎ𝐴𝐴 𝐴𝐴𝑑𝑑𝑗𝑗𝑜𝑜𝑔𝑔𝑗𝑗𝐴𝐴𝑑𝑑 𝑁𝑁𝐴𝐴𝑖𝑖𝐴𝐴𝑄𝑄 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝑖𝑖𝑖𝑖𝐴𝐴 𝑖𝑖𝑖𝑖µg m3⁄ 𝑁𝑁𝐴𝐴=𝑗𝑗ℎ𝐴𝐴 𝑑𝑑𝐴𝐴𝑖𝑖𝐴𝐴𝑄𝑄 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝑖𝑖𝑖𝑖𝐴𝐴 𝑖𝑖𝑖𝑖µgm3⁄ 𝐻𝐻=𝑗𝑗ℎ𝐴𝐴 ℎ𝐴𝐴𝑜𝑜𝑝𝑝𝑔𝑔 𝐴𝐴𝐴𝐴𝑝𝑝𝐿𝐿 𝑖𝑖𝑖𝑖 24 ℎ𝐴𝐴𝑜𝑜𝑝𝑝𝑔𝑔 If the emissions are unacceptable at the end of the 5 days of monitoring, or a trend of exceedances is apparent from the 5 days of monitoring, the monitoring shall continue at the contractor’s expense until 5 days of acceptable monitoring limits have been obtained. After the initial 5 days of monitoring, if visible emissions are in excess of the stated duration for 2 days, additional monitoring shall be required for a period of 2 consecutive days of TSP monitoring. If the emissions are unacceptable after the 2 days of monitoring, the monitoring shall continue at the contractor’s expense until 2 days of acceptable monitoring limits have been obtained. The Contractor shall conduct additional ambient air monitoring after periods of prolonged shutdown or following any significant changes in work practices. Laboratory Analysis and Report The Contractor shall have all filters analyzed for lead using a State -certified laboratory. The analysis shall be conducted in accordance with 40 CFR 50. The Contractor shall provide the Engineer with verbal results of the laboratory analysis within 72 hours after the monitoring was performed, with a written summary report within seven days. II.569 202 4 Edition Visible Emissions The Contractor shall conduct visible emissions assessments in accordance with 40 CFR 60, Appendix A, Method 22. This assessment is based on total visible emissions regardless of the opacity of the emission. Visible emissions are permitted at the following duration provided they do not extend beyond the established regulated areas. Random airborne emissions of a cumulative duration of no more than 1% of the workday are permitted. This amounts to a duration of 5 minutes in an 8 -hour workday. Visible emissions in excess of this criterion are cause for immediate project shut down until the cause of the emissions is corrected. The visible emissions assessment will account for all locations where emissions of lead dust might be generated, including but not limited to, the containment or work area, dust collection and waste recovery equipment as applicable and waste containerizing areas. Observations and corrections of visible emissions and releases of dust debris are an ongoing daily requirement.
The Contractor shall not contaminate the soil. An approved impervious covering must be placed on the ground under the work and decontamination areas and under waste containers. In the event that it is not practical to place tarpaulins directly on the ground, shielding devices must be supported by suitable frame works to prevent falling contaminants from escaping. Prior to the start of any work, the Contractor and the Engineer shall make a site inspection to determine the cleanliness of the area. Clean -up procedures that are required as a result of soil contamination caused by the Contractor shall be the responsibility of the Contractor. The Contractor shall pay all associated costs of the cleanup including, Licensed Site Professional services and documentation. The Contractor shall perform a pre -job and post -job soil analysis for lead. The Engineer will select locations for sampling within the likely dispersion zone of airborne dust or spills of debris. The number of sites will be sufficient to properly characterize project conditions. Particular attention will be paid to wind direction, height of the structure, and the dust -producing nature of the operation when selecting the sites. Samples around equipment, in debris containerizing areas, inside and around regulated areas, beneath and around the structure being prepared and other locations of potential public or environmental exposure will be included. The Contractor shall collect samples prior to the commencement of activities in a given area (e.g., collect samples in equipment staging areas prior to mobilization in those areas, and collect samples around the structure prior to the erection of the containment). A plot plan showing actual locations of sample sites shall be given to the Engineer. Samples shall be collected in the identical locations upon completion of all project activities. Sample Removal Criteria The Contractor shall comply with the following minimum requirements for the collection of each sample: II.570 202 4 Edition a) Tools and resealable containers for the collection and storage of the samples shall be comprised of a material that will not contaminate the samples.
diameter and ½ in. in depth from the four corners of the template and from the center. Place the 5 plugs into a single sample container. This represents a single sample from the test site.
and collect a duplicate sample (5 plugs). Package the sample in a separate container.
removing the sample. Complete a chain of custody record. Repeat the procedure at each sampling location, cleaning the sampling tool prior to each use. Acceptance Criteria for Ground (Soil) Analysis The soil samples shall be analyzed for lead in accordance with EPA Method 3050 or approved equivalent method by a State- certified laboratory. The ground (soil) is considered to have been impacted by project activities based on increases over the geometric mean pre -job lead concentration. If the geometric mean pre -job total lead concentration is less than 200 ppm, an impact is considered to have occurred if the post -job geometric mean lead concentration is an increase of 100 ppm or more. If the pre- job concentration is greater than 200 ppm, an impact is considered to have occurred if the post -job geometric mean lead concentration exceeds the pre -job geometric mean plus 2 standard deviations, or an increase of 100 ppm occurs, whichever is greater. The Contractor shall provide the Engineer with verbal results of the laboratory analysis within 7 calendar days, and a written summary report within 14 calendar days after the sampling was performed.
The Contractor shall take all necessary precautions to prevent debris due to paint related activities from entering the water. Any notification and clean -up procedures required to abate lead contamination in sediments or water shall be the responsibility o f the Contractor. The Contractor shall protect all drains to prevent debris from entering the storm sewer system. For bridges over water, the Contractor shall provide water booms, a method for anchoring the water booms and a procedure for removing the debris that inadvertently enters the water.
961.67: Containment
The Contractor shall design, install, and maintain a containment to retain water, debris, and paint used during cleaning, surface preparation, and coating operations. The containment shall be designed to reduce worker exposure to lead, protect vehicular tr affic, pedestrians, and the surrounding environment. Table 961.67 -1 outlines the minimum requirements for containment design for various activities, such as: cleaning, surface preparation, and paint application. Containment classifications and II.571 202 4 Edition descriptions are based on SSPC – Guide 6, Guide for Containing Debris Generated During Paint Removal Operations. Table 961. 67-1: Minimum Requirements for Containment Design Dry Abrasive Blasting, Class 1A Power Washing or Wet Abrasive Blasting, Class 1W Power Tool Cleaning (both vacuum -assisted and not) , Class 2P Coating Application, Class 3A Containment Materials A1 Rigid or A2 Flexible Penetrability B1 Air Impenetrable B1 Air Impenetrable and B3 Water Impenetrable B1 Air Impenetrable B1 Air Impenetrable Support Structure D1 Fully Sealed D1 Fully Sealed D2 Partially Sealed D2 Partially Sealed Entryway E2 Re -sealable Door E2 Re -sealable Door E3 Overlapping Door E3 Overlapping Door Air Make-Up F1 Controlled Air F2 Open Air Supply F2 Open Air Supply F2 Open Air Supply Input Air Flow G2 Natural Input Air Air Pressure H1 Instrumentation and H2 Visual Verification H3 Not Required H3 Not Required H3 Not Required Air Movement I1 Minimum Specified I2 Not Specified I2 Not Specified I2 Not Specified Exhaust Dust Filtration J1 Air Infiltration J2 Not Required J2 Not Required J1 Air Infiltration
The Contractor shall provide plans and calculations detailing the proposed method of containment and ventilation. The plans shall include an elevation view of the containment enclosure clearly showing any encroachments on the surroundings. The vertical cle arance shall be maintained above any active travel lanes. The plans shall contain details of the method of sealing joints, the entrance/exit openings, air intake points (including filters, louvers, and baffles), type/placement of lighting systems, and connections to the bridge. Methods of attachment that require welding, drilling, bolting, or any methods requiring alteration of the structure or part of it, are not allowed. The Contractor shall analyze the bridge to determine its ability to safely support the proposed containment system, vehicular traffic, and the Contractor's vehicles and equipment. The following calculations are required: the maximum dead and live load impo sed on the bridge by the containment system, and the maximum allowable load for the floor/platform. The calculations shall include an analysis of the stresses in all affected members and applicable load rating capacities for II.572 202 4 Edition Type H, Type 3, and Type 3S2 AASHTO truckloads. The stress limits for all loads shall not exceed 120% of the inventory level allowable stress. If the containment system is suspended from the bridge, each connection to the bridge shall have a tension load cell attached. A multi -channel digital load indicator shall be connected to all load cells and located in an accessible area. The Contractor shall report load readings to the Engineer at scheduled intervals (or at times) directed by the Engineer. The load indicator shall b e capable of storing peak load readings. All containment systems shall be analyzed to determine the amount of stress applied to the bridge as a result of wind loads on the containment. The Contractor shall calculate an “allowable wind speed” which will be used, in the field, to determine the thre shold for dismantling the containment system.
All tarps, drapes and plastic sheeting materials used for containment or ground cover shall be fire - retardant and impermeable to air and water. All materials shall be in good condition.
Light at the steel surface within the enclosure shall be maintained by the Contractor at a minimum of 30 fc as measured by a light meter. Such lighting shall be maintained throughout the surface preparation, painting, and inspection activities. The use of explosion -proof lighting is mandatory. The Contractor shall maintain, as fully operational and functional, all existing lighting systems including navigation lights, aerial lighting, and roadway or parking lot lighting. If existing lighting will be concealed, the Contractor shall install temporary lighting. A temporary lighting plan shall be included in the Contractor’s submittal and forwarded to the Coast Guard or FAA, if appropriate, for approval in advance of the work.
All debris and abrasive, which have accumulated, as the result of surface preparation shall be vacuum cleaned at a frequency specified in the Contractor’s containment submittal, or more frequently if directed by the Engineer. Prior to removal or relocation to another point along the structure, all debris must be removed from the containment materials and equipment. The level of cleanliness shall be such that wind or physical contact during handling and transportation does not dislodge debris or dust.
When negative pressure is required within a containment system, the designed system shall maintain a minimum negative pressure as measured by 0.76 mm (0.03 in.) of water column relative to external ambient air. Air velocity within the enclosure shall meet the minimum requirements of 30 m/min (100 ft/min) crossdraft and 18 m/min (60 ft/min) downdraft. Submittals shall include a description of the dust collection and filtration equipment, including the equipment data sheets and airflow capacity. II.573 202 4 Edition 961.68: Handling of Hazardous Waste and Reporting Release Programs The Contractor shall submit a plan to the Engineer detailing all aspects of waste management including an Emergency Response Contingency Plan in accordance with 310 CMR 30.00 and 310 CMR 40.00. The plan shall detail the methods for the collection, handling , sampling, testing, site storage, and disposal of wastewater, lead paint and related debris. The Contractor and the Department are the co -generators of the waste. The Department will provide the EPA identification number and the Contractor is responsible for all other waste management.
All waste streams generated as part of the work shall be tested by TCLP for all eight metals to determine proper disposal. The Engineer shall be the final authority on what shall be tested for possible contamination. Four samples representative of each waste stream shall be collected and tested in accordance with 310 CMR 30.155B (EPA SW846 Method 1311) The Engineer must be notified of the date and time of sample collection prior to sampling activities. The Contractor, in the presence of the Engineer, shall perform sampling for testing and a State certified laboratory shall perform testing. Chain of custody must be adhered to for sample removal. TCLP test results certified by the testing laboratory shall be provided to the Engineer. The following information must be contained in the laboratory report as a minimum: • Contract number • Bridge Identification Number (BIN) • Identification of the waste stream analyzed • Number of samples collected and tested • Dates of sampling and testing • Defined laboratory test procedures • The names and signatures of sampling technicians and laboratory technicians • Summary of test results The Contractor shall provide the Engineer with an original signed copy of the report no later than 10 days after the samples have been collected. Non -hazardous waste shall not be mixed with hazardous waste. The DEP requires that a mixture of non- hazardous waste with hazardous waste must be treated as hazardous. All debris cleaned and collected from abutments, pier caps, girder flanges and other areas of collection shall be disposed of properly. Debris which include, but not limited to, sand, gravel, bituminous materials and bird excrement shall be packaged and stored separately from waste generated as a result of surface preparation. A representative sample of the debris shall be analyzed to determine its classification prior to disposal. All wastes generated through the use of steel abrasives shall be treated as hazardous and identified as such to the treatment facility.
Lead paint and related debris must be collected daily and placed in DOT approved containers of good integrity (i.e. , no dents, holes, missing lids or locking mechanisms, etc.). The Contractor shall II.574 202 4 Edition inspect drums weekly and the results recorded in an on -site logbook accessible to the Engineer. Containers shall be closed and clearly labeled to identify the contents. Hazardous wastes must be labeled with the words “HAZARDOUS WASTE, ” the name of the waste, the hazards associated with the waste, and the date when accumulation began in the container. The hazardous waste label shall also include the generators’ name, address, and EPA identification number. Containers shall be stored in a safe and suitable location at the job site. Storage shall be in a manner that protects the public and the environment , i.e., on a level impervious base, away from waterways, etc. Storage area(s) shall be approved by the Engineer prior to generating wastes. Storage areas shall be labeled with the words “HAZARDOUS WASTE. ” Appropriate security (i.e., fencing, locked gated, etc.) must be maintained at the site to avoid injury, theft or vandalism with regards to hazardous waste. Once a container in the work area is full, it shall be moved to the secure storage area within 3 days. If a suitable location for hazardous waste storage does not exist on -site, the Contractor shall find an alternate storage site. The alternate storage shall only be allowed with documented permission by the Engineer and the DEP. Evidence of improper storage and handling shall be cause for immediate shutdown until corrective action is taken. Storage of hazardous waste on site is limited to 90 days with the start date of initial accumulation in each container. The Engineer is to be informed one week in advance of the planned date(s) when hazardous waste is to be removed from the job site.
Hazardous waste shall only be removed from the site by DEP licensed haulers in the presence of the Engineer. Only EPA licensed Treatment Storage Disposal Facilities (TSDF) shall accept the hazardous waste. The Contractor shall submit the name, address, pho ne number, name of contact person and the EPA identification number of the TSDF. Before the start of work, the Contractor shall provide the Engineer with a letter of intent from the TSDF stating that they agree to accept and treat said waste in accordance with all state and federal regulations. All hazardous waste manifests must be signed by the Engineer upon removal of the waste. The Contractor shall provide the Engineer with a Certificate of Disposal upon receipt from the TSDF. The Engineer must receive a signed manifest copy directly from the TSDF.
The Contractor’s on -site emergency response contingency plan shall outline steps to take in the event of a hazardous waste spill or release including procedures for notification to DEP in accordance with 310 CMR 30.00 and 310 CMR 40.00. The Contractor is advised that a discharge of one or more pounds of lead with a particle size of 0.1 mm (4 mils) or less to the atmosphere, water or soil, within a 24 -hour period, is considered to be a reportable release in accordance with 310 CMR 40.00 (40 CFR 300 and 40 CFR 302).
961.69: Submittals
The Contractor shall submit the following written programs and plans to the Engineer within 30 days of the Notice to Proceed. No work shall commence until the Engineer has approved all submittals with the exception of the Worker Health & Safety Program, wh ich will only be received II.575 202 4 Edition by the Engineer. Reception of the Worker Health & Safety Submittal does not constitute approval by the MassDOT.
The Contractor shall provide a site -specific compliance program prepared under the direction and approval of a Certified Industrial Hygienist (CIH), in accordance with 29 CFR 1926.62 and 29 CFR 1910.134. The program shall describe all engineering, administrative, housekeeping and protective equipment that will be used to reduce the exposure of the employees to a level less than the PEL. The program shall provide the name, address, accreditation, and qualifications for the Certified Industrial Hygienist and the firm(s) that will be utilized for monitoring, testing and analysis. The name and qualifications of the project’s competent person shall be included along with an emergency contact person. The Program shall include the following elements: • Employee Training Program • Hazard Communication Training Program • Medical Surveillance and Medical Removal Program • Procedures for Exposure Monitoring / Initial Assessment • Respiratory Protection Program • Recordkeeping • Protective Clothing and Equipment • Personal Hygiene Facilities and Equipment • Housekeeping
The written program shall ensure the protection of the environment from project activity in accordance with this specification and 40 CFR 50 and 310 CMR 7.00. The program shall detail programs for monitoring activities and provisions for complying with the results of any monitoring and analysis that is conducted. Included shall be a statement that corrective action will be implemented immediately in the event of unacceptable monitoring results. The program shall include the following elements: • Procedures for High Volume Air Sampling • Methods for monitoring and Establishing Baseline Levels • Methods for Establishing Regulated Areas • Assessment of Visible Emissions and Releases • Methods for Sampling and Analysis for soil, waste water and debris
The Contractor shall provide a written plan and drawings for the method employed for surface preparation, containment and ventilation. The submittal shall be approved and stamped by a Professional Engineer registered in the Commonwealth of Massachusetts. T he submittal shall include the following: • Methods and equipment to be used for precleaning (washing) and surface preparation II.576 202 4 Edition • Location of equipment and impact on traffic • Engineering Calculations: Load -bearing capacity, Wind load and Ventilation • Connection Details • Lighting plan • Drawings and Plans for installing, moving, and removing the containment. • Provisions for Emergency breakdown of containment. • Provisions for moving the containment out of navigation lanes when working over active waterways. • Provisions for the containment of debris that might escape when working over land, streams, rivers, lakes, or other bodies of water. • Descriptions and product data or cut sheets for all containment system materials and all equipment to be used • Confirmation that appropriate notification and coordination with other organizations or agencies such as the Coast Guard and Railroad have been accomplished with regard to right of ways, containment clearances, and other project restrictions.
The written program shall establish the procedures that will be followed for the proper handling, packaging and disposal of all waste generated during contract activities. The program shall be in accordance with applicable EPA regulations, the requirements of this specification and 310 CMR
30.00& 310 CMR 40.00. The program shall include the following elements:
• Methods for Sampling, Testing and Classification • Methods for Handling, Packaging and Storage • Identification of Transporter and Treatment Storage and Disposal Facility • Methods for Reporting Releases into the Environment • Emergency Response Contingency Plan COMPENSATION
961.80: Method of Measurement
The above work will be measured as a complete unit. For purpose of estimating partial payments, the work will be separated into distinct phases as listed below and the value of each will be assigned a percentage of the lump sum: Containment .................................................................................................................................. 30% Clean, Collect and Prime ........................................................................................................... 35% Intermediate Coat ........................................................................................................................ 10% Finish Coat ...................................................................................................................................... 10% Final Inspection ............................................................................................................................ 15% Partial payment for each phase will be based on the length of work completed, divided by the total length of the structure to be painted, or as determined by the Engineer. Final inspection will be paid after the completion of punch list items, cleaning of the site(s), the removal of all equipment, materials and the removal of contaminated and hazardous waste generated during the cleaning operations. II.577 202 4 Edition 961.81 : Basis of Payment The work will be paid at the contract price per Lump Sum which shall include full compensation for all labor, equipment, worker protection, environmental compliance, materials, tools, rigging, and all incidentals necessary to complete the work as specified. Incidental to this work is the removal and replacement of, anti -missile fencing, protective screening, signs and sign supports. The Contractor shall determine if anti -missile fencing, protective screening, signs and sign supports are to be removed to facilitate complete cleaning and painting of the structure as specified. Removal shall be accomplished prior to cleaning activities and will be subject to the approval of the Engineer.
961.82: Payment Items
961.1 * Clean and Paint (Overcoat) Bridge No. ___ ......................................................... Lump Sum 961.2 * Clean (Full Removal) and Paint Bridge No. _ __................................................. Lump Sum * - number assigned to the bridge being painted . SUBSECTION 965: MEMBRANE WATERPROOFING FOR NEW BRIDGE DECKS DESCRIPTION
965.20: General
Membrane waterproofing systems are defined as a thin impermeable membrane that is used to protect the concrete deck from penetration of moisture and deicing chemicals. The work to be performed shall consist of the furnishing and application of an approved membrane system and all concrete surface preparation work necessary to install the membrane system. The membrane waterproofing system applied to the surface of the bridge deck as indicated on the plans shall consist of the primer, spray applied membrane (either methyl methacrylate, polyurea, or polyurethane methyl methacrylate), aggregate keycoat, and polymer modified tack coat. MATERIALS
965.30: General
Materials shall meet the requirements specified in the following Subsections of Division III , Materials. Spray -Applied Waterproofing Membrane ......................................................................... M9.08.1 CONSTRUCTION METHODS
965.40: Submittals
The Contractor shall submit to the Engineer for approval the following documents:
• The membrane system to be installed. II.578 202 4 Edition • The manufacturer’s installation instructions for the applicable system. • Safety data sheets (SDS) for all components . • Cleaning solvents approved by the membrane manufacturer .
• Manufacturer’s written approval of the Applicator’s qualifications. • The QC Plan in accordance with Subsection 965: Membrane Waterproofing for New Bridge Decks . • Installation procedure including storage and protection instructions as well as handling and mixing instructions. • List of application equipment to be used. • Manufacturer’s written approval of the proposed polymer modified tack coat and the application rate that it shall be applied at. • Certificate of Compliance certifying that the aggregate for the keycoat meets the required hardness.
Engineer for approval.
• All QC installation test results for the tests specified in the materials section, including the name, address, and contact person of the laboratory that performed the tests and the date of the tests. • A Certificate of Compliance, from the membrane waterproofing system manufacturer, certifying that the membrane waterproofing system materials meet the requirements of the manufacturer and the contract specifications.
965.41: Preconstruction
Membrane waterproofing shall be installed in accordance with the manufacturer’s instructions. The handling, mixing, and addition of membrane components shall be performed in a safe manner to achieve the desired results in accordance with the manufacturer’s recommendations. Care shall be taken to prevent adjacent areas from overspray or other contamination.
965.42: Applicator Qualifications
The Contractor applying the waterproofing system shall be certified by the membrane waterproofing system manufacturer and have at least 2 years of experience in membrane installation. The Engineer shall receive the manufacturer’s written approval of the co ntractor’s qualifications at least 30 days prior to the application of any system component. This approval shall apply only to the named individuals performing the application.
965.43: Material Delivery and Storage
All components of the membrane system shall be delivered to the site in the manufacturer’s original packaging, clearly identified with the products type and batch number. The storage area for all components shall be cool, dry, out of direct sunlight, and c omply with relevant health and safety regulations. Copies of safety data sheets for all components shall be given to the Engineer and kept on site at the Contractor’s field office. II.579 202 4 Edition 965.44: Pre -Application Meeting A minimum of 14 days before the anticipated start of membrane application, the Contractor shall schedule and conduct a pre -application meeting at the site to review the approved submittals, and other pertinent matters related to the application including the schedule for coordination between trades. At a minimum, the Contractor, the subcontractor performing the application and the Engineer shall be present at the meeting.
965.45: Mockup to Validate Bond Strength
For those projects where the concrete will be aged less than 28 days the manufacturer shall concur that the system is acceptable for use with the shortened aging period and a mockup shall be required. The intent is to validate the bond strength using the membrane waterproofing manufacture’s primer and membrane. In order to emulate the actual placement conditions, the mockup shall take place as close as possible to the intended date of the waterproofing application but be a minimum of 7 days before concrete placement. The mockup activities shall be representative of what will take place during the specified final bridge placement. It shall include the placement and surface preparation of the concrete and installation of membrane waterproofing system. Inspection and testing shall be in accordance with Tables 965.63 -1 and 965.64- 1. The results of moisture and adhesion testing performed on a mockup of the bridge deck and closure pours shall meet these specifications. The mockup shall simulate the actual j ob conditions in all respects including air temperature, transit equipment, travel conditions, admixtures, forming, placement equipment, and personnel. If the mockup is unable to validate that the waterproofing membrane meets the project requirements, then the Engineer may require the Contractor to conduct additional mockups. Removal of the mockup after its completion shall be the responsibility of the Contractor. In addition to the requirements contained herein, all weather and concrete temperature requirements contained in Subsection 901: Cement Concrete shall be satisfied. Acceptance of the mockup shall be the responsibility of the Engineer.
965.46: Application
The installation procedure shall consist of preparation of the concrete surface and application of primer, membrane, aggregate keycoat, and polymer modified tack coat. Special attention shall be paid to the bridge deck surface preparation prior to the membrane waterproofing system application. The membrane system shall be installed in accordance with the manufacturer’s requirements. The Contractor shall be responsible for the field testing including, but not limited to, adhesion bond testing, deck moisture content measurement, and all other required documentation and reporting. The membrane waterproofing system shall not be applied in either wet, damp, or foggy weather, or when the ambient temperature is 40 ℉ or below or is forecast to fall below 40 ℉ during the application period. The temperature of the concrete deck surface shall also exceed the dew point by at least 5 ℉. II.580 202 4 Edition The membrane waterproofing shall not be placed until the Contractor is ready to follow within 24 hours with the first layer of hot mix asphalt pavement. Where the areas to be waterproofed are bound by a vertical surface including, but not limited to, a curb or a wall, the membrane waterproofing system shall be continued up the vertical as necessary. A neat finish with well -defined boundaries and straight edges shall be provided.
Concrete surfaces which are to be waterproofed shall be screeded to the true cross section and sounded. All spalls and depressions shall be repaired prior to the application of the primer. Depressions shall be filled to a smooth flush surface with 1:2 mort ar (one part cement to two parts sand) or an approved rapid setting patching mortar that is compatible with the membrane waterproofing system. Other surfaces shall be trimmed free of rough spots, projections, or other defects which might cause puncture of the membrane so that the surface profile of the prepared concrete surface shall not exceed a ¼ inch amplitude, peak to valley. The use of resin or wax -based deck curing membranes are not acceptable. Unless a mockup is completed in accordance with 965.45: Mockup to Validate Bond Strength , the concrete shall be aged a minimum of 28 days, including curing time, before application of the membrane waterproofing system. Immediately prior to the application of the primer, the concrete to which the membrane is to be applied shall be cleaned of all existing bond inhibiting materials in accordance with ASTM D4259 or as required by the manufacturer. Dust or loose particles shall be removed using clean, dry, oil -free compressed air or industrial vacuums. The surface preparation shall produce a clean dry surface and ensure that the concrete surface is free of asphaltic product, surface laitance, oil staining, soiling, and dust. Any exposed steel components to receive membrane waterproofing shall be blast cleaned in accordance with the Society for Protective Coatings (SSPC) SSPC -SP6 or as required by the manufacturer and coated with the membrane waterproofing system within the sam e work shift.
The primer shall only be applied when the temperature of the concrete deck surface exceeds the dew point by at least 5℉ and when the concrete deck surface has a moisture content of 5% or less, as confirmed by a portable electronic surface moisture meter su pplied by the Contractor. The primer shall be applied in a manner to ensure full coverage and shall consist of one coat with an overall coverage rate of 125 -175 ft²/gal unless otherwise recommended in the manufacturer’s written instructions. All components shall be measured and mix ed in accordance with the manufacturer’s recommendations. The primer shall be spray applied using a single or multiple component spray system approved for use by the manufacturer. If required by site conditions, brush or roller application shall be allowed . The primer shall be allowed to cure tack -free for a minimum of 30 min or as required by the manufacturer’s instructions, whichever time is greater, prior to application of the first lift of waterproofing membrane. A second coat of primer shall be required if the first coat is absorbed by the concrete. The membrane shall be applied within the primer re -coat drying time allowed by the manufacturer but II.581 202 4 Edition in no case shall it exceed 24 hr. Beyond this period, the surface shall be prepared again and re - primed following the manufacturer’s recommendations prior to membrane application.
The waterproofing membrane shall be applied following the approved mixing and application procedure. The membrane shall be spray applied, with the mixing of the two components taking place at the nozzle and shall be applied to the primed deck in accordance with the manufacturer’s instructions. The spray equipment shall be controlled so that the quantities applied may be monitored and shall allow for coverage rates to be checked. Following the application of the membrane waterproofing system, the cured surface shall be visually inspected. If any defects or pinholes are found, an appropriate quantity of membrane material shall be mixed and repaired in accordance with 965.46: Application , Part D. In all cases, the thickness of the repair shall be sufficient to bring the area up to the specified thickness. The thickness of the repair patch, measured over peaks, shall be a minimum of 80 mils or the thickness used to pass the ASTM C1305 Crack Bridging Test, whichever is greater. For multi -stage construction, the subsequent stage membrane application shall overlap the existing cured membrane from the previous stage to form a continuous layer with a 6 -in. overlap onto the existing membrane. The existing membrane shall be cleaned of all contamination including tack coat material or dirt to an edge distance of a least 6 in . and wiped with a solvent as approved by the membrane waterproofing manufacturer.
If an area of membrane requires repair or if the membrane becomes damaged, a patch repair shall be carried out to restore the integrity of the membrane waterproofing system. T he damaged area shall be cut back to sound materials and wiped with a solvent up to a width of at least 6 in . beyond the periphery of the damaged area, removing contaminants. The concrete shall be primed as necessary followed by the application of the membrane. A continuous layer shall be obtained over the concrete with a 6 -in. overlap onto the existing membrane. The solvent shall be as approved by the membrane waterproofing manufacturer. Repairs shall comply with the manufacturer’s guidelines for any over -coating times. Where the membrane is to be joined to existing cured material and at joints, the new application shall overlap the existing membrane/joint by at least 4 in. The existing membrane/joint shall be cleaned of all contamination including tack coat material or d irt to an edge distance of a least 6 in. and wiped with a solvent as approved by the membrane waterproofing manufacturer. If pin holes or holidays are observed in the membrane surface they shall be repaired in accordance with the manufacturer’s instructions and the approved Contractor Quality Control Plan (QC Plan). In all cases, the thickness of the repair shall be sufficient to bring the area up to the specified thickness. The thickness of the repair patch, measured over peaks, shall be a minimum of 80 mils or the thickness used to pass the ASTM C1305 Crack Bridging Test, whichever is greater.
Following the membrane application, an additional layer of membrane or resin, compatible with the membrane, shall be spray applied to a thickness of 30 to 40 mils into which an aggregate II.582 202 4 Edition approved by the membrane manufacturer shall be broadcast ensuring a minimum coverage of 95%. The application rate shall be designated by the manufacturer. Loose aggregate shall be removed with brooms or oil/moisture -free compressed air before applying the tack coat. For multi -stage construction, the aggregate keycoat of the previous stage shall be applied to a limit of 6-in. from the stage construction joint to allow the subsequent stage membrane material to bond directly to the existing membrane. The application of the aggregate keycoat for the subsequent stage shall cover the 6- in. overlap.
The polymer modified tack coat shall be applied in accordance with the membrane manufacturer’s recommendations after a minimum of three hours from initial membrane application. The tack coat shall be allowed to c ure for a minimum of 1 hr prior to HMA paving. The tack coat application rate shall be in accordance with the manufacturer’s recommendation. The application rate of the tack coat shall be set at a rate that achieves the specified residual rate and coverage. Tack coat shall be applied to cover a mini mum of 95% of the membrane surface. The tack coat application shall be monitored by Quality Control personnel in accordance with the approved QC Plan.
Placement of the HMA surface shall be in accordance with Subsection 450: Hot Mix Asphalt Pavement and the contract specifications. During paving, a light soap spray should be applied to the paving equipment wheels to prevent tack coat pick- up.
965.47: Protection of Exposed Surfaces
The Contractor shall exercise care in the application of the waterproofing membrane system to prevent surfaces not receiving treatment from being spattered or marred, such as the face of curbs, copings, finished surfaces, substructure exposed surfaces, and outside faces of the bridge. Any material that spatters on these surfaces shall be removed and the surfaces cleaned to the satisfaction of the Engineer. CONTRACTOR QUALITY CONTROL
965.60: General
The Contractor shall provide a Quality Control System (QC System) and a QC Plan adequate to ensure that all materials and workmanship meet the required quality levels for each specified Quality Characteristic. The Contractor shall provide qualified QC personnel and QC laboratory facilities and perform Quality Control inspection, sampling, testing, data analysis, corrective action (when necessary), and documentation as outlined further below.
965.61: Contractor Quality Control Plan
The Contractor shall provide and maintain a QC Plan which shall sufficiently document the QC processes of all Contractor parties (i.e. , Contractor, Subcontractors, Producers) performing work required under this specification. II.583 202 4 Edition A. QC Plan Submittal Requirements. At the preconstruction meeting, the Contractor shall be prepared to discuss the QC Plan. Information to be discussed shall include the proposed QC Plan submittal date, QC organization, and sources of materials. The Contractor shall submit the QC Plan to t he Engineer for approval not less than 30 days prior to the start of any work activities related to membrane waterproofing installation (including preparation of underlying surface) addressed in 965.40: Submittals through
: Protection of Exposed Surfaces . The Contractor shall not start work on the subject work
items without an approved QC Plan.
The QC Plan shall be structured to follow the format and section headings outlined in the MassDOT Model QC Plan. The pages of the QC Plan shall be sequentially numbered. The QC Plan shall address, in sufficient detail, the specific information requested under each section and subsection contained in the MassDOT Model QC Plan.
Approval of the QC Plan will be based on the inclusion of the required information. Revisions to the QC Plan may be required prior to approval for any part of the QC Plan that is determined by the Department to be insufficient. Approval of the QC Plan does not imply any warranty by the Engineer that the QC Plan will result in completed work that complies with the specifications. It remains the responsibility of the Contractor to demonstrate such compliance. The Contractor may modify the QC Plan as work pro gresses when circumstances necessitate changes in Quality Control personnel, laboratories, or procedures. In such case, the Contractor shall submit an amended QC Plan to the Department for approval a minimum of three calendar days prior to the proposed changes being implemented.
965.62: Quality Control Personnel Requirements
The Contractor’s Quality Control organization shall, at a minimum, consist of the personnel qualified by the manufacturer to perform the required inspection and testing. Every effort should be made to maintain consistency in the QC organization; however, s ubstitution of qualified personnel shall be allowed. When circumstances necessitate substitution of QC personnel not originally listed in the approved QC Plan, the Contractor shall submit an amended QC Plan for approval in accordance with 965.61: Contractor Quality Control Plan , Part C.
965.63: Quality Control Inspection
The Contractor shall perform QC inspection of all work items addressed under this specification. Inspection activities during placement may be performed by qualified production personnel (e.g. Skilled Laborers, Foremen, and Superintendents). However, the Contractor’s QC personnel shall have overall responsibility for QC inspection. The Contractor shall not rely on the results of the Engineer’s Acceptance inspection for QC purposes. The Engineer shall be provided the opportunity to monitor and witness all QC inspection. QC inspection activities must address the following four primary components:
II.584 202 4 Edition c. Environmental Conditions
The minimum frequency of QC inspection activity shall be in accordance with the requirements below and as outlined in the approved QC Plan. The Contractor shall document the results and findings of QC inspection. The quality of each waterproofing membrane surface will be inspected and evaluated on the basis of Lots and Sublots. A Lot is defined as an isolated quantity of work which is assumed to be produced by the same controlled process. A Lot shall constitute no greater than the entire waterproofing membrane surface area on the bridge deck completed within the same construction season using the same placement process. Each Lot shall be divided into Sublots of equal sizes unless specified otherwise below. All inspection reports shall be submitted to the Engineer within 72 hours of the test completion.
The Contractor’s personnel will perform QC inspection during preparation of the underlying surface in accordance with the requirements of 965.46: Application , Part A. The minimum items to be inspected shall be as outlined in Table 965.63 -1. The Contractor shall identify in the QC Plan the specific inspection activities necessary to ensure the quality of the work, including any additional inspection activities n ot specifically listed in the table.
The Contractor’s QC personnel will perform QC inspection at the site of waterproofing membrane field placement to ensure that the production and placement processes are providing work conforming to the contract and manufacturer requirements. The minimum it ems to be inspected for each waterproofing membrane Lot shall be in accordance with the requirements of 965.43: Material Delivery and Storage through 965.47: Protection of Exposed Surfaces and as outlined in Table 965.63 -1. The Contractor shall identify in the QC Plan the specific inspection activities necessary to ensure the quality of the work, including any additional inspection activities not specifically listed in the table. Inspection shall include:
holidays. All pin hole/holidays shall be located, marked for repair, documented, and repaired in accordance with a repair procedure developed by the manufacturer and approved by the Engineer.
II.585 202 4 Edition Table 965.63- 1: Minimum QC Inspection of Waterproofing Membrane Operations Inspection Component Inspection Attribute Minimum Inspection Frequency Point of Inspection Inspection Method Equipment As specified in QC Pan Per QC Plan Per QC Plan Per QC Plan Materials Primer (Correct Type) Per QC Plan Per QC Plan Check Manufacturer COC Membrane (Correct Type) Per QC Plan Per QC Plan Check Manufacturer COC Aggregate (Correct Type) Per QC Plan Per QC Plan Check Manufacturer COC Tack Coat (Correct Type) Per QC Plan Per QC Plan Check Manufacturer COC Environmental Conditions Temperature of Air & Underlying Surface 1 per Day At Project Site Check Measurement Underlying Surface
Surface (Standing Moisture) Per QC Plan Underlying Surface & Membrane Surface Visual Check Surface
& Membrane Surface Visual Check Workmanship Pin Hole/Holidays Per QC Plan Membrane Surface Visual Check Membrane Coverage Rate Per QC Plan From Distributor Check Measurement Aggregate Coverage Rate Per QC Plan Membrane Surface Visual Check Tack Coat Application Rate Per QC Plan From Distributor Check Measurement
965.64: Quality Control Sampling and Testing Requirements
The Contractor’s QC personnel will perform QC sampling and testing at the site of membrane waterproofing placement to ensure that the production and placement processes are providing work conforming to the contract and manufacturer’s requirements. The Engineer will not sample or test for Qu ality Control or assist in controlling the Contractor’s operations. All QC sampling and testing shall be in accordance with the current AASHTO, ASTM, NETTCP, or Department procedures specified in Table 965.64- 1. The Contractor shall furnish approved contai ners for all material samples. The Engineer shall be provided the opportunity to monitor and witness all QC sampling and testing. The following testing shall be conducted and recorded on a test report form to be submitted to the Engineer. All reports shall be submitted to the Engineer within 72 hours of the test completion. II.586 202 4 Edition a. Deck moisture: The concrete deck’s surface moisture content shall be measured to determine if it is suitable to allow for installation to proceed.
be at a frequency of 1 test per 5,000 ft² with a minimum of 3 tests per day. Areas smaller than 5,000 square feet shall receive a minimum of 3 tests.
• Wet film thickness shall be checked every 300 ft² in accordance with ASTM D4414 using a gauge pin or standard comb type thickness gauge or a magnetic gauge. Film thickness checks shall be carried throughout the application process. • Dry Film Thickness: If the membrane waterproofing system cures too quickly to perform wet film thickness testing, dry film thickness shall be checked every 300 ft² in accordance with ASTM D6132 using magnetic or ultrasonic gauges or using a destructive me thod. If a destructive method is used, areas shall be repaired in accordance with 965.46: Application , Part C.
the tensile force. A minimum bond strength of 100 psi and failure in the concrete will be required for acceptance. Testing shall be at a frequency of 1 test per 5,000 ft² with a minimum of 3 tests per day. Areas smaller than 5,000 ft² shall receive a minimum of 3 tests. The Contractor shall take a representative sample of the membrane from that day’s installation. The samples shall consist of two 10-in. by 10 -in. square samples of the membrane with smooth surfaces. The primer and aggregate shall not be incorporated into the sample. The sample shall be sprayed on a non- adhesive surface using the same application techniques used for the deck. The sample shall be removed from the non -adhesive surface by the Contractor in a manner that does not damage the sample and that sample shall be delivered to the Engineer for Department testing. II.587 202 4 Edition Table 965.64- 1: Minimum Quality Control Sampling & Testing of Waterproofing Membrane Lots Quality Characteristic Test Method(s) Sublot Size Minimum Test Frequency Point of Sampling Engineering Limits Deck Concrete Moisture Manufacturer’s Recommendation 5,000 ft ² 1 per Sublot (see Not e 1) Deck Concrete Surface ≤ 5% Primer Adhesion to Concrete ASTM D7234 5,000 ft ² 1 per Sublot (see Not e 1) Primed Concrete Surface ≥ 100 psi minimum; and failure in concrete Film Thickness Wet: ASTM D4414 Dry: ASTM D6132 or other approved method 300 ft² 1 per Sublot (see Not e 1) Membrane Surface ≥ Thickness used to pass ASTM C1305 Membrane Adhesion to Concrete ASTM D7234 5,000 ft² 1 per Sublot (see Note 1) Membrane Surface ≥ 100 psi minimum; and failure in concrete Note 1: In the event that the total daily production is less than three Sublots, a minimum of three random QC samples shall be obtained for the day’s production. DEPARTMENT ACCEPTANCE
965.70: General
The Department is responsible for performing all Acceptance activities and making the final Acceptance determination for each membrane waterproofing surface. The Department’s Acceptance system will include monitoring the Contractor’s QC activity and performing Acceptance inspection and testing in order to determine the quality and corresponding payment for each Lot.
965.71: Acceptance Inspection
The Engineer will perform Acceptance inspection of all work items addressed under Subsection 965: Membrane Waterproofing for New Bridge Decks to ensure that materials and completed work are in conformance with the contract requirements. Acceptance inspection is intended to visually assess the quality of each Lot produced and placed and will address only the inspection components of Materials and Workmanship in support of the Department’s final Acceptance determination. All Acceptance inspection activities by the Department will be performed independent of the Contractor’s QC inspection. II.588 202 4 Edition Table 965.71- 1: Department Acceptance Inspection of Waterproofing Membrane Operations Inspection Component Inspection Attribute Minimum Inspection Frequency Point of Inspection Inspection Method Materials Primer (Correct Type) 1 Per Day At Placement Site Check Manufacturer COC Membrane (Correct Type) 1 Per Day At Placement Site Check Manufacturer COC Aggregate (Correct Type) 1 Per Day At Placement Site Check Manufacturer COC Tack Coat (Correct Type) 1 Per Day At Placement Site Check Manufacturer COC Workmanship Pin Hole/Holidays 25% of Sublots Membrane Surface Visual Check Membrane Coverage Rate 25% of Sublots From Distributor Check Measurement Aggregate Coverage Rate 25% of Sublots Membrane Surface Visual Check Tack Coat Application Rate 25% of Sublots From Distributor Check Measurement
965.72: Acceptance Sampling and Testing Requirements
The two 10- in. by 10 -in. samples fabricated by the Contractor during installation shall be submitted to the Department for testing. Table 965.72- 1: Department Acceptance Sampling and Testing of Waterproofing Membrane Lots Quality Characteristic Test Method(s) Engineering Limits Minimum Thickness (Membrane only) ASTM D6132 or other approved method ≥ thickness used to pass ASTM C1305 Percent Elongation at Break ASTM D638 ≥ 130% Tensile Strength ASTM D638 Type IV @ 2 in./min > 1,100 psi Shore Hardness ASTM D2240 ( see Note 1 ) ≥ 50 Type 00 Note 1: ASTM D2240 shall be modified in accordance with ASTM C836 Section 6.5.
965.73: Lot Acceptance Determination Based on Inspection Results
The Engineer’s Acceptance inspection results will be used in the final Acceptance determination for all Lots. Prior to final Acceptance of each Lot produced and placed, the Engineer will periodically evaluate all Acceptance inspection information for the prepared underlying surface and the Lot. The materials and product workmanship for the completed work will be evaluated for conformance with the plans and the requirements specified in 965.40: Submittals through 965.47: Protection of Exposed Surfaces . II.589 202 4 Edition When the Acceptance information identifies deficiencies in either material quality or product workmanship for any underlying surface location or waterproofing membrane Sublot(s), the location or Sublot(s) will be isolated and further evaluated by the Engineer through additional Acceptance inspection (or sampling and testing, if relevant or possible). Depending upon the findings of the additional Acceptance inspection activity, the Engineer will determine the disposition of the nonconforming work in accordance with Subsection 5.03: Conformity with Plans and Specifications.
965.74: Lot Acceptance Determination Based on Testing Data
Evaluation of Testing Data Prior to final Acceptance of each Lot produced and placed , the Engineer will periodically evaluate all available Acceptance testing data for the Lot. Conformance with Engineering Limits The Engineer will evaluate all Acceptance testing data and Contractor QC testing data for each Lot to determine conformance with the Engineering Limits in Tables 965.63 -1 and 965.72 -1. Each Sublot test value for the Acceptance Quality Characteristics ident ified in the tables shall be within the Engineering Limits. If a Sublot test result is outside of the Engineering Limits, the Contractor and Engineer will further assess the Sublot quality to determine whether the material in the Sublot can remain in place. The Engineer will determine the disposition of the Sublot in accordance with Subsection 5.03: Conformity with Plans and Specifications. If the Engineer’s assessment determines that the material quality is not sufficient to permit the Sublot to remain in place the Sublot shall be removed and replaced. When a nonconforming Sublot is corrected or replaced, the Engineer will perform Acceptance testing of the Sublot and evaluate the test results for conformance with the Engineering Limits. Once the above requirements have been met, the Engineer will accept all completed Sublots.
965.75: Final Lot Acceptance Determination
For each Lot produced and placed, the Engineer will evaluate all Acceptance inspection and testing data for the Lot after all Sublots are complete in place. The final review and visual inspection shall be conducted jointly by the Contractor and Engineer. I rregularities or other items that do not meet the requirements of the specifications and plans shall be addressed/repaired at this time, at no additional cost to the Department. After each Lot is complete, including any corrective action, the Engineer will perform a final evaluation of all Acceptance data and Contractor QC data for the Lot. The Engineer will accept the Lot if the Engineer’s evaluation of all inspection and testing data for the Lot is in conformance with this specification and the contract documents. II.590 202 4 Edition COMPENSATION
965.80: Method of Measurement
Membrane Waterproofing for Bridge Decks will be measured by the square foot of the membrane system complete in place with no allowance for overlapping or for edges turned up or carried into recesses for seals, except that the area of the full membrane turned down in back of the backwalls and extended up the face of the curb or under and in back of median curbs shall be included for payment.
965.81: Basis of Payment
Payment under this Item shall be made at the unit bid price per square foot, which includes the primer, spray applied membrane, aggregate for keycoat, polymer modified tack coat, and all labor, materials, equipment, safety devices, tools, inspections and incidentals necessary to complete all work specified under this Item.
965.82: Payment Items
965. Membrane Waterproofing for Bridge Decks .................................................... Square Foot SUBSECTION 966: MEMBRANE WATERPROOFING FOR BRIDGE DECK REPAIRS DESCRIPTION
966.20: General
Membrane waterproofing applied to the repaired deck surface as indicated on the plan and elsewhere as directed shall consist of one of the following systems: • Sheet membrane - either reinforced rubberized asphalt or reinforced tar and resin. • Hot applied rubberized asphalt membrane. This system shall not be used on grades in excess of 3 percent. MATERIALS
966.30: General
Materials shall meet the requirements specified in the following Subsections of Division III, Materials: Asphalt Emulsions ................................................................................................................. ...... M3.03.1 Sheet Membrane .......................................................................................................................... M9.08.2 Hot Applied Rubberized Asphalt Membrane ................................................................... M9.08.3 Primer ............................................................................................................................................... M9.09.1 II.591 202 4 Edition CONSTRUCTION METHODS
966.40: Application
No waterproofing shall be done in wet, damp or foggy weather, nor when the ambient temperature is 40℉ or below, without permission of the Engineer. The membrane waterproofing on bridge deck repairs shall not be placed unless the Contractor is ready to follow within 24 hours with the first layer of hot mix asphalt pavement; a longer period of time will be allowed only with the approval of the Engineer. Immediately prior to the membrane application, the concrete surface shall be thoroughly swept and blown clean with an air compressor to remove any loose debris. If the concrete surface is damp it shall be dried by use of a propane gas torch or similar equi pment.
The primer shall be applied to all surfaces at a rate of 0.015 gal per yd². The primer shall be thoroughly mixed and continuously agitated during application. It shall be applied by spray or squeegee. It shall thoroughly dry before application of the rubbe rized asphalt membrane. Should the membrane not be placed over the primed surface within 8 hours the surface shall be re -primed.
This system shall consist of the application of preformed reinforced rubberized asphalt membrane. Composition and dimensional requirements shall be as stipulated by the manufacturer of the sheet membrane. Membrane Application Membrane application shall be in accordance with the manufacturer’s instructions. The preformed membrane sheets shall be applied to the primed surfaces either by hand or by mechanical applicators. The membrane sheet shall be placed in such a manner that a shingling effect is achieved in the direction that water will drain. After being laid, the membrane sheets shall be rolled with hand rollers or other apparatus as necessary to develop a firm and un iform bond with the primed concrete surface. Wrinkles and air bubbles shall be eliminated to the extent possible. A mastic, approved by the Sheet Membrane manufacturer, shall be applied as a bead along the exposed edge of the membrane sheet that extends up the barrier railing or curb face and that terminates in the high -side gutter after the sheets have been installed . Any tears, cuts, or narrow overlaps shall be patched, using a satisfactory adhesive and by placing sections of membrane sheet over the defective area in such a manner that the patch extends at least 6 in. beyond the defect. II.592 202 4 Edition (2) Hot Applied Rubberized Asphalt Membranes Membrane Application Melting of the rubberized asphalt membrane shall be in accordance with the manufacturer’s instructions. The kettle shall be equipped with a suitable agitator and temperature gauges for the kettle. Sufficient lead time shall be allowed for heating of the rubberized asphalt so that it will be in a fluid state at the time scheduled for application. Caution should be observed that the melting temperature does not exceed the manufacturer’s recommendation. When fluid, the material shall be drawn off in suitable containers and poured onto the primed and dried deck surface. It shall be evenly spread with a special spray nozzle or silicone squeegees at a uniform rate to yield a coating at a minimum thickness of ⅛ in. and an average of ³⁄₁₆ in. All horizontal surfaces shall be completely covered and vertical surfaces (curbing, edging, etc.) shall be covered up to 4 in . above the deck surface. Any defects shall be repaired in accordance with the manufacturer’s recommendations prior to HMA pavement overlayment. Immediately following the application of the hot applied rubberized asphalt membrane and before it cools, the protective covering shall be laid parallel to the roadway centerline covering the entire area of membrane waterproofing.
If an area of membrane requires repair or if the membrane becomes damaged, a patch repair shall be carried out to restore the integrity of the membrane waterproofing system. The damaged area shall be cut back to sound materials to a width of at least 6 in. beyond the periphery of the damaged area, removing contaminants. The concrete shall be primed as necessary followed by the application of the membrane. A continuous layer shall be obtained over the concrete with a 6 -in. overlap onto the existing membrane. The solvent shall be as approved by the membrane waterproofing manufacturer. Repairs shall comply with the manufacturer’s guidelines. Where the membrane is to be joined to existing cured material and at joints, the new application shall overlap the existing membrane/joint by at least 4 in. The existing membrane/joint shall be cleaned of all contamination including tack coat material or dirt to an edge distance of a least 6 in. If pin holes or holidays are observed in the membrane surface they shall be repaired in accordance with the manufacturer’s instructions.
Tack coat, meeting 966.30: General, shall be applied in accordance with the membrane manufacturer’s recommendations after a minimum of three hours from initial membrane application. The tack coat application rate shall be in accordance with the manufacturer’s recommendation. The applicatio n rate of the tack coat shall be set at a rate that achieves the specified residual rate and coverage. II.593 202 4 Edition F. HMA Pavement Over Membrane . Placement of the HMA surface shall be in accordance with Subsection 450: Hot Mix Asphalt Pavement and the contract specifications. To eliminate any possible damage to the membrane and in accordance with 450.50: HMA Pavement on Bridges , the HMA overlayment shall be applied as soon as possible. Caution must be observed to assure that the paver does not cause damage to the membrane. During paving, a light soap spray should be applied to the paving equipment wheels to prevent tack coat pic k-up.
966.41: Protection of Exposed Surfaces
The Contractor shall exercise care in the application of the waterproofing membrane system to prevent surfaces not receiving treatment from being spattered or marred, such as the face of curbs, copings, finished surfaces, substructure exposed surfaces, and outside faces of the bridge. Any material that spatters on these surfaces shall be removed and the surfaces cleaned to the satisfaction of the Engineer. CONTRACTOR QUALITY CONTROL
966.60: General
The Contractor shall provide Quality Control (QC) activities to ensure that their operations will provide waterproofing that conforms to the specified material and workmanship requirements.
966.61: Quality Control Inspection
The Contractor shall perform QC inspection of all work items addressed under this specification. Inspection activities during placement may be performed by qualified production personnel (e.g. Skilled Laborers, Foremen, and Superintendents). The Contracto r shall not rely on the results of the Engineer’s Acceptance inspection for QC purposes. The Engineer shall be provided the opportunity to monitor and witness all QC inspection. QC inspection activities must address the following four primary components:
The minimum frequency of QC inspection activity shall be in accordance with the requirements below. The Contractor shall document the results and findings of QC inspection.
The Contractor’s personnel will perform QC inspection during preparation of the underlying surface in accordance with the requirements of 966.40: Application , Part A. The minimum items to be inspected shall be as outlined in Table 966.61 -1.
The Contractor will perform QC inspection at the site of waterproofing membrane field placement to ensure that the production and placement processes are providing work conforming to the II.594 202 4 Edition contract and manufacturer requirements. The minimum items to be inspected for each waterproofing membrane shall be in accordance with the requirements of 966.40: Application , Parts C thr ough F, and as outlined in Table 966.61 -1. Inspection shall include:
Table 966.61- 1: Minimum QC Inspection of Waterproofing Membrane Operations Inspection Component Inspection Attribute Minimum Inspection Frequency Point of Inspection Inspection Method Equipment As specified by Contractor As specified by Contractor As specified by Contractor As specified by Contractor Materials Primer (Correct Type) 1 per Day As specified by Contractor Check Manufacturer COC Membrane (Correct Type) 1 per Day As specified by Contractor Check Manufacturer COC Tack Coat (Correct Type) 1 per Day Per QC Plan Check Manufacturer COC Environmental Conditions Temperature of Air & Underlying Surface 1 per Day At Project Site Check Measurement Underlying Surface
Surface (Standing Moisture) Entire Surface Underlying Surface & Membrane Surface Visual Check Surface
& Membrane Surface Visual Check Workmanship Pin Hole/Holidays Entire Surface Membrane Surface Visual Check Membrane Coverage Rates Entire Surface From Distributor Visual Check Tack Coat Application Rate 1 per Day From Distributor Check Measurement DEPARTMENT ACCEPTANCE
966.70: General
The Department is responsible for performing all Acceptance activities and making the final Acceptance determination for each membrane waterproofing surface. The Department’s II.595 202 4 Edition Acceptance system will include monitoring the Contractor’s QC activity and performing Acceptance inspection in order to determine the quality and corresponding payment.
966.71: Acceptance Inspection
The Engineer will perform Acceptance inspection of all work items addressed under Subsection 966: Membrane Waterproofing for Bridge Deck Repairs to ensure that materials and completed work are in conformance with the contract requirements. Acceptance inspection is intended to visually assess the quality of the materials and work and will address only the inspection components of Materials and Workmanship in support of the Department’s final Acceptance determination. All Acceptance inspection activities by the Department will be performed independent of the Contractor’s QC inspection. Table 966.61- 1: Minimum QC Inspection of Waterproofing Membrane Operations Inspection Component Inspection Attribute Minimum Inspection Frequency Point of Inspection Inspection Method Materials Primer (Correct Type) 1 Per Day At Placement Site Check Manufacturer COC Membrane (Correct Type) 1 Per Day At Placement Site Check Manufacturer COC Tack Coat (Correct Type) 1 Per Day At Placement Site Check Manufacturer COC Workmanship Pin Hole/Holidays Entire Surface Membrane Surface Visual Check Membrane Coverage Rates Entire Surface At Placement Site Visual Check Tack Coat Application Rate 1 per day At Placement Site Check Measurement
966.72: Acceptance Determination
The Engineer’s Acceptance inspection results will be used in the final Acceptance determination. Prior to final Acceptance, the Engineer will periodically evaluate all Acceptance inspection information for the prepared underlying surface and the waterproo fing membrane. The materials and product workmanship for the completed work will be evaluated for conformance with the plans and the requirements specified in 966.40: Application and 966.41: Protection of Exposed Surfaces . When the Acceptance information identifies deficiencies in either material quality or product workmanship for any underlying surface location or waterproofing membrane, the location will be isolated and further evaluated by the Engineer through additional Acceptance inspection. Depending upon the findings of the additional Acceptance inspection activity, the Engineer will determine the disposition of the nonconforming work in accordance with Subsection 5.03: Conformity with Plans and Specifications. II.596 202 4 Edition The final review and visual inspection shall be conducted jointly by the Contractor and Engineer. Irregularities or other items that do not meet the requirements of the specifications and plans shall be addressed/repaired at this time, at no additional cos t to the Department. After the work is complete, including any corrective action, the Engineer will perform a final evaluation of all Acceptance data and Contractor QC data. The Engineer will accept the work if the Engineer’s evaluation of all inspection data is in conformance with this specification and the contract documents. COMPENSATION
966.80: Method of Measurement
Membrane waterproofing for bridge deck repairs will be measured by the square foot of surface covered with no allowance for overlapping or for edges turned up or carried into recesses for seals, except that the area of the full membrane turned down in back of the backwalls and extended under and in back of curb or edging will be included for payment.
966.81: Basis of Payment
The membrane waterproofing will be paid for at the contract unit price per square foot under the item for Membrane Waterproofing for Bridge Deck Repairs, complete in place. Tack coat shall be paid under item 452. Tack Coat.
966.82: Payment Items
966. Membrane Waterproofing for Bridge Deck Repairs ...................................... Square Foot SUBSECTION 970: DAMP -PROOFING DESCRIPTION
970.20: General
Damp -proofing to be applied as shown on the plans shall consist of a primer and damp -proofing material. If material other than that specified herein is permitted to be used, the method of application shall conform to the published specifications of the ma nufacturer . MATERIALS 970. 30: General Materials shall meet the requirements specified in the following Subsections of Division III , Materials. Primer ............................................................................................................................................... M9.09.1 Damp -proofing .............................................................................................................................. M9.09.2 II.597 202 4 Edition CONSTRUCTION METHODS 970. 40: General Concrete surfaces shall be allowed to dry for a period of at least 5 days after the removal of forms before damp -proofing is applied. Surfaces to be damp -proofed shall be made reasonably smooth and free from all projections and holes. All holes in concrete surfaces shall be satisfactorily filled with 1 part cement to 2 parts sand mortar before damp -proofing is applied. Concrete surfaces shall be properly cured before being damp- proofed. Surfaces shall be dry and immediately before the application of the damp -proofing shall be thoroughly cleaned of dust and all loose material. Damp -proofing shall not be done during wet, damp, or foggy weather, or when the ambient temperature is 40℉ or below or is forecast to fall below 40℉ during the application period. The temperature of the concrete surface shall also exceed the dew point by at least 5℉. One coat of primer shall be uniformly applied to the surface in accordance with the manufacturer’s recommendation. The material for damp -proofing shall be mopped or sprayed on the designated surfaces in two coats. Application methods, rates, temperature constraints shall be as recommended by the manufacturer. The initial coat of damp -proofing shall be allowed to dry thoroughly before a second coat is applied. The final coat shall be thoroughly dry before any fill is placed against it. CONTRACTOR QUALITY CONTROL
970.60: General
The Contractor shall provide Quality Control (QC) activities to ensure that their operations will provide damp -proofing that conforms to the specified material and workmanship requirements.
970.61: Damp -proofing Materials and Workmanship
The Contractor shall verify that they are using the correct damp -proofing materials as specified under 970.30: General . All damp -proofing operations shall exhibit satisfactory workmanship including ensuring a dry, smooth, and clean concrete surface which is cured properly, as well as correct application of the primer and damp -proofing. COMPENSATION
970.80: Method of Measurement
Damp -proofing will be measured by the actual area of surface covered in square foot .
970.81: Basis of Payment
Damp -proofing will be paid for at the contract unit price per square foot of surface and shall include the primer and all materials, equipment and labor to install the damp -proofing complete in place.
970.82: Payment Items
970. Damp -Proofing .............................................................................................................. Square Foot II.598 202 4 Edition SUBSECTION 971: ASPHALTIC BRIDGE JOINT SYSTEM DESCRIPTION
971.20: General
The work shall include the furnishing and installation of a polymeric binder and aggregate system composed of specially blended, polymer modified asphalt and selected aggregate, placed into a prepared joint blockout as shown on the plans. The system shall provide a flexible waterproof bridge joint capable of accommodating a total movement of up to 2 in. from maximum expansion to maximum contraction, and maintain a continuous load bearing surface. Incidental to this system shall be the placement of the non -sag joint sealer and backing rod through the safety curb and sidewalk deck joint as shown on the plans. MATERIALS
971.40: General
Materials shall meet the requirements specified in the following Subsections of Division III, Materials: Polyurethane Joint Sealer, Non -Sag ..................................................................................... M9.14.4 Asphaltic Binder for Asphaltic Bridge Joint System ...................................................... M9.17.0 Aggregate for Asphaltic Bridge Joint System ................................................................... M9.17.1 Backer Rod ..................................................................................................................................... M9.17.2 Bridge Plate for Asphaltic Bridge Joint System ............................................................... M9.17.3 CONSTRUCTION METHODS
971.60: General
A qualified employee of the manufacturer or an installer certified by the manufacturer and approved by the Department shall be at the job site prior to the beginning of the joint construction process to instruct the work crews in proper joint construction procedures and shall remain on the job site for the duration of the joint installation. The minimum ambient air temperature during installation shall be 40°F and rising. The Contractor shall produce uniform and parallel surfaces in the forming and placement of the blockout area within the reinforced concrete deck slabs as detailed on the plans. The formed blockout area shall be protected by the Contractor to prevent any edge damage by any site equipment throughout the ongoing construction process. The Contractor shall produce the required gap width within the full depth of the joint as dimensioned on the plans. If the existing curb stones bridge the existing sidewalk and safety curb joint gaps, they shall be modified by saw cutting a smooth face which shall be aligned and placed to maintain the uniform joint gap. Immediately prior to placing any binder, the blocked out section and the joint gap shall be inspected full depth and any debris shall be removed. Immediately thereafter the blockout, sidewalk and safety curb gap, and road surface 6 in. either side of the blockout shall be thoroughly II.599 202 4 Edition cleaned and dried using a hot compressed air (H.C.A.) lance capable of producing flame -retarded air stream at a temperature of at least 2,000°F. The lance’s blast orifice shall be capable of producing 150 psi of pressure. The backer rod shall be installed in the sidewalk and safety curb gap to the proper depth to ensure a correct width/depth ratio as specified by the manufacturer. The backer rod shall be set in accordance with the plans. There will be no splicing of the bac ker rod at the curb lines. The binder shall be melted and heated to the application temperature in a double jacketed, hot oil, heat transfer kettle, or as recommended by the manufacturer. The kettle shall be equipped with a continuous agitation system and temperature controls that can accurately maintain the material temperatures. The binder shall be poured into the joint gap. The binder shall overfill the roadway joint gap to allow the binder to be spread onto the adjacent concrete deck in order to form a bond breaker between the deck and the bridge plate. For sidewalk, curb, and median joint gaps a non -sag polyurethane joint sealer compatible with the asphaltic binder shall be used. The bridge plate shall be centered and placed over the entire length of the roadway joint gap. The plate shall be secured by placing locating pins through the pre -drilled holes into the joint gap backer rod. The bridge plate sections shall not overlap. The horizontal and vertical surfaces of the joint blockout joint shall be coated immediately with hot binder before pouring hot binder over the floor area of the joint. The coating shall be continuous and adhere to the surfaces. The aggregate shall be heated to a temperature of 300°F to 390°F in a suitable rotating drum blending unit with a heat source attached or by a secure H.C.A. lance to remove moisture. Temperature of the aggregate shall be controlled by a hand held calibrated digital temperature sensor or other means as approved by the Engineer. The heated aggregate and polymeric binder shall be combined in the blending unit with sufficient binder to thoroughly coat each aggregate individually while avoiding an excess of binder. In no instance shall the amount of the binder added to the blending unit be less than 15% by weight. The binder used for coating is not included in the above percentage. The coated aggregate shall be placed in the blockout in layers and raked level as recommended by the joint material manufacturer. The final layer shall be raked level and compacted flush with adjacent deck surface. This layer shall be compacted to the point of refusal with a 1.5 -ton to 2.5 -ton roller to ensure the proper density and interlocking of the aggregate in the layer. Immediately following the compaction, the surface of the joint and surrounding road shall be dried and cleaned using the H.C.A. lance. Sufficient binder shall immediately be spread over the joint and adjacent road surface to fill surface voids and seal the surface stone. The finished joint shall then be dusted with a fine, dry aggregate to prevent tackiness. II.600 202 4 Edition QUALITY CONTROL
971.70: General
The Contractor shall have sufficient mixers and personnel at the site to assure continuous and timely installation of the joint. The Manufacturer shall document and submit the successful performance of their material in a similar Asphaltic Bridge Joint System. The Installer shall have previously demonstrated the ability to have successfully produced a joint of similar nature and shall provide documentation of a working joint to the Department. The Contractor shall furnish Certified Test reports, Materials Certificates and Certificates of Compliance for the asphaltic polymeric binder, the aggregate, and the joint sealer. The backer rod and locating pins require Certificates of Compliance. COMPENSATION
971.80: Method of Measurement
Item 971. Asphaltic Bridge Joint System will be paid for at the contract unit bid price per foot, as measured between curb lines complete in place. Item 971.1 Asphaltic Bridge Joint System will be paid for at the contract unit bid price per cubic foot. The volume measurement shall consist of the product of (1) the distance between the curbs along the length of the joint times (2) the width of the asph altic plug joint noted on the plans times
The joint treatment at the safety curb, sidewalk and median shall be considered incidental to the work to be done under these items.
971.81: Basis of Payment
Payment shall be considered full compensation for installation of the Asphaltic Bridge Joint System including all labor, material, equipment, manufacturer’s representative and all items incidental to the satisfactory completion of the work. Removal of existing joints and materials will be paid for under separate Item.
971.82: Payment Items
971. Asphaltic Bridge Joint System ................................................................................. Foot
971.1Asphaltic Bridge Joint System ................................................................................. Cubic Foot
II.601 202 4 Edition SUBSECTION 972: STRIP SEAL BRIDGE JOINT SYSTEM DESCRIPTION
972.20: General
The work shall consist of furnishing and installing strip seal bridge joint systems. This system shall consist of structural steel components, bolts, nuts, washers, lock washers, expansion anchors, preformed neoprene seal and lubricant- adhesive, and elasto meric concrete, all combined in the manner required by the Contract Documents so that a fully operational, waterproof system will seal the joint over which it is installed. MATERIALS
972.40: General
Materials shall meet the requirements specified in the following Subsections of Division III, Materials: Epoxy -Resin Base Bonding System for Concrete .......................................................... .. M4.05.5 Elastomeric Concrete ................................................................................................................. M4.07.0 Structural Steel ............................................................................................................................. M8.05.0 Steel Extrusions ............................................................................................................................ M8.05.7 Galvanized Coatings .................................................................................................................... M7.10.0 Neoprene Seal ............................................................................................................................... M9.17.4 CONSTRUCTION METHODS
972.60: General
The joint system shall be installed in strict accordance with the manufacturer's instructions and this Subsection. In the event of a conflict, the more stringent requirement shall rule. A representative of the strip seal joint manufacturer shall be present throughout the installation. The representative shall be fully conversant in all respects with the correct installation methods. The representative shall be responsible to advise both the Engineer and the Contractor, that the proper installation method is being followed.
972.61: Preparation of Surfaces, Handling, and Storage
The preformed recess or blockout that is to receive the joint system shall be air blown or vacuum- cleaned such that all loose or foreign matter is removed prior to installation of the system. The blockout shall be constructed to the dimensions shown on the approved shop drawings. The concrete substrate must be clean (free of dirt, coatings, rust, grease, oil and other contaminants), sound, and durable. New concrete must have been cured for a minimum of 14 days and all laitance removed. Suitable preparation methods include sandblasting, chipping and scarification. The joint system shall be stored, inspected and handled in accordance with the manufacturers requirements and approved by the Engineer. No material shall be dropped, thrown, or dragged upon the ground. Material shall be kept clean, properly drained and sto red on proper supports above the ground. All material shall be adequately shored, braced, or clamped to resist lateral forces that might occur. Permanent distortion of the steel extrusions will be cause for rejection of II.602 202 4 Edition material. Galvanizing shall be in accordance with M7.10.0: Galvanized Coatings and 960.64: Galvanizing and shall be done before other coatings are applied.
972.62: Pre -Installation Inspection
Immediately prior to installation, the steel extrusions shall be inspected by the Engineer for proper alignment and anchor effectiveness. No bends or kinks in the steel extrusions shall be allowed, nor shall the straightening of such bends or kinks be allowed. Steel extrusion segments exhibiting bends or kinks shall be removed from the work site and replaced with new steel extrusion segments at the Contractor's expense. Anchorage bars or studs and their welds shall be inspected visually. Any anchorage bars or studs that do not have complete attachment weld shall be replaced.
972.63: Field Preparation
In order for the steel extrusion segments to be installed properly, they must be set at a width that is directly dependent upon the ambient temperature at the start of installation, as shown on the shop drawings. Before casting the elastomeric concrete, th e setting dimension shall be adjusted under the direction of the Engineer to correspond to the proper ambient temperature setting as shown on the approved shop drawings. The width setting shall be accomplished through the use of mechanical devices supplied by the strip seal bridge joint system fabricator. After the steel extrusions have been set to their proper line and grade and securely attached to their supports, the mechanical devices shall be removed.
972.64: Field Splicing of Steel Extrusions
If the system is to be installed in sections, the manufacturer will ship the joint with the appropriate ends beveled for field welding in accordance with the field splice detail shown on the approved shop drawings and the approved welding procedure specifi cations. Once the first joint section is installed and the elastomeric concrete has been cast, the adjacent length shall be field welded.
972.65: Placement and Finishing of Elastomeric Concrete
Prior to the placement of elastomeric concrete in the prepared blockout, the inside bottom faces of the steel extrusions shall be aligned and spaced using the manufacturer’s support devices. The steel extrusions shall not be unsupported or cantilevered into the joint blockout. Foam backer rod shall be placed inside the seal cavities of the steel extrusions prior to the placement of the elastomeric concrete. The backer rod will remain inside the steel extrusions until such time as the neoprene seal is about to be placed inside th e extrusions. The equipment used for the mixing and placement of the elastomeric concrete shall be supplied by the manufacturer or shall be approved by the manufacturer. The mixing and placement of elastomeric concrete shall be in accordance with the joint manufacturers written instructions. Proper consolidation of the elastomeric concrete shall be achieved around all embedded elements. A minimum clearance of ½ in. between the bottom of the steel extrusions and the concrete substrate shall be consistent throughout the le ngth of the joint ensuring proper flow and consolidation of the elastomeric concrete. Bonding agent must be used as a primer on the properly prepared joint blockout prior to the installation of the elastomeric concrete. The aggregate component and the liqu id component of the elastomeric concrete shall be thoroughly mixed until II.603 202 4 Edition all aggregate is completely coated (approximately 1 minute). This mix shall then be poured into the properly prepared blockout.
972.66: Installation of Neoprene Seal
The neoprene seals shall be field installed in continuous lengths spanning the entire roadway width. The neoprene seal shall be prefabricated in the shop to the final dimensions of the joint. Field splices or repairs of the neoprene seal shall not be permitted. To ensure proper fit of the seal and increase the ease of installation, dirt, spatter or standing water shall be removed from the steel extrusion using a brush, scraper or compressed air. Prior to installation, the neoprene strip seal lugs shall be thoroughly coated with a lubricant -adhesive that is approved and supplied by the strip seal joint manufacturer.
972.67: Watertight Integrity Test
At least five workdays after the joint system has been fully installed, the Contractor shall test the entire (full length) joint system for watertight integrity to the satisfaction of the Engineer. The entire joint system shall be covered with water, either ponded or flowing, for a minimum duration of 15 minutes. The concrete surfaces under the joint shall be inspected, during this 15 minute period and also for a minimum of 45 minutes after the supply of water has stopped, for any evidence of dripping water or moisture. Water tightness shall be interpreted to be no dripping water on any surface on the underside of the joint. Should the joint system exhibit any evidence of water leakage, the Contractor shall locate the place(s) of leakage and take all measures necessary to stop the leakage. All methods proposed by the Contractor to stop the leakage shall be approved by the Engineer. This work shall be done at the Contractor's expense. A subsequent water integrity test shall be performed subject to the same conditions and consequences as the original test. COMPENSATION
972.80: Method of Measurement
Item 972. Strip Seal Bridge Joint System will be paid for at the contract unit price per foot, as measured along the joint centerline between curb lines complete in place. The additional plates, angles, and all related hardware required at the safety curb, sidewalk and median shall be considered incidental to the work to be done under this item.
972.81: Basis of Payment
Payment shall be considered full compensation for installation and testing of the Strip Seal Bridge Joint System including all labor, material, equipment, manufacturer’s representative and all items incidental to the satisfactory completion of the work. Removal of existing joints and materials will be paid for under a separate Item.
972.82: Payment Items
972. Strip Seal Bridge Joint System ................................................................................ Foot
II.604 202 4 Edition SUBSECTION 975: METAL BRIDGE RAILINGS, PROTECTIVE SCREENS AND SNOW FENCES DESCRIPTION
975.20: General
Work under this item shall consist of furnishing and erecting metal bridge railing, protective screens, and snow fences in accordance with the plans and specifications. MATERIALS
975.40: General
Materials shall meet the requirements specified in the following Subsections of Division III, Materials: Paint and Protective Coatings ................................................................................................ M7 Anodized Coatings ....................................................................................................................... M7.20.0 Powder Coatings .......................................................................................................................... M7.25.0 Bridge Railing, Aluminum ........................................................................................................ M8.13.0 Aluminum Handrail and Protective Screen Type I and Type II ................................ M8.13.3 Bridge Railing, Steel, Type S3 -TL4 ........................................................................................ M8.13.1 Molded Fabric Bearing Pad ..................................................................................................... M9.16.2 The Contractor will be required to submit specifications showing the chemical and physical analyses to the Department for approval. CONSTRUCTION METHODS
975.60: Shop Drawings
The Contractor shall furnish the Engineer with complete detail or shop drawings of the proposed work in accordance with the requirements of Subsection 5.02: Plans and Detail Drawings . No material for the bridge railings, protective screens, and snow fences shall be fabricated before the approval of the detail or shop drawings by the Engineer.
975.61: Fabrication
Fabrication of the Metal members can only be performed by fabricators who are approved by the Department as specified in 960.61: Design, Fabrication and Erection . All steel, except for the pickets and the anchor plates shall be blast cleaned prior to fabrication in accordance with 960.61: Design, Fabrication and Erection, Paragraph C. The blast cleaning shall conform to Steel Structures Painting Council Surface Preparation Specification “Near White Blast Cleaning,” SSPC -SP10. Aluminum components shall be cleaned of any foreign matter. In assembly and during welding, the component parts of built up members shall be held by sufficient clamps or by other adequate means to keep parts straight and in close contact. Welding and fabrication of steel shall conform to the AASHTO Standard Specifications for Highway Bridges and the ANSI/AASHTO/AWS D1.5 Bridge Welding Code. If the members are tubular sections, the fabrication and welding shall conform to the ANSI/AWS D1.1 S tructural Welding Code - II.605 202 4 Edition Steel. Welding and fabrication of aluminum shall conform to AASHTO and the ANSI/AWS D1.2 Structural Welding Code -Aluminum. After welding aluminum members, all exposed joints in the rail or cap plate elements shall be finished by grinding or filing to produce a neat appearance. All welding of aluminum members shall be completed prior to anodizing. Prior to galvanizing, the fabricator shall ensure that all rail and rail components are smooth and without sharp protrusions that would present an injury hazard to pedestrians. Any drain holes necessary to ensure safe galvanizing shall be drilled by the fa bricator.
975.62: Setting Railing and Protective Screens
Anchor bolts for Type II Protective Screen and Aluminum Handrail shall be tightened ⅓ turn past snug -tight conditions. Anchor bolt nuts for the S3 -TL4 steel bridge railing shall be tightened ⅛ turn past snug -tight conditions and shall have between ³⁄₁₆ in. and ⅜ in. of exposed thread after tightening.
The three -rail aluminum railing, Protective Screen Type II posts, and snow fence posts shall be set plumb except in those locations where roadway grade is less than 1.50% in which case they shall be set normal to the grade. Handrail posts shall be set to normal grade. Longitudinal members shall follow the grade of the coping. During the erection of the railing, protective screens, and snow fence, care shall be taken to ensure proper grade and alignment in order to prevent springing or bending of the railing , protective screens, and snow fence during erection. Where required on curves, the rails shall be accurately formed to the required radius. Protective Screen Type I and Type II components and snow fence components shall be carefully adjusted prior to fixing in place to ensure proper matching or interlocking at abutting joints, and correct alignment and camber throughout their length. Holes for field connections to be drilled in the field shall be drilled with the screen railing in place in the structure at the proper grade and alignment. Field welding of aluminum components shall not be allowed. Base plates shall be set on ⅛ -in. thick molded fabric bearing pads. If additional shimming of the base plates is required, the shims shall be made from fully annealed aluminum alloy sheets or plates. The anchor cages for Protective Screen Type II, Snow Fence, and Aluminum Handrails shall be accurately set as shown on the drawings. The ferrules shall have a plastic cap in the bottom to act as a seal and shall have a temporary bolt installed while the concrete is being placed. Caps shall be installed in the tops of the ferrules if the temporary bolts are removed prior to erecting the posts. Protective Screen Type I posts shall be attached with extruded aluminum clamps to the steel tabs on the back of the steel bridge railing posts.
The post shall be set plumb except in those locations where the roadway grade is less than 1.50% in which case they shall be set normal to the grade. The rails shall follow the profile grade of the bridge at the vertical dimensions shown on the plans. When the bridge is on a vertical curve, the II.606 202 4 Edition bridge rail shall be shop cambered to follow the profile grade of the bridge. The rails may follow chords for shallow curves if the deviation at the post from the theoretical curve is ±½ in. or less. Care shall be taken for bridge railing layouts with both horizontal and vertical curves or angles. Field bending of the tube sections will not be allowed. Base plates shall be set on ⅛- in. thick molded fabric bearing pads. If additional shimming of the base plates is required, the shims shall be of the same material as the base plates. The edges of the base plates shall be caulked to make a watertight joint .
975.63: Galvanizing
The galvanizing bath for structural components, excluding hardware, shall contain nickel (0.05% to 0.09% by weight). Galvanized members requiring shop assembly shall be welded and drilled prior to galvanizing. The fabricator shall ensure that all welds are cleaned thoroughly in accordance with the AASHTO/AWS Bridge Welding Code and AASHTO M 111M/M 111 and shall have a suitable surface to accept the galvanizing. All bolts, screws, nuts and washers shall be hot dipped galvanized in accordance with AASHTO M 232M/M 232 or mechanically galvanized in accordance with ASTM B695. The screws may be electroplate galvanized. The posts, base plates, rails, pickets, angles and splice tubes shall be galvanized after fabrication in accordance with AASHTO M 111M/M 111 .
975.64: Painting
Aluminum bridge railing shall not be painted. Galvanized hardware need not be shop painted; however, any part of the bolts, screws, nuts and washers that are accessible after installation shall be painted in the field in accordance with 975.65: Touch -up and Repairs . Prior to painting, the galvanizer shall ensure that all rails and rail components are smooth and have a suitable surface for accepting the paint. All runs shall be removed by grinding. The galvanized surface shall be prepared for painting by one of the following methods . Method 1: The two -coat paint system shall be applied within 12 hours of galvanizing. The surface shall be blast cleaned immediately before painting (maximum of 8 hours) in accordance with requirements of SSPC SP7 “Brush- Off Blast Cleaning” or other method producing equivalent results and uniform profile, to achieve a 1.0 to 1.5 mil anchor profile as indicated by Keane Tator Surface Profile Comparator or similar device. All detrimental material, i.e., dirt, grease, other foreign matter, shall be removed prio r to blasting. Method 2: The two -coat paint system shall be applied within 15 days of galvanizing. In preparation for the two -coat painting system, the surface shall be blast cleaned in accordance with the requirements of SSPC SP7 “Brush- Off Blast Cleaning,” or other method producing equivalent results and uniform profile, to achieve a 1.0 to 1.5 mil anchor profile as indicated by a Keane Tator Profile Comparator or similar device. All detrimental material such as oil, grease, dirt, other foreign matter, II.607 202 4 Edition shall be removed prior to blast cleaning. The blast cleaning shall be performed prior to the formation of “white rust” on the galvanized surface. If “white rust” is detected, the steel shall be stripped and re -galvanized in accordance with these specifications. The preparation shall be followed by a pretreatment of zinc or iron phosphate. The phosphate shall be applied to the blast cleaned material within eight hours of blast cleaning. Phosphating shall be applied in accordance with the manufacturer's recommendations. The material shall be painted within twelve hours of phosphating. The applicator shall submit the procedure for phosphating to the Engineer for approval prior to performing the work. The phosphating applicator shall maintain a record of in -process quality checks on the solutions. The prime coat material shall be a polyamide epoxy applied to a minimum dry film thickness of 3.0 mils and force cured as given below for the finish coat. The finish coat material shall be a two component, catalyzed aliphatic urethane applied by airless spray to a minimum dry film thickness of 3.0 mils. The color and the corresponding Color Number as found in Federal Standard 595B, “Colors Used in Government Procurement,” shall be stated on the Plans. The fabricator shall submit to the Engineer for approval, paint chips of the intended color prior to any work being done under this heading. All finish coat material shall be applied under conditions within the following tolerances : Air Temperature: ......................................................................................................................... 50°F to 90°F Surface Temperature: ................................................................................................................ 50°F to 90°F Humidity ......................................................................................................................................... . 65% maximum The finish coat shall be cured in a booth maintained at 150°F for 2 to 4 hours. Should the coating system fail within one year after the project has been accepted, the damaged coating shall be repaired by the Contractor at no cost to the Department. The method of repair shall be acceptable to the Department.
975.65: Touch -up and Repairs
Should any damage occur to the coating during shipping or handling at the job site, the contractor shall repair and touchup any damaged areas to the satisfaction of the Engineer and the following: Touch -up of the galvanizing before the finish coat is applied shall be accomplished by applying a galvanizing repair paint in accordance with M7.04.11. The dry film thickness of the applied repair paint shall not be less than 3.0 mils. Applications shall be in accordance with the Manufacturer’s instructions. Field touch -up procedures shall conform to the recommendations of the company that performed the initial painting. Touch -up of the finish coat shall be by applying a coating of a two -part urethane, as supplied by the company that performed the initial painting, to achieve a dry film thickness of at least 3.0 mils. Prior to the application of the paint, remove all damaged coatings down to a solidly adhered coating and apply galvanizing repair paint as a primer. Allow the primer to dry for at least four hours . II.608 202 4 Edition The Contractor shall also use the touch -up paint material to paint the galvanized hardware used in the field erection of the railing that has not been finish coated previously. All paint used for touch -up and repair shall be the same manufacturer’s brand and lot number as was used in the shop. The Contractor shall be careful to not damage the anodized aluminum surfaces. Protective Screen Type I and Type II fabric and Snow Fence fabric shall be wrapped to prevent damage during shipment and storage. Touch - up coating shall be applied by spray to t he fabric after installation. Touch up of the anodized surface will be at the Contractor’s expense and shall be subject to the approval of the Engineer .
975.66: Inspection
Inspection may be done at the mill and or fabricating plant by the Engineer or the Engineer’s representative (Verification Inspector). The Contractor shall give 3 business days’ notice to the Engineer prior to starting the work so that the Department may a rrange for inspection. The contractor shall give the same notice when material is being shipped between the fabricator, galvanizer and painter so that inspection may be arranged. No material shall be shipped to a project until the Verification Inspector affixes their stamp to the material. Material shipped without such stamp shall be rejected and immediately removed from the job site . COMPENSATION
975.80: Method of Measurement
Metal bridge railings, protective screens, and snow fence shall be measured by the foot from end to end of the top rail. Curved portions shall be measured along the centerline of the top rail.
975.81: Basis of Payment
Metal bridge railing, protective screens, and snow fence shall be paid for at the contract unit price per foot under the item of railing, screen, or fence required, complete in place.
975.82: Payment Items
975.1Metal Bridge Railing (3 Rail), Steel (Type S3 -TL4) ........................................ Foot
975.2Metal Bridge Railing (3 Rail), Aluminum (TypeAL -3) ................................ . Foot
975.3Protective Screen Type I ........................................................................................... Foot
975.4Protective Screen Type II .......................................................................................... Foot
975.5Aluminum Handrail ................................................................................................ ..... Foot
975.6Snow Fence 3 -Foot High ........................................................................................... Foot
975.7Snow Fence 4 -Foot High ........................................................................................... Foot
II.609 202 4 Edition SUBSECTION 983: REVETMENT DESCRIPTION
983.20: General
Revetment shall consist of slope protection of the required type at the location shown on the plans and in accordance with these specifications and in close conformity with the lines and grades shown on the plans or established by the Engineer.
983.21: Classification
This work shall consist of angular shaped stones dumped in place to form a well graded mass with a minimum of voids, in location where damage may be caused by water conditions and below water level as a foundation for slope paving.
This work shall consist of a protective covering of angular shaped stones laid on slopes in front of abutments, wingwalls, piers and elsewhere as required, to insure protection of structures and embankments.
Slope paving shall consist of angular shaped stones, having a reasonably flat face, carefully placed on slopes to insure their protection.
This special slope paving is intended for use on slopes under bridges where not in contact with flowing water and shall consist of quarry stone, precast concrete blocks or cement concrete laid on slopes in uniform courses under bridges.
Channel Paving, of the type specified, shall be placed as protective covering along the slopes around culvert inlets or outlets, around foundations, bridge berms and dikes.
This work shall consist of slope protection of ditches and at ends of cross- culverts. II.610 202 4 Edition MATERIALS
983.40: General
Materials shall meet the requirements specified in the following Subsections of Division III, Materials: Dumped Riprap ............................................................................................................................ M2.02.2 Modified Rockfill .......................................................................................................................... M2.02.4 Riprap ............................................................................................................................................... M2.02.0 Slope Paving ................................................................................................................................... M2.06.0 Special Slope Paving under Bridge (Quarry Stone) ....................................................... M2.06.1 Special Slope Paving under Bridge (Precast Concrete Blocks) ................................ . M4.05.3 Channel Paving ............................................................................................................................. M2.06.2 4,000 psi, 1.5 -inch, 565 Cement Concrete ......................................................................... M4.02.00 Reinforcing Steel .......................................................................................................................... M8.01.0 Preformed Bituminous Joint Filler for Concrete ............................................................. M3.05. 5 Hot Applied Crack Sealer .......................................................................................................... M3.05. 2 Crushed Stone for Drainage Foundation ............................................................................ M2.01.1 Mortar ............................................................................................................................................... M4.02.15 CONSTRUCTION METHODS
983.60: General
Areas to be protected by revetment shall be free of brush, trees, stumps and other organic material and be dressed to a smooth surface. All soft or spongy material shall be removed to the depth shown on the plans or as directed by the Engineer and replaced with approved materials. A toe trench as shown on the plans shall be dug and maintained until the revetment is placed. Protection for structure foundations shall be provided as early as the foundation construction permits. The area to be protected shall be cleaned of waste materials and the surface to be protected prepared as shown on the plans. Where shown on the plans a foundation shall be placed on the area before the stone is placed. The foundation will be specified as either gravel borrow or crushed stone and at least 12 in. in thickness.
983.61: Dumped Riprap
Stone for riprap shall be placed on the prepared slope or area in a manner which will produce a reasonably well graded mass of stone with the minimum practicable percentage of voids and minimum thickness of 2 ft. Riprap protection shall be placed to its full course thickness at one operation and in such a manner as to avoid displacing the underlying material. Placing of riprap protection in layers or by dumping into chutes or by similar methods likely to causese gregation will not be permitted. The larger stones shall be well distributed, and the entire mass of stone shall conform approximately to the gradation specified in M2.02.2: Dumped Riprap . All material going into riprap II.611 202 4 Edition protection shall be so placed and distributed that there will be no large accumulations of either the larger or smaller sizes of stone. It is the intent of these specifications to produce a fairly compact riprap protection in which all sizes of material are placed in their proper proportions. Hand placing or rearranging of individual stones by mechanical equipment may be required to the ex tent necessary to secure the results specified. The riprap protection shall be placed in conjunction with the construction of the embankment with only sufficient lag in construction of the riprap protection as may be necessary to allow for proper construction of the portion of the embankment protected an d to prevent mixture of embankment and riprap material. In no case will the elevation of the embankment be greater than 5 ft above the elevation of the riprap material.
983.62: Riprap
The stones shall be placed upon an approved bed of gravel, crushed stone or other acceptable material, to the lines and grades shown on the plans and as directed. Each stone shall be carefully placed by hand or machine, on a prepared bed, normal to the slope and firmly bedded thereon. The larger stones shall be placed closely together and the intervening spaces filled with smaller stones in such a manner that the entire surface will form a compact mass.
983.63: Slope Paving
The stones shall be placed upon an approved bed of gravel, crushed stone or other acceptable material, to the lines and grades shown on the plans and as directed. The larger stones shall be placed closely together throughout the surface and the interstices carefully chinked with smaller stones. All stones shall be securely bedded, with the exposed surfaces approximately parallel to and within 6 in. of the slope shown on the plans. When the paving cannot be laid to the required line and grade below water, a suitable foundation of dumped riprap shall be constructed.
983.64: Special Slope Paving Under Bridges
This type of slope paving shall consist of either quarry stone, precast concrete blocks or cement concrete and shall be firmly bedded on a 6 -in. gravel foundation. The finished paving shall have a continuous surface of uniform appearance, approximately parallel to and within 3 in . of the slope shown on the plans.
The paving shall be laid in uniform courses with broken joints not exceeding 2 in . in width. The joints shall then be filled with sand or fine gravelly material to within 2 in. of the paved surface. Cement mortar (M4.02.15: Cement Mortar) shall then be placed in the joints to the top of the paved surface. II.612 202 4 Edition C. Cement Concrete. The paving shall be placed as specified in Subsection 901: Cement Concrete; the surface shall be finished as specified in 901.68: Joints , Paragraph C.
983.65: Channel Paving and Grouted Channel Paving
All stones shall be placed upon an approved bed to the lines and grades shown on the plans and as directed. The larger stones shall be placed as closely together as poss1ble throughout the surface. All stones shall be securely bedded and laid so that the exposed surfaces will be approximately parallel to and within 3 in. of the grade shown on the plans. The finished paving shall present a continuous uniform surface of stonework. Grouting, when required, shall be done after the paving is completely in place. The paving stones shall be sprinkled with water immediately before placing the grout. The grout shall conform to M4.02.15: Cement Mortar .
983.66: Modified Rockfill
Stone shall be placed on the prepared area in a manner which will produce a reasonably well graded mass with a minimum practical percentage of voids and a minimum thickness of 1 ft. The stone will be placed to its full thickness in one operation and in such a manner as to avoid displacing the underlying material. It is the intent of these specifications to produce a fairly compact Rockfill protection in which all sizes of material are placed in their proper proportions. Hand -placing or rearranging of individual stones by mechanical equipment may be required to the extent necessary to secure the results specified. Modified Rockfill shall be placed in conjunction with the adjacent construction as shown on the plans. COMPENSATION
983.80: Method of Measurement
The quantity of Dumped Riprap, Riprap and Modified Rockfill shall be the weight of the stones. Slope Paving, Special Slope Paving under Bridges, Channel Paving and Grouted Channel Paving will be measured in place by the square yard on the surface of the paved slope as constructed.
983.81: Basis of Payment
No deduction from the excavation pay quantities will be made for stone taken from excavation and used in any type of revetment, provided that any additional filling material made necessary by such use shall be furnished as specified in Subsection 4.09: Rights In the Use of Materials Found on the Work. Excavation below the original ground surface at the toe of slopes when required in the construction of revetment will be paid for under the item for Class A Trench Excavation, but where the excavation is made along the slopes of an existing or proposed channel, such excavation will be paid for under the Item for Channel Excavation. II.613 202 4 Edition Excavation in cuts when required in the construction of revetment, will be paid for at the contract unit price per cubic yard under the Item of Earth Excavation or Bridge Excavation, whichever is applicable. Gravel Borrow required in the construction of revetment will be paid for under the contract unit price per cubic yard for Item 151. Gravel Borrow, complete in place. Crushed stone when required for foundation revetment will be paid for at the contract unit price per ton for Crushed Stone for Drainage Foundations. The tonnage of Dumped Riprap, Riprap and Modified Rockfill will be paid for at the contract unit price per ton for the kind of stone required, complete in place. Slope Paving, Special Slope Paving under Bridges, Channel Paving and Grouted Channel Paving will be paid at the contract unit price per square yard, complete in place.
983.82: Payment Items
983. Dumped Riprap ............................................................................................................. Ton
983.1Riprap ............................................................................................................................... Ton
984. Stone and Stone Chips for Waterway Revetments, Groins, Jetties Breakwaters and Mounds ......................................................................................... Ton 985. Slope Paving ................................................................................................................... Square Yard 986. Modified Rockfill .......................................................................................................... Ton 987. Special Slope Paving under Bridge – Option ................................................. .... Square Yard
987.1Special Slope Paving under Bridge – Quarry Stone ....................................... Square Yard
987.12Special Slope Paving under Bridge – Quarry Stone (Grouted) ................. . Square Yard
987.2Special Slope Paving under Bridge – Precast Concrete Blocks ................. Square Yard
987.3Special Slope Paving under Bridge – Cement Concrete ............................... Square Yard
988. Channel Paving .......................................................................................................... .... Square Yard
988.1Grouted Channel Paving ............................................................................................ Square Yard
SUBSECTION 995: BRIDGE STRUCTURE DESCRIPTION
995.20: General
Work included in this section shall consist of constructing bridge structures in accordance with the designs and to the lines and grades shown on the plans, and in accordance with these specifications complete in place including the furnishing and installation of all materials that are part of the structures. The work also includes approach slabs, wing walls and retaining walls when specified. The work under this section does not include the various classes of excavation, hot mix asphalt pavement, any work on piles, backfill, revetments, temporary structure, removal of present superstructure, cofferdams, control of water, or other items noted in the contract. II.614 202 4 Edition MATERIALS
995.40: General
The materials to be used shall be in accordance with the applicable sections of these specifications and/or the Special Provisions for each respective item included in the construction of the structure. CONSTRUCTION METHODS
995.60: General
The method of construction shall be in accordance with the applicable sections of these specifications and the Special Provisions for each respective item. COMPENSATION
995.81: Basis of Payment
The above work will be paid for at the contract lump sum price under the respective item of “Bridge Structures.” Where more than one structure is included in the Contract the following provisions shall apply to each structure. The schedule is for the purpose of estimating partial payments, and it shall not affect the contract terms in any way. Except as stipulated in the following paragraphs, the payment shall be a lump sum for each bridge structure complete in place. In general, payment will include the full compensation for all concrete (including approach slabs, and all concrete sidewalks adj acent to the wingwalls), prestressed concrete beams and deck beams, steel reinforcement for structures, structural steel, shear connectors, bituminous damp -proofing, membrane waterproofing, protective course, curbing, edging, scuppers, drains, bridge raili ngs, concrete penetrant sealer, and incidental work such as flashings, waterstops, fillers, tile under sidewalk; brickwork at parapet walls, crushed stone for weep holes, fastenings, painting and other materials, equipment and labor that are indicated or implied as part of the construction for the bridge structure. Payment for each bridge structure includes all work indicated on the plans under one bridge number even though two or more structures may be included under one bridge number, due to a wide center reservation or some other physical feature. Walls, other than wingwalls or connecting walls between the structures, will not be included for payment under an item for Bridge Structure. When the Engineer orders changes from the contract plans of a bridge structure, the cost of such changes will be negotiated based on the provisions of Subsection 4.03: Extra Work and Subsection 9.03: Payment for Extra Work . Where more than one structure is included in the contract under separate items, the foregoing paragraphs apply to each structure separately, and only to the structure for which changes are ordered. Placing concrete on the deck in excess of that shown on the plans, to compensate for camber of structural steel, will not be considered a change from the plans. Full compensation for the additional concrete is included in the lump sum bid price. II.615 202 4 Edition Basis for Partial Payments. Within 10 days after Notice to Proceed, the Contractor shall submit, in duplicate, for approval by the Engineer, a schedule of quantities and unit prices for the major components of the respective items for Bridge Structure as listed in the Special Provisions. The approval of the schedule by the Engineer shall not be considered as a guarantee to the Contractor that the quantities shown on the schedule are the approximate quantities actually included in the structure as indicated on the plans. The schedule is only for the purpose of estimating partial payments, and it shall not affect the contract terms in any way. The volume occupied by the tile under the sidewalk shall be considered as an equivalent volume of cement concrete. Fillers, flashings, brickwork at parapet walls, tar paper, fastenings, painting and other materials and work shall be included with the appropriate components. The schedule shall list the item, the quantity and the unit of measurement, the Contractor's price per unit, the amount for the item, and the total that the Contractor bid for the lump sum. Each schedule applies only to the respective bridge structure. Similar materials and constructions at other locations are not included in the schedule.
995.82: Payment Items
995. Bridge Structure Bridge No. ( ) ............................................................................... Lump Sum SUBSECTION 996: NOISE BARRIER STRUCTURE DESCRIPTION
996.20: General
Work included in this section shall consist of constructing noise barrier structures in accordance with the plans and these specifications to provide a satisfactory structure, complete in place. MATERIALS
996.40: General
All structural steel shall be new and in conformance with Subsection 960: Structural Steel and Miscellaneous Metal Products .
Materials shall meet the requirements specified in the following Subsections of Division III, Materials: II.616 202 4 Edition Anchor bolts ................................................................................................................................... M8.01.5 Galvanizing ..................................................................................................................................... M7.10.0 Paint and protective coatings ................................................................................................ . M7. Reinforcement steel .................................................................................................................... M8.01.0 Epoxy coating for reinforcing bars ....................................................................................... M8.01.07 4,000 psi, ¾-inch, 565 Cement Concrete ........................................................................... M4.02.00 Elastomeric bearing pads ......................................................................................................... M9.14.5 Joint sealer ...................................................................................................................................... M9.14.4 Backer rod ...................................................................................................................................... M9.17.2 CONSTRUCTION METHODS
996.60: General
The method of construction shall be in accordance with the plans and these specifications. The Contractor shall submit shop drawings in accordance Subsection 5.02: Plans and Detail Drawings . The shop drawings shall include all pertinent dimensions, reinforcing steel, pick points and precasting details. The Contractor shall submit an erection procedure in accordance with 960.61: Design, Fabrication and Erection . All open excavations shall be suitably covered or filled in to the satisfaction of the Engineer at the end of the shift.
996.61: Weep Holes
Weep holes, if required, shall be located as shown on the plans or as directed by the Engineer. They shall be located to avoid reinforcing steel. The Contractor shall propose a method for locating rebar that is satisfactory to the Engineer. The weep holes shall be cored in a manner which results in a smooth bore hole and which does not break or chip either panel surface at the edge of the hole. COMPENSATION
996.80: Method of Measurement
The Noise Barrier Structure shall be measured by the square foot, one face. The length of each wall section shall be measured centerline of post to centerline of post. The height of each wall panel shall be measured vertically from the bottom of the lowest panel to the top of the wall panel. Noise Barrier Foundations shall be measured vertically by the foot, from the bottom of the shaft to the top of the concrete. Weep Holes for Noise Barrier Structure shall be measured by each hole installed.
996.81: Basis of Payment
The above work will be paid for at the contract unit price under the respective item of Noise Barrier Structure, Noise Barrier Foundation, and Weep Hole for Noise Barrier Structure. II.617 202 4 Edition Payment for Noise Barrier Structure shall include all panels including coloring, surfacing and anti - graffiti protection application, post assemblies including galvanizing and painting, signs, access doorways, hand holes, bearing pads, caulking, hardware, brick, plates, nuts, washers, temporary post supports, grout and mortar, and any and all incidental work necessary to construct the structure complete in place. Payment for Noise Barrier Foundation shall include all earth support, water control, grouting of pre-cast foundations concrete, reinforcing steel, anchor bolts, and any and all incidental work necessary to construct the foundations complete in place and ready to accept the posts. Payment for Weep holes for Noise Barrier Structure will be made at the contract unit price each, complete in place. Payment for excavation, test pits, crushed stone, geotextile fabric and clearing and grubbing shall be made under the respective items.
996.82: Payment Items
945.101 Drilled Shaft Excavation 3.0 Foot Diameter ...................................................... Foot
1 Rock Socket Excavation 3.0 Foot Diameter ....................................................... Foot
945.301 Obstruction Excavation 3.0 Foot Diameter ....................................................... Foot
996.1Noise Barrier Structure Square ........................ ...................................................... Foot
996.11Noise Barrier Foundation .................................... ..................................................... Foot
996.2Weep Hole for Noise Barrier Structure ............................................................... Each
COMMONWEALTH OF MASSACHUSETTS DEPARTMENT OF TRANSPORTATION STANDARD SPEC IFICATIONS for Highways and Bridges 202 4 Edition
i 202 4 Edition TABLE OF CONTENTS
Section M: Materials .................................................................................................................................. III.1 Section M1: Soils and Borrow Materials ............................................................................................ III.2 M1.00.0: General .................................................................................................................................................. III.2 M1.01.0: Ordinary Borrow ............................................................................................................................... III.2 M1.02.0: Special Borrow ................................................................................................................................... III.2 M1.03.0: Gravel Borrow .................................................................................................................................... III.2 M1.03.1: Processed Gravel for Subbase ...................................................................................................... III.3 M1.04.0: Sand Borrow ........................................................................................................................................ III.4 M1.04.1: Sand Borrow for Subdrains ........................................................................................................... III.4 M1.05.0: Loam ....................................................................................................................................................... III.4 M1.06.0: Compost ................................................................................................................................................ III.5 M1.08.0: Impervious Soil Borrow ................................................................................................................. III.8 M1.09.0: Reclaimed Pavement Borrow Material .................................................................................... III.8 M1.10.0: Pavement Milling Mulch ................................................................................................................. III.9 Section M2: Aggregates and Related Materials ............................................................................. III.10 M2.01.0: Crushed Stone .................................................................................................................................. III.10 M2.01.7: Dense Graded Crushed Stone for Sub -base ......................................................................... III.11 M2.01.8: Processed Glass Aggregate ......................................................................................................... III.12 M2.02.0: Riprap ................................................................................................................................................. III.12 M2.02.1: Rockfill ................................................................................................................................................ III.12 M2.02.2: Dumped Riprap ............................................................................................................................... III.12 M2.02.3: Stone for Pipe Ends ....................................................................................................................... III.13 M2.02.4: Modified Rockfill ............................................................................................................................ III.13 M2.03.0: Granite Rubble Block .................................................................................................................... III.14 M2.04.0: Aggregate for Sand Blasting ....................................................................................................... III.14 M2.05.0: Stone Screenings ............................................................................................................................ III.14 M2.06.0: Slope Paving ..................................................................................................................................... III.14 M2.06.1: Special Slope Paving Under Bridge (Quarry Stone). ........................................................ III.14 M2.06.2: Channel Paving ................................................................................................................................ III.14 Section M3: Asphaltic Materials .......................................................................................................... III.15 M3.00.0: General ............................................................................................................................................... III.15 M3.01.0: Performance Graded Asphalt Binder ..................................................................................... III.15 M3.01.1: Standard Asphalt Binder Grade ............................................................................................... III.16 M3.01.2: Modified Asphalt Binder Grades .............................................................................................. III.16 M3.01.3: Asphalt Binder Grade for Recycled Asphalt Materials .................................................... III.17 M3.01.4: Warm Mix Asphalt Additive ....................................................................................................... III.17 M3.01.5: Asphalt Anti -Stripping Additive ............................................................................................... III.18 M3.01.6: Asphalt Release Agents ................................................................................................................ III.19 M3.02.0: Cutback Asphalts ............................................................................................................................ III.19 M3.03.0: Asphalt Emulsions ......................................................................................................................... III.19 ii 202 4 Edition M3.03.1: Anionic Emulsified Asphalt ........................................................................................................ III.19 M3.03.2: Cationic Emulsified Asphalt ....................................................................................................... III.19 M3.03.3: Polymer Modified Emulsified Asphalt ................................................................................... III.19 M3.05.0: Pavement Crack Sealers and Joint Adhesives ..................................................................... III.19 M3.05.1: Chemically Modified Crumb Rubber Crack Sealer ........................................................... III.20 M3.05.2: Hot Applied Crack Sealer ............................................................................................................ III.20 M3.05.3: Asphalt -Fiber Crack Sealer ......................................................................................................... III.21 M3.05.4: Hot Applied Pavement Joint Adhesive .................................................................................. III.21 M3.05.5: Preformed Bituminous Joint Filler for Concrete ............................................................... III.21 M3.06.0: Hot Mix Asphalt ............................................................................................................................... III.21 M3.06.1: General ............................................................................................................................................... III.21 M3.06.2: Aggregate for Hot Mix Asphalt .................................................................................................. III.22 M3.06.3: Performance Graded Asphalt Binder ..................................................................................... III.26 M3.06.4: Hot Mix Asphalt Mixture Design .............................................................................................. III.26 M3.06.5: Verification of Laboratory Trial Mix Formula .................................................................... III.31 M3.07.0: HMA for Driveways, Sidewalks, Berm, and Curb .............................................................. III.33 M3.08.0: Cold Patch for Temporary Patching ....................................................................................... III.35 M3.10.0: Surface Preservation Treatment .............................................................................................. III.35 M3.10.2: Stress Absorbing Membrane & Stress Absorbing Membrane Interlayer ................ III.35 M3.10.5: Ultrathin Bonded Overlay ........................................................................................................... III.36 M3.12.0: Hot Mix Asphalt Production Facility ...................................................................................... III.40 M3.12.1: HMA Plant Facility Inspection .................................................................................................. III.43 M3.13.0: Hot Mix Asphalt Materials Testing Laboratory and Equipment ................................. III.43 M3.13.1: Contractor Quality Control Laboratory ................................................................................. III.43 M3.13.2: Department Acceptance Laboratory at HMA Production Facility ............................. III.44 Section M4: Cement and Cement Concrete Materials ................................................................. III.48 M4.00.00: General ............................................................................................................................................. III.48 M4.01.0: Portland Cement ............................................................................................................................. III.48 M4.01.1: Blended Hydraulic Cements ...................................................................................................... III.48 M4.01.2: Fly Ash ................................................................................................................................................ III.48 M4.02.00: Cement Concrete.......................................................................................................................... III.48 M4.02.01: Cement ............................................................................................................................................. III.49 M4.02.02: Aggregates ...................................................................................................................................... III.49 M4.02.03: Lightweight Aggregates ............................................................................................................ III.50 M4.02.04: Water ................................................................................................................................................ III.50 M4.02.05: Chemical Admixtures ................................................................................................................. III.50 M4.02.06: Proportioning ................................................................................................................................ III.51 M4.02.07: Measuring Materials ................................................................................................................... III.54 M4.02.08: Plant and Equipment ................................................................................................................. III.54 M4.02.09: Mixers and Agitators .................................................................................................................. III.55 M4.02.10: Mixing and Delivery .................................................................................................................... III.56 M4.02.11: Storage and Handling of Materials ....................................................................................... III.58 M4.02.13: Test Specimens ............................................................................................................................. III.58 M4.02.14: Precast Concrete Highway Units ........................................................................................... III.62 M4.02.15: Cement Mortar .............................................................................................................................. III.86 iii 202 4 Edition M4.02.17: Self- Consolidating Concrete for Precast Concrete Products ..................................... III.87 M4.03.0: Concrete Produced by Volumetric Mixers ........................................................................... III.88 M4.04.0: Mortar for Prestressed Concrete Deck Beams ................................................................... III.90 M4.05.0: Cement Concrete Brick ................................................................................................................ III.91 M4.05.1: Cement Concrete Blocks .............................................................................................................. III.92 M4.05.2: Clay Brick ........................................................................................................................................... III.92 M4.05.3: Precast Concrete Block for Slope Paving .............................................................................. III.92 M4.05.4: Sidewalk Brick ................................................................................................................................. III.92 M4.05.5: Epoxy -Resin Base Bonding System for Concrete .............................................................. III.93 M4.06.1: High Performance Concrete ....................................................................................................... III.93 M4.06.2: High Early Strength Concrete .................................................................................................... III.96 M4.06.3: Rapid Hardening Concrete ......................................................................................................... III.97 M4.06.4: Lightweight Concrete ................................................................................................................... III.99 M4.07.0: Elastomeric Concrete ................................................................................................................... III.99 M4.08.0: Controlled Low -Strength Materials ..................................................................................... III.100 Section M5: Pipe, Culvert Sections and Conduit ........................................................................ III.102 M5.00.0: Pipe, Culvert Sections and Conduit ...................................................................................... III.102 M5.01.0: Joint Materials for Pipe ............................................................................................................. III.102 M5.02.1: Reinforced Concrete Pipe ........................................................................................................ III.102 M5.02.2: Reinforced Concrete Pipe Flared Ends ............................................................................... III.102 M5.03.0: Corrugated Metal Pipe .............................................................................................................. III.102 M5.03.1: Perforated Corrugated Metal Pipe ....................................................................................... III.103 M5.03.6: Metal End Sections ..................................................................................................................... III.103 M5.03.7: Plastic (PVC) Pipe ........................................................................................................................ III.103 M5.03.8: Polymeric Precoated Corrugated Metal Pipe................................................................... III.103 M5.03.9: Slot -Perforated Corrugated Plastic Pipe ............................................................................ III.103 M5.03.10: Corrugated Plastic Pipe .......................................................................................................... III.103 M5.03.11: Porous Concrete Pipe .............................................................................................................. III.103 M5.04.0: Asphalt Coated Corrugated Metal Pipe Arches ............................................................... III.103 M5.04.2: Structural Plate for Pipe and Pipe Arches ......................................................................... III.104 M5.04.3: Asphalt Coated Smooth Steel Liner Helically Corrugated Shell Metal Pipe ........ III.104 M5.05.3: Ductile Iron Pipe and Fittings ................................................................................................ III.105 M5.05.4: Acrylonitrile - Butadiene - Styrene (ABS) Pipe ............................................................... III.105 M5.06.0: Copper Tubing .............................................................................................................................. III.105 M5.07.0: Electrical Conduit -Rigid Nonmetallic (Type NM) .......................................................... III.105 M5.07.1: Electrical Conduit -Rigid Metallic (Type RM) ................................................................... III.106 M5.07.2: Electrical Conduit -Flexible Metallic (Type FM) .............................................................. III.106 M5.08.0: Pull and Junction Boxes – Metallic ....................................................................................... III.106 Section M6: Roadside Development Materials ........................................................................... III.107 M6.00.0: General ............................................................................................................................................ III.107 M6.01.0: Inorganic Amendments ............................................................................................................ III.107 M6.02.0: Fertilizer ......................................................................................................................................... III.107 M6.03.0: Long Term Seed Mixes for Lawns and Slopes ................................................................. III.107 M6.03.1: Short Term Erosion Control Seed ......................................................................................... III.108 iv 202 4 Edition M6.04.0: Mulch ................................................................................................................................................ III.109 M6.04.1: Hay Mulch ....................................................................................................................................... III.109 M6.04.2: Straw Mulch ................................................................................................................................... III.109 M6.04.3: Wood Chip Mulch ........................................................................................................................ III.109 M6.04.4: Wood Fiber Mulch ...................................................................................................................... III.109 M6.04.5: Aged Pine Bark Mulch ............................................................................................................... III.110 M6.05.0: Sod ..................................................................................................................................................... III.110 M6.06.0: General Planting .......................................................................................................................... III.111 M6.06.1: Nursery Stock – General ........................................................................................................... III.111 M6.06.2: Nursery Stock – Balled and Burlapped .............................................................................. III.112 M6.06.3: Nursery Stock – Container Grown ........................................................................................ III.112 M6.06.4: Nursery Stock – Bare -Root ...................................................................................................... III.113 M6.06.5: Nursery Stock – Seedlings ....................................................................................................... III.113 M6.06.6: Nursery Stock – Trees ............................................................................................................... III.113 M6.06.7: Nursery Stock – Shrubs, Vines, Groundcover and Perennials .................................. III.114 M6.07.0: Delivery and Protection ............................................................................................................ III.114 M6.07.1: Wrapping for Transport ........................................................................................................... III.114 M6.08.0: Materials for Guying and Staking ......................................................................................... III.114 M6.08.1: Temporary Fencing for Tree Protection ............................................................................ III.114 M6.08.2: Trunk Cladding for Tree Protection. ................................................................................... III.114 M6.08.3: Sheeting for Tree Root Protection ....................................................................................... III.115 M6.09.0: Water for Irrigation .................................................................................................................... III.115 Section M7: Paints, Protective Coatings and Pavement Markings ...................................... III.116 M7.00.0: General Requirements for Paints and Protective Coatings ....................................... III.116 M7.01.0: Pavement Markings .................................................................................................................... III.117 M7.01.3 Liquid Thermoplastic Striping Material .............................................................................. III.117 M7.01.07: Glass Beads .................................................................................................................................. III.119 M7.02: Structural Paint ................................................................................................................................ III.120 M7.03: Enamels ............................................................................................................................................... III.121 M7.04: Miscellaneous Coatings ................................................................................................................ III.121 M7.05: Epoxy Protective Coating ............................................................................................................ III.121 M7.10.0: Galvanized Coatings ................................................................................................................... III.121 M7.15.0: Metallized Coatings .................................................................................................................... III.122 M7.20.0: Anodized Coatings ...................................................................................................................... III.122 M7.25.0: Powder Coatings .......................................................................................................................... III.122 Section M8: Metals and Related Materials ................................................................................... III.124 M8.00.0: General ............................................................................................................................................ III.124 M8.01.0: Reinforcing Bars .......................................................................................................................... III.124 M8.01.1: Cold Drawn Steel Wire .............................................................................................................. III.124 M8.01.2: Welded Steel Wire Fabric ........................................................................................................ III.124 M8.01.3: Steel Bar Mats ............................................................................................................................... III.124 M8.01.4: Tie Bars and Bolts ....................................................................................................................... III.124 M8.01.5: Anchor Bolts, Nuts and Washers .......................................................................................... III.125 M8.01.7: Epoxy Coated Reinforcing Bars ............................................................................................. III.125 v 202 4 Edition M8.01.8: Galvanized Reinforcing Bars .................................................................................................. III.125 M8.01.9: Mechanical Reinforcing Bar Splicer ..................................................................................... III.125 M8.02.0: Drilled Steel Rods ........................................................................................................................ III.126 M8.03.0: Iron Castings ................................................................................................................................. III.126 M8.03.2: Steel Castings ................................................................................................................................ III.126 M8.04.1: Stud Shear Connectors .............................................................................................................. III.127 M8.04.2: Steel Pins ......................................................................................................................................... III.128 M8.04.3: High Strength Bolts .................................................................................................................... III.128 M8.05.0: Structural Steel ............................................................................................................................. III.131 M8.05.1: Steel Piles ........................................................................................................................................ III.132 M8.05.3: Steel Baffles and Drainage Troughs ..................................................................................... III.132 M8.05.4: Steel Sheeting ................................................................................................................................ III.132 M8.05.5: Steel Pipe Piles ............................................................................................................................. III.132 M8.05.6: Steel Casing .................................................................................................................................... III.133 M8.05.7: Steel Extrusions ........................................................................................................................... III.133 M8.07.0: Guardrail ......................................................................................................................................... III.133 M8.07.1: Guardrail End Treatment ......................................................................................................... III.135 M8.09.0: Chain Link Fences and Gates .................................................................................................. III.135 M8.09.1: Bonded Vinyl Coated Chain Link Fences, Posts, Rails, Fabric, Gates and Accessories ................................................................................................................................................................ III.138 M8.10.0: Steel Pipe Rail or Fence ............................................................................................................ III.138 M8.10.1: Aluminum Pipe Rail or Fence ................................................................................................. III.139 M8.11.0: Bronze Self -Lubricating Bearing Plates ............................................................................. III.139 M8.13.0: Bridge Railings, Aluminum, TypesAL -1 & AL -3 ............................................................. III.141 M8.13.1: Bridge Railing, Steel, Type S3 -TL4 ....................................................................................... III.141 M8.13.2: Metal Bin -Type Retaining Wall .............................................................................................. III.142 M8.13.3: Aluminum Handrail, Protective Screen Type I and Type II, and Snow Fence .... III.142 M8.14.0: Load Transfer Assembly .......................................................................................................... III.143 M8.15.0: Strand Chuck ................................................................................................................................. III.143 M8.16.0: Electrical Wire & Cable ............................................................................................................. III.144 M8.16.1: Type 1 Traffic Signal Cable (Installed above ground or in Duct) ............................ III.144 M8.16.2: Type 2 Traffic Signal Cable (Installed above ground or in Duct) ............................ III.144 M8.16.3: Type 3 Traffic Signal Cable (Installed above ground) .................................................. III.144 M8.16.4: Type 4 Traffic Signal Cable (Installed above ground) .................................................. III.144 M8.16.5: Type 5 Traffic Signal Cable (Direct Burial) ....................................................................... III.144 M8.16.7: Type 7 General Purpose Wire (XHHW -2 with XLP Jacket) ........................................ III.144 M8.16.8: Type 8 Direct Burial Wire (USE) ........................................................................................... III.144 M8.16.9: Type 9 Special Purpose Wire (TW -THW -UF) .................................................................. III.144 M8.16.10: Type 10 Grounding and Bonding Conductors (Solid or Standard, Insulated or Bare) .................................................................................................................................................... III.145 M8.16.11: Shielded Loop Detector Lead -In cable ............................................................................. III.145 M8.16.12: Type 12 Multi -conductor heavy duty portable power cord ................................... III.145 M8.16.13: Type 13 Loop Detector Wire THHN with Tube ............................................................ III.145 M8.16.14: Type 14 Coaxial Cable ............................................................................................................. III.145 M8.16.15: Type 15 Cat5e Ethernet Cable ............................................................................................. III.145 M8.16.16: Type 16 Twisted Pair Copper Cable ................................................................................. III.145 vi 202 4 Edition M8.16.17: Type 17 Twisted Pair Copper/Fiberoptic Hybrid Cable .......................................... III.146 M8.17.0: Ground Rod .................................................................................................................................... III.146 M8.18.0: Traffic Signal, Highway Lighting and Sign Supports ..................................................... III.146 M8.18.1: Traffic Signal Supports .............................................................................................................. III.146 M8.18.2: Highway Lighting Poles and Arms ....................................................................................... III.147 M8.18.3: Sign Supports ................................................................................................................................ III.147 M8.19.1: Aluminum Sign Panels .............................................................................................................. III.148 M8.20.4: Anti -Glare Systems ..................................................................................................................... III.149 M8.21.0: Stay -in-Place Bridge Deck Forms ......................................................................................... III.149 M8.22.0: Cross Hole Sonic Testing Access Pipes ............................................................................... III.149 Section M9: Miscellaneous Materials ............................................................................................. III.150 M9.00.0: General ............................................................................................................................................ III.150 M9.01.0: Calcium Chloride ......................................................................................................................... III.150 M9.01.1: Sodium Chloride .......................................................................................................................... III.150 M9.02.0: Herbicides ...................................................................................................................................... III.150 M9.03.0: Insecticides .................................................................................................................................... III.150 M9.04.0: Curb and Edging .......................................................................................................................... III.150 M9.04.1: Granite Curb .................................................................................................................................. III.150 M9.04.2: Granite Edgestone ....................................................................................................................... III.152 M9.04.4: Stone for Stone Masonry Walls ............................................................................................. III.154 M9.04.5: Granite Curb Inlets ..................................................................................................................... III.154 M9.04.6: Granite Curb Corners ................................................................................................................. III.155 M9.04.8: Granite Bounds ............................................................................................................................ III.155 M9.04.9: Dry Stone Masonry ..................................................................................................................... III.155 M9.05.0: Lumber and Wood Sheeting ................................................................................................... III.155 M9.05.1: Wood Products ............................................................................................................................. III.155 M9.05.5: Wood Preservatives ................................................................................................................... III.155 M9.05.6: Timber Piles .................................................................................................................................. III.155 M9.06.0: Waterproof Paper Covers ........................................................................................................ III.156 M9.06.1: Polyethylene Covers .................................................................................................................. III.157 M9.06.2: Tar Paper ........................................................................................................................................ III.157 M9.06.3: Burlap ............................................................................................................................................... III.157 M9.06.4: Polyethylene Coated Burlap ................................................................................................... III.157 M9.06.5: Impervious Liquid Membrane ............................................................................................... III.157 M9.07.0: Plastic Waterstops ...................................................................................................................... III.158 M9.08.0: Waterproofing Membranes ..................................................................................................... III.159 M9.08.1: Spray -Applied Waterproofing Membrane ........................................................................ III.159 M9.08.2: Sheet Membrane .......................................................................................................................... III.161 M9.08.3: Hot Applied Rubberized Asphalt Membrane ................................................................... III.162 M9.09.0: Primer and Damp- Proofing ..................................................................................................... III.164 M9.09.1: Primer .............................................................................................................................................. III.164 M9.09.2: Damp -Proofing ............................................................................................................................. III.164 M9.11.0: Insulation and Waterproof Jackets ...................................................................................... III.164 M9.11.1: Cellular Glass ................................................................................................................................. III.164 M9.11.2: Fiberglass ....................................................................................................................................... III.164 vii 202 4 Edition M9.11.3: Polystyrene .................................................................................................................................... III.164 M9.11.4: Urethane ......................................................................................................................................... III.165 M9.11.5: Waterproof Jackets ..................................................................................................................... III.165 M9.12.0: Reflectors for Barriers .............................................................................................................. III.165 M9.13.0: Hydrated Lime .............................................................................................................................. III.165 M9.14.0: Preformed Expansion Joint Filler ......................................................................................... III.165 M9.14.1: Preformed Compression Joint Seals (Bridges) ............................................................... III.165 M9.14.2: Closed Cell Foam Joint Filler ................................................................................................... III.166 M9.14.3: Polyurethane Joint Sealer ........................................................................................................ III.166 M9.14.4: Polyurethane Joint Sealer, Non -Sag ..................................................................................... III.166 M9.14.5: Elastomeric Bridge Bearing Pads ......................................................................................... III.166 M9.14.6: Bonded Closed Cell Joint System .......................................................................................... III.167 M9.15.0: Liquid Penetrant/Sealant ........................................................................................................ III.167 M9.16.1: Rubber -Cotton Duck Bearing Pad ........................................................................................ III.168 M9.16.2: Molded Fabric Bearing Pad ..................................................................................................... III.168 M9.17.0: Asphaltic Binder for Asphaltic Bridge Joint System ..................................................... III.168 M9.17.1: Aggregate for Asphaltic Bridge Joint System ................................................................... III.169 M9.17.2: Backer Rod ..................................................................................................................................... III.169 M9.17.3 Bridge Plate for Asphaltic Bridge Joint System ................................................................ III.170 M9.17.4: Neoprene Seals ............................................................................................................................. III.170 M9.18.0: Impact Attenuators ..................................................................................................................... III.170 M9.18.1: Redirective Impact Attenuators ............................................................................................ III.170 M9.18.2: Non -Redirective Impact Attenuators .................................................................................. III.171 M9.18.3: Low -Maintenance Impact Attenuators ............................................................................... III.171 M9.30.0: Retroreflective Sheeting ........................................................................................................... III.171 M9.30.4: Acrylic Plastic 3.25 Inch Diameter Center -Mount Reflectors ................................... III.172 M9.30.6: Temporary Raised Pavement Markers .............................................................................. III.172 M9.30.7: Guardrail Delineator .................................................................................................................. III.172 M9.30.8: Reflectorized Flexible Delineator Post ............................................................................... III.172 M9.30.9: Reflectorized Drum .................................................................................................................... III.172 M9.30.10: Guardrail Termini Delineator .............................................................................................. III.172 M9.30.11: Traffic Cones ............................................................................................................................... III.173 M9.31.0: Non -motorized Traffic Counting Stations (NTCS) ......................................................... III.173 M9.31.1: NTCS for Intersections .............................................................................................................. III.173 M9.31.2: NTCS for Trails ............................................................................................................................. III.174 M9.40.0: Drilling Slurry ............................................................................................................................... III.174 M9.40.1: Well casing Pipe ........................................................................................................................... III.175 M9.40.2: Water Pumps ................................................................................................................................ III.175 M9.40.3: Chlorine Solution ......................................................................................................................... III.175 M9.40.4: Plastic Water Pipe, Flexible ..................................................................................................... III.175 M9.40.5: Plastic Water Pipe, Rigid (PVC) ............................................................................................. III.175 M9.40.6: Plastic Water Pipe, Rigid (ABS) ............................................................................................. III.176 M9.40.7: Copper Water Tube, Seamless ............................................................................................... III.176 M9.40.8: Steel Water Pipe, Galvanized .................................................................................................. III.176 M9.50.0: Geotextile Fabrics ........................................................................................................................ III.176 viii 202 4 Edition Section M10: Traffic Control Devices ............................................................................................. III.177 M10.00.0: General .......................................................................................................................................... III.177 M10.01.0: Advanced Transportation Controller Cabinets (General) ....................................... III.177 M10.01.1: P4 ATC Cabinet .......................................................................................................................... III.181 M10.01.4: 336S ATC Cabinet ..................................................................................................................... III.190 M10.02.0: Advanced Transportation Controller ............................................................................... III.193
Section M: Materials Section M1: Soils and Borrow Materials Section M2: Aggregates and Related Materials Section M3: Asphaltic Materials Section M4: Cement and Cement Concrete Materials Section M5: Pipe, Culvert Sections and Conduit Section M6: Roadside Development Materials Section M7: Paints, Protective Coatings Section M8: Metals and Related Materials Section M9: Miscellaneous Materials Section M 10: Traffic Control Devices
III.1 202 4 Edition SECTION M : MATERIALS Approval and Acceptance. All materials must be approved prior to incorporation in the work. Approval of materials shall be in accordance with the applicable requirements of Subsection 5.03: Conformity with Plans and Specifications and Section 6.00: Control of Materials. Materials may be approved at the source of manufacture or at the project site. Information regarding the origin, composition and/or manufacture of any material shall be furnished if requested by the Engineer. Approval and acceptance of any material intended for use in the work of the Department is contingent upon the particular material conforming to a designated specification. All questions relating to materials will be resolved by RMS or its duly authorized representative. The Department maintains a QCML of commonly used materials that meet these specifications. Sampling and Testing. Materials will be sampled and tested in accordance with the designated Standards. The applicable edition of the Standard shall be as stipulated in Subsection 1.03: Defined Terms . Sampling of materials will be performed by Department personnel, personnel authorized by the Department or personnel under Department supervision. Certification. Materials accepted on certification as stipulated in Subsection 6.01: Source of Supply and Quality fall into two categories:
A listing of materials falling into one or the other of the above categories will be furnished upon request to RMS .
III.2 202 4 Edition SECTION M1 : SOILS AND BORROW MATERIALS M1.00.0 : General All Soils and borrow materials shall conform to the requirements of the specifications as designated hereinafter. M1.01.0 : Ordinary Borrow Ordinary Borrow shall consist of a material satisfactory to the Engineer and not specified as gravel borrow, sand borrow, special borrow material or other particular kind of borrow. This material shall have the physical characteristics of soils designated as group A -1, A-2-4 or A -3 under AASHTO M 145. It shall have properties such that it may be readily spread and compacted for the formation of embankments. The use of PGA meeting the requirements of M2.01.8: Processed Glass Aggregate may be homogeneously blended with the borrow material up to an addition rate of 10 % by mass in areas that will not be exposed, providing the AASHTO M 145 physical characteristics are maintained. M1.02.0 : Special Borrow Special Borrow shall consist of one of the following:
A-2 with less than 12% passing the No. 200 sieve as determined by AASHTO T 311 .
Percent of wear LA abrasion test .......................................................................................... 50% Maximum Plasticity Index ............................................................................................................................. 6% Maximum Table M1.02.0- 1: Gradation Requirements for Special Borrow Sieve Designation Percent Passing 6 in. 100 2 in. 90-100 No. 4 mesh 20-65 No. 200 mesh 0-12 The use of PGA meeting the requirements of M2.01.8: Processed Glass Aggregate may be blended with either special borrow material outlined above. An addition rate of 10% by mass in areas where the borrow will not be exposed will be allowed, providing the physical characteristics are maintained. The PGA will be blended so as to produce a homogeneous borrow material. M1.03.0: Gravel Borrow Gravel Borrow shall consist of inert material that is hard, durable stone and coarse sand, free from loam and clay, surface coatings, and deleterious materials. III.3 202 4 Edition Gradation requirements for gravel shall be determined by AASHTO T 311 and shall conform to the following: Table M1.03.0- 1: Gradation Requirements for Gravel Borrow Sieve Designation Percent Passing ½ in. 50-85 No. 4 40-75 No. 50 8-28 No. 200 0-10 Maximum size of stone in gravel shall be as follows: M1.03.0 Type a ...................................................................................... 6 in. largest dimension M1.03.0 Type b ..................................................................................... 3 in. largest dimension M1.03.0 Type c ...................................................................................... 2 in. largest dimension M1.03.0 Type d ..................................................................................... 1.5 in. largest dimension The gradation for Gravel Borrow for Bridge Foundations shall have at least 70% passing the ¾- in. sieve. The use of PGA meeting the requirements of M2.01.8: Processed Glass Aggregate may be homogeneously blended with the processed gravel up to an addition rate of 10% by mass, providing the subbase material will not be exposed. The resulting blend will meet the physical requirements of gravel borrow types a, b, c and d specified above. M1.03.1: Processed Gravel for Subbase This specification covers the quality and gradation for subbase material of crusher run gravel. Gravel shall consist of inert material that is hard, durable stone and coarse sand, free from loam and clay, surface coatings and deleterious materials. The coarse aggregate shall have a percentage of wear, by the Los Angeles Abrasion Test, of not more than 50. The gradation shall meet the following requirements: Table M1.03.1- 1: Gradation Requirements for Processed Gravel for Subbase Sieve Designation Percent Passing 3 in. 100 1 ½ in. 70-100 ¾ in. 50-85 No. 4 30-60 No. 200 0-10 The approved source of bank -run gravel material shall be processed by mechanical means. The equipment for producing crushed gravel shall be of adequate size and with sufficient adjustments III.4 202 4 Edition to produce the desired materials. The processed material shall be stockpiled in such a manner to minimize segregation of particle sizes. All processed gravel shall come from approved stockpiles. The use of PGA meeting the requirements of M2.01.8: Processed Glass Aggregate may be homogeneously blended with the processed gravel up to an addition rate of 10% by mass, providing the subbase material will not be exposed. The resulting blend will meet the physical requirements of processed gravel specified above. M1.04.0: Sand Borrow Sand Borrow shall consist of clean inert, hard, durable grains of quartz or other hard durable rock, free from loam or clay, surface coatings and deleterious materials. The allowable amount of material passing a No. 200 sieve as determined by AASHTO T 11 shall not exceed 10% by weight. The maximum particle size for Sand Borrow shall be as follows: M1.04.0 Type a ...................................................................................... ¼ in. M1.04.0 Type b ..................................................................................... ⅜ in. The use of PGA meeting the requirements of M2.01.8: Processed Glass Aggregate will be allowed at an addition rate of 10% mass to type b sand borrow. This addition is allowed providing the material will not be exposed, that the blended material is homogeneous and that the physical requirements specified for Sand Borrow above are main tained. M1.04.1: Sand Borrow for Subdrains Sand for use in subdrain installations shall conform to the requirements of M1.04.0: Sand Borrow with the following grading limitations, as determined by AASHTO T 311 : Table M1.04.1- 1: Gradation Limitations for Sand Borrow for Use in Subdrains Sieve Size Minimum Percent by Weight Passing Through Maximum Percent by Weight Passing Through ½ in. 100 ⅜ in. 85 100 No. 4 60 100 No. 16 35 80 No. 50 10 55 No. 100 2 10 M1.05.0: Loam Loam shall be fertile, friable soil obtained from naturally well- drained areas or shall be the product of a commercial sand and gravel processing facility. It shall be uncontaminated by salt water, foreign matter, or substances harmful to plant growth. Loam shall be free of debris rocks, clods, and any other extraneous matter. Loam for Roadsides shall have no material greater than 1 in. in diameter. Loam for Lawns shall have no material greater than ½ in. in diameter. Loam shall have the following mechanical analysis: III.5 202 4 Edition Table M1.05.0- 1: Gradation Requirements for Loam Sieve Size Percent Passing No. 10 85-100 No. 40 35-85 No. 200 10-35 <20 µm <5 Testing shall be on material that has passed the No. 10 sieve. Loam shall contain 4% to 10% organic matter as determined by the loss on ignition of oven -dried samples. Lawn areas shall have an organic content of at least 4%. Organic content for lawn areas shall be at least 4%; for woody plantings, organic content shall be 7% to 10%. Salinity (electrical conductivity) shall be less than 0.1 S/m as determined by a 1:2 (by volume) soil -to-water mix. Salt test samples shall not be oven - dried. The acidity range of the Loam shall be pH 5.5 to 7.0. The Contractor shall provide testing submittals as follows: • One 25-lb representative sample per source of loam • For sources providing >1,000 yd ³, one additional 25 -lb representative sample for each 1,000 yd³ unit of soil In addition, five random representative 25 -lb samples of on -site stockpiles of delivered loam shall be collected and packaged in the presence of the Engineer. The Contractor shall deliver samples to testing laboratories and shall have the testing report sent directly to the Engineer. Testing and analysis will be at the Contractor's expense. Soil samples shall be dry. Tests for particle gradation, organic content, and pH shall be performed by an Agricultural Experiment Station testing laboratory or other testing laboratory approved by t he Engineer. Soil analysis tests shall show recommendations for soil additives to correct soils deficiencies, and for additives necessary to accomplish particular planting objectives noted. University of Massachusetts Agricultural Extension Service methods for soil and soil additive analysis shall be used. No Loam shall be delivered to the site until the review and approval of loam test results by the Engineer. M1.06.0: Compost The Contractor shall submit for approval a written list of all vendors of manufactured compost that will be used on the project, includi ng locations of compost facilities and feedstock materials. All vendors shall submit certified results of regular periodic testing by an approved testing facility. Certification shall be per US Composting Council Seal of Testing Assurance (STA) Program . In addition, the Contractor shall provide representative 1- gallon samples from each proposed source for testing and analysis. The Contractor shall deliver samples to testing laboratories and shall have the testing report sent directly to the Engineer. Compost tests shall be performed by STA - certified laboratory. (https://www.compostingcouncil.org/page/CertifiedLabs ) III.6 202 4 Edition Compost shall be a well -decomposed humus material derived from the aerobic decomposition of biodegradable matter, free of viable weed seeds and other plant propagules (except airborne weed species), foreign debris such as glass, plastic, etcetera and substances toxic to plants. Compost shall be suitable for use as a soil amendment and shall support the growth of ornamental nursery stock and turf establishment. Compost shall be in a shredded or granular form and free from hard lumps. Food and agriculture residues, animal manure are acceptable source materials. Biosolids and peat are not acceptable as source materials. Composted material with an unpleasant odor, such as that of ammonia or fecal material shall be rejected by the Engineer. Compost shall have the following properties: III.7 202 4 Edition Table M1.06.0- 1: Compost Properties by Type of Compost Parameter Units Type 1 Organic Amendment to Loam Type 2 Compost Blanket and Compost for Modified Rock Type 3 Compost Filter Berm Type 4 Sediment Barrier Media pH pH Scale Range 6.0-8.5 6.0-8.5 6.0-8.5 5.0-8.5 Soluble Salt Concentration (Electrical Conductivity) dS/m Max 10 Max 5 Max 5 Max 10 Moisture Content %, wet weight 30-60 30-60 30-60 < 60 Organic Matter Content %, dry weight 30-65 25-65 25-65 25-100 Particle Size % passing a selected mesh size, dry weight basis 3 in. - 100 100 100 2 in. 99-100 1 in. - 90-100 90-100 - ¾ in. - 65-100 70-100 ⅜ in. 95 - - 0-50 ¼ in. 95 0-75 30-75 (no more than 60% passing in high rainfall/flow rate situations) - Particle length Max. 6 in . Max. 6 in . Max. 6 in . Max. 2 in . Stability (Carbon Dioxide Evolution Rate ) mg CO2 -C per g OM per day < 4 < 4 < 4 < 8 Maturity (plant bioassay) %, germination and vigor > 80 / 80 > 80 / 80 N/A N/A Physical Contaminants (Man -made inert materials) %, dry weight < 0.5% (0.25% film plastic) < 0.5 (0.25 film plastic) < 0.5 (0.25 film plastic) < 0.5 (0.25) film plastic)
III.8 202 4 Edition M1. 08.0: Impervious Soil Borrow Impervious Soil shall have the physical characteristics of one of the following, under AASHTO M 145:
The Impervious Soil shall be reasonably free of stumps, brush, and stones larger than 3 in. in diameter. Material excavated near salt water to be used as impervious soil will be tested for salt content. The maximum soluble salt index shall be 100. M1.09.0: Reclaimed Pavement Borrow Material Reclaimed Pavement Borrow material shall consist of crushed asphalt pavement and/or crushed cement concrete, and gravel borrow meeting M1.03.0: Gravel Borrow . The material shall be free of loam, clay, and deleterious materials such as brick, reinforcing steel, wood, paper, plaster, lathing, and building rubble, etc. The coarse aggregate shall have a percentage of wear not greater than 50 as measured by the Los Angeles Abrasion Test. Gradation requirements shall be determined by AASHTO T 311 except the material shall not be oven dried. It shall be air dried, fan dried at low speed, or other low temperature heat so as not to liquefy the asphalt or cause the asphalt to adhere to the sieves. Water used for the No. 200 sieve analysis shall be cold tap water. The gradation shall meet the following requirements: Table M1.09.0- 1: Gradation Requirements for Reclaimed Pavement Borrow Sieve Designation Percent Passing 3 in. 100 1 ½ in. 70-100 ¾ in. 50-85 No. 4 30-60 No. 50 8-24 No. 200 0-10 The portion of materials passing the No. 40 sieve shall have a liquid limit not greater than 25 and a plasticity index not greater than 6. The reclaimed pavement borrow shall be compacted to a minimum of 95% of AASHTO T 180 proctor density. Liquid limits shall be determined by AASHTO T 90. Reclaimed pavement borrow material shall be processed by mechanical means and blended to form a homogeneous material. The equipment for producing crushed material shall be of adequate size and have sufficient adjustments to produce the desired materials. Blended materials that are III.9 202 4 Edition stockpiled for more than 3 months shall be reworked to a uniform material and retested prior to use however, the Engineer may require additional testing any time the materials appear excessively hard, wet and/or segregated. The processed materials shall be stockpiled in such a manner as to minimize segregation of particle sizes. All reclaimed pavement borrow material shall come from approved sources and stockpiles. The amount of combined crushed asphalt pavement and crushed cement concrete shall not exceed 50% by volume as determined by visual inspection, and/or by laboratory tests required by the Engineer. M1.10.0: Pavement Milling Mulch Pavement milling mulch shall consist of recently milled asphalt concrete pavement. The milled material shall meet the following gradation requirements as determined by AASHTO T 311 : Table M1.10.0- 1: Gradation Requirements for Pavement Milling Mulch Square Opening Sieve Percent Passing by Weight 1 ½ in. 100 1 in. 85-100 ½ in. 10-98 No. 4 0-70 No. 200 0-12
III.10 202 4 Edition SECTION M2 : AGGREGATES AND RELATED MATERIALS M2.01.0 : Crushed Stone Crushed stone shall consist of one or the other of the following materials:
crushing solid or shattered natural rock, and free from a detrimental quantity of thin, flat, elongated* or other objectionable pieces. A detrimental quantity will be considered as any amount in excess of 15% of the total weight.
with a minimum diameter before crushing of 8 in. *Thin or elongated pieces are defined as follows: Thin stones shall be considered to be such stones whose average width exceeds 4 times their average thickness. Elongated stones shall be considered to be such stones whose average length exceeds 4 times their average width. The crushed stone shall be reasonably free from clay, loam or deleterious material and not more than 1.0% of satisfactory material passing a No. 200 sieve will be allowed to adhere to the crushed stone. Where crushed stone is to be used for surfacing, this requirement shall be not more than 0.5% of satisfactory material passing a No. 200 sieve. The crushed stone shall have a maximum percentage of wear as determined by the Los Angeles Abrasion Test (AASHTO T 96) as follows:
**Crushed stone for this use shall consist of crushed or shattered natural rock only. Crushed gravel stone will not be permitted. ***Except for 5 ,000 psi or greater cement concrete and prestressed concrete which shall be 30%. The crushed stone shall be uniformly blended according to the grading requirements for the respective stone sizes shown in Table M2.01.0 -1. III.11 202 4 Edition Table M2.01.0- 1: Tabulation of Stone Sizes Percent by Weight Passing Through Square Opening Sieve M2.01.1 & M2.02.2 M2.01.3 M2.01.4 M2.01.5 M2.01.6 1 ½ in. 1 ¼ in. ¾ in. ½ in. ⅜ in. 2 ½ in. 2 in. 100 1 ½ in. 95-100 100 1 ¼ in. 85-100 1 in. 35-70 100 ¾ in. 0-25 10-40 90-100 ⅝ in. 100 ½ in. 0-8 10-50 85-100 100 ⅜ in. 0-20 15-45 85-100 No. 4 0-5 0-15 20-50 No. 8 0-5 0-15 No. 16 0-5 M2.01.7: Dense Graded Crushed Stone for Sub -base This Specification covers the quality and gradation requirements for a sub -base material combining crusher -run coarse aggregates of crushed stone (trap only, meeting M2.01.0,1), and fine aggregates uniformly premixed with a predetermined quantity of water. Coarse aggregate shall consist of hard, durable particles of fragments of stone. Materials that break up when alternately frozen and thawed or wetted and dried shall not be used. Coarse aggregate shall have a percentage of wear, by the Los Angeles test, of not more than 45. Fine aggregate shall consist of natural or crushed sand. The composite material shall be free from clay, loam or other plastic material, and shall conform to the following grading requirements: Table M2.01.7- 1, Gradation Requirements for Dense Graded Crushed Stone for Sub -base Sieve Designation Percentage by Weight Passing Square Mesh Sieves 2 in. 100 1 ½ in. 70-100 ¾ in. 50-85 No. 4 30-55 No. 50 8-24 No. 200 3-10 III.12 202 4 Edition Testing shall be in accordance with AASHTO T 311. The use of PGA meeting the requirements of M2.01.8: Processed Glass Aggregate will be allowed at a maximum addition rate of 10% mass, providing the blended material is homogeneous and the physical requirements of dense graded crushed stone are maintained. M2.01.8: Processed Glass Aggregate PGA shall be manufactured from an approved supplier of crushed cullet. The material shall consist of recycled glass food or beverage containers free of debris such as paper, metals, fabrics, toxins, clay, loam, or other materials that would be associated with the glass recycling process. A maximum of 5% mass of the material may be produced from china dishes, ceramics, plate glass or other glass products. The material will have a nominal aggregate size of ⅜ in. and meet the following gradation requirements. Table M2.01.8- 1: Gradation Requirements for P rocessed Glass Aggregate Sieve Designation Percent by Mass Passing ⅜ in. 100 No. 4 70-100 No. 8 35-88 No. 16 15-40 No. 50 4-12 No. 200 0-5 The percent wear as determined by the Los Angeles Abrasion Test, Class C or D will be a maximum of 40%. M2.02.0: Riprap Riprap shall be sound, durable rock which is angular in shape. Rounded stones, boulders, sandstone or similar soft stone or relatively thin slabs will not be acceptable. Each stone shall weigh not less than 50 lb and at least 75% of the volume shall consist of stones weighing not less than 500 lb each. The remainder of the stones shall be so graded that when placed with the larger stones the entire mass will be compact. M2.02.1: Rockfill Stone for rockfill shall be sound, angular in shape, free from structural defects and comparatively free of chemical decay. From 50% to 70% of the stones shall weigh not less than 500 lb each and remainder shall weigh not less than 50 lb each. M2.02.2: Dumped Riprap Stone used for dumped riprap shall be hard, durable, angular in shape, resistant to weathering and shall meet the gradation requirement specified. Neither breadth nor thickness of a single stone should be less than one -third its length. Rounded stone or bo ulders will not be accepted. Stone shall be free from overburden, spoil, shale, and organic material and shall meet the following gradation requirement specified: III.13 202 4 Edition Table M2.02.2- 1: Gradation Requirements for Dumped Riprap Size of Stone (lb) Maximum Percent of Total Weight Smaller Than Given Size 400 100 300 80 200 50 *25 10 *No more than 5% by weight shall pass a 2 in. sieve. Each load of riprap shall be reasonably well graded from the smallest to the maximum size specified. Stones smaller than the specified 10% size and spalls will not be permitted in an amount exceeding 10% by weight of each load. Control of gradation will be by visual inspection. The Contractor shall provide at the locations specified a mass of rock of at least 5 tons meeting the gradation for the class specified. The sample at the construction site may be a part of the finished riprap covering. At the quarry, an additional sample shall be provided. These samples shall be used as a frequent reference for judging t he gradation of the riprap supplied. Any difference of opinion between the Engineer and the Contractor shall be resolved by dumping and checking the gradation of two random truckloads of stone. Mechanical equipment, a sorting site and labor needed to assist in checking gradation shall be provided by the Contractor at no additional cost to the Department. M2.02.3: Stone for Pipe Ends Stone for pipe ends shall be sound, durable rock which is angular in shape. Rounded stones, boulders, sandstone or similar stone or relatively thin slabs will not be acceptable. Each stone shall weigh not less than 50 lb not more than 125 lb and at least 75% of the volume shall consist of stones weighing not less than 75 lb each. The remainder of the stones shall be so graded that when placed with the larger stones the entire mass will be compact. M2.02.4: Modified Rockfill Modified rockfill shall consist of hard, durable angular shaped stones which are the product of the primary crushing of a stone crusher. Rounded stone, boulders, sandstone and similar soft stone or relatively thin slabs will not be acceptable. Stone shall be free from overburden, spoil, shale, organic material and meet the following gradation requirements: Table M2.02.4- 1: Gradation Requirements for Modified Rockfill Size of Stone (in.) Passing Percentages 8 95-100 4 0-25 2 ½ 0-5 III.14 202 4 Edition M2.03.0: Granite Rubble Block Rubble pavement blocks shall be granite, basically light grey in color, free from seams and other structural imperfections or flaws which would impair its structural integrity, and of a smooth splitting appearance. Natural color variations characteristic of the deposit fr om which the paving blocks are obtained will be permitted. Rubble pavement blocks shall be not less than 4 in. nor more than 12 in . in length, not less than 3.5 in. nor more than 4.5 in . in width and depth. Rubble blocks shall be rectangular in shape with one good face. Opposite faces of rubble blocks shall be approximately parallel and adjoining faces shall be approximately at right angles to each other. Blocks shall be dressed so that they may be laid with 1 in. to 1.5 in . joints. M2.04.0: Aggregate for Sand Blasting Aggregate to be used for sand blasting shall be an approved material currently used in the industry. It shall be graded to produce the profile requirements of the material being cleaned and shall meet the applicable requirements of OSHA, EPA, and DEP . M2.05.0: Stone Screenings Stone Screenings shall be that product from a stone crusher that completely passes a No. 4 sieve and not less than 40% passes a No. 8 sieve. M2.06.0: Slope Paving Stone for slope paving shall be sound, angular in shape and free from structural defects. Each stone shall have one reasonably flat face and a thickness perpendicular to the face of not less than 6 in ., which shall be the least dimension of the stone. Approximately 60% of the stones shall vary from 2 ft³ to 3 ft ³ each in volume and the remainder of the stones shall each be from 1 ft³ to 2 ft ³ in volume. M2.06.1: Special Slope Paving Under Bridge (Quarry Stone). Quarry stone shall consist of granite or other similar durable stone. The exposed surface of the stones shall range from roughly square to rectangular shape, with split or quarry face finish and uniform in color. The stones shall be from 12 in . to 28 in . long, 10 in . to 14 in . wide and from 3 in . to 6 in. thick. M2.06.2: Channel Paving Stones for Channel Paving and Grouted Channel Paving shall be sound, approved quality angular blocks, as nearly rectangular or cubical as practicable. Rounded stones or relatively thin slabs will not be acceptable. At least 75% of the volume shall consist of stones weighing at least 200 lb each. The remainder of the stones shall be so graded that when placed with the larger stones a compact mass will result.
III.15 202 4 Edition SECTION M3 : ASPHALTIC MATERIALS M3.00.0 : General Asphaltic materials (also referred to as bituminous materials) include liquid asphalts as well as Hot Mix Asphalt (HMA) mixtures and other related materials. All asphaltic materials shall conform to the requirements of the specifications as designated here inafter. The sampling of liquid asphalt materials shall be in accordance with AASHTO R 66. The following procedure shall be followed in obtaining liquid asphalt samples from pressure distributors or tankers used for the transport of liquid asphalt materials:
valves on tankers shall be installed in the rear bulkhead approximately ⅓ of the height from the bottom. The sampling valves on pressure distributors may be located in the side of the tank somewhere in the middle third of the tank depth.
containers with solvents or water will not be permitted. M3.01.0: Performance Graded Asphalt Binder Performance Graded Asphalt Binder (PGAB) delivered to a project or to an HMA plant must be accompanied by a Bill of Lading (BOL) signed by the asphalt binder Supplier’s authorized representative in accordance with AASHTO R 26. Shipments of material not accompanied by a BOL will not be accepted for use in the work. The PGAB Supplier and the Contractor shall perform random Quality Control (QC) sampling and testing of PGAB as specified in 450.65: Quality Control Sampling and Testing Requirements, Part F(1). The Contractor shall furnish, to the Engineer, the PGAB Supplier’s BOL for each truckload of asphalt binder shipped to the project or HMA plant. The Contractor shall also submit to the Engineer the Supplier’s Certificate of Compliance (COC) along with copies of the Certificate of Analysis (COA) showing the certified AASHTO M 320 test results for each Supplier Lot of PGAB. The COA shall meet the requirements of AASHTO R 26. The Contractor shall maintain a copy of the COA for each Lot of PGAB used, with a copy attached to each sample obtained for testing. The Contractor shall assist the Engineer in obtaining random Department Acceptance samples of PGAB from the HMA plant in accordance with AASHTO R 66 and as specified in 450.74: Acceptance Sampling & Testing, Part C. Each sample shall be labeled with the PGAB grade, Supplier source and Lot number, sampling location, quantity represented, project name, plant, date, and the sampling inspector. When the PGAB is used for HMA production under Subsection 450: Hot Mix Asphalt Pavement the sample shall be obtained from an in -line sample valve located between the asphalt tanks and mixing chamber at a sampling location downstream of all additive injection ports. The Engineer will test the Department Acceptance samples for verification of the PGAB grade. The material shall conform to the specification requirements for the applicable performance grade as specified herein. Material not conforming to specification r equirements shall be subject to corrective action, production suspension, rejection, or removal as determined by the Engineer. III.16 202 4 Edition The blending of binder of different grades or binder from different Suppliers at the HMA plants is strictly prohibited without the Engineer’s approval. Contractors may switch to another approved source of binder, upon written notification to the Engineer, and by certifying that the tank to be utilized has been drained to an un -pumpable condition. The binder tanks at the HMA production facility shall be managed in a manner which prevents contamination. The Contractor shall not switch binder suppliers in th e middle of a production Lot as defined in 450.20: Quality Assurance, Part B. Contractors who modify, blend PG binders, or add additives to the PGAB at the HMA production facility will be reclassified as a Supplier and shall be required to certify the binder in accordance with AASHTO R 26. A copy of the COA for each Lot shall be provided in accordance with AASHTO R 26. The data reported shall meet the requirements of the specific binder specification:
M3.01.1: Standard Asphalt Binder Grade The asphalt binder for HMA mixtures shall be a PGAB which meets the specification requirements of AASHTO M 320. PGAB shall be provided by an Approved Supplier in accordance with AASHTO R
The standard PGAB Grade of PG64 -28 shall be used. M3.01.2: Modified Asphalt Binder Grades When specified by the contract documents, the PGAB shall be modified in accordance with the following:
The polymer modified asphalt binder shall be a PGAB which meets the specification requirements of AASHTO M 332, however “E” grades will not be subject to the J nrdiff difference requirement. PGAB shall be provided by an approved Supplier in accordance with the AASHTO R 26. The modified PGAB Grade of PG64E -28 shall be used.
The modified binder shall be in accordance with ASTM D6114 -09, Type II. Virgin PGAB for the crumb rubber modified asphalt shall be a PG 58 -28 or PG 64- 28 provided by an approved Supplier in accordance with the AASHTO R 26. The grade selected shall be based on laboratory testing by the asphalt -rubber Manufacturer. The granulated rubber shall be vulcanized rubber product from the ambient temperature processing of scrap, pneumatic tires. The granulated rubber shall meet the gradation found in Table M3.01.2- 1. III.17 202 4 Edition Table M3.01.2- 1: Crumb Rubber Gradation Sieve Size Percent by Weight Passing No. 10 100 No. 16 90-100 No. 30 25-100 No. 80 0-20 The use of crumb rubber of multiple types from multiple sources is acceptable provided that the overall blend of crumb rubber meets the gradation requirements. The length of the individual rubber particles shall not exceed ⅛ in. The rubber shall be certified by the crumb rubber Manufacturer. The percent of crumb rubber shall be a minimum of 15% by weight of binder. The temperature of the asphalt shall be between 350°F and 400°F at the time of addition of the granulated crumb rubber. The asphalt and crumb rubber shall be combined and mixed together in a blender unit and reacted in the distributor for a period of time as required by design. The temperature of the asphalt -rubber mixture shall be above 325°F during the reaction for a period of one hour. M3.01.3: Asphalt Binder Grade for Recycled Asphalt Materials For any HMA mixture containing recycled asphalt materials, a binder that is softer than the standard asphalt binder shall be utilized in the mixture to account for the amount and stiffness of the recycled binder in accordance with Table M3.01.3 -1. If greater than 25% Reclaimed Asphalt Pavement (RAP) or any quantity of Recycled Asphalt Shingles (RAS) are used in an asphalt mixture, the virgin PGAB grade when blended with the RAP binder shall meet the binder grade specified by the project. The resulti ng final PGAB grade shall be in accordance with Table M3.01.3 -1. Only PGABs meeting the requirements of AASHTO M 320 or M 323 will be used. The type and amount of virgin asphalt binder to be used in the HMA mixture shall be included as part of the Laboratory Trial Mix Formula (LTMF). The Contractor shall submit certified test results from an AASHTO accredited laboratory showing the testing of the individual binders and the blending. Table M3.01.3- 1: PGAB Grades for HMA Containing RAP/RAS Amount of RAP in Mixture Virgin PGAB Grade Resulting PGAB Grade ≤25% RAP by Weight of Mixture Project Specified Grade Project Specified Grade >25% to 40% RAP by Weight of Mixture Follow AASHTO M 323 Appendix X1 Project Specified Grade ≤5% RAS by Weight of Mixture Follow AASHTO PP 78 Project Specified Grade M3.01.4: Warm Mix Asphalt Additive All HMA shall be modified using a WMA additive. The WMA additive shall be listed on the QCML. No WMA foaming technology which requires the mechanical injection of steam or water into the liquid asphalt will be permitted. III.18 202 4 Edition For HMA placed on bridge decks, the WMA additive shall not be used to lower the mixing and compaction temperatures. The mixing and compaction temperatures specified for the binder prior to addition of the WMA additive shall be used. The WMA additive must be compatible with polyphosphoric acid modified binders, polymer modified binders, and anti -stripping agents. The WMA additive shall be introduced in accordance with the Manufacturer’s dosing rates and approved blending methods. The HMA mixture design shall incorporate the requirements of AASHTO R 35 Appendix X2: Special Mixture Design Considerations and Practices for Warm Mix Asphalt (WMA). Laboratory mixing and compaction temperatures shall be reduced per the WMA Manufacturer’s recommendations, however, the optimum laboratory compaction temperature for unmodified asphalt binders shall be less than 260°F. Target laboratory mixing and compaction temperatures shall be submitted to the RMS for review prior to performing a mix design. When the asphalt binder is modified with the WMA additive at the HMA plant, all WMA additive equipment shall be fully automated and integrated into the plant controls and shall record actual dosage rates on the plant printouts. The Contractor’s QSM shall provide mixture production and placement alterations due to the WMA additive and shall incorporate the modification of asphalt binders when the WMA additive is blended with the asphalt binder at the plant. This plan shall specifically address WMA me tering requirements, tolerances and other QC measures. M3.01.5: Asphalt Anti -Stripping Additive An anti -stripping additive may be required in a HMA mixture to increase the resistance of the asphalt binder coating to stripping in the presence of water. An anti -stripping additive may be a liquid anti -strip or hydrated lime. The Engineer may verify the effectiveness of the anti -strip used in a HMA mixture. When added at the dosage rate recommended by the Manufacturer to a HMA mixture showing moisture susceptibility, the anti- strip shall cause an improvement to the mixture’s mo isture susceptibility. This shall be determined by testing specimens with and without the anti -strip additive in accordance with AASHTO T 324. If the antistrip does not show an improvement in the moisture susceptibility the additive will not be permitted f or use. The Manufacturer shall certify that the material is in accordance with this specification. The Manufacturer shall submit a COC for each Lot in accordance with Division 1 Section 6.0. The COC shall also include the:
The hydrated lime for HMA shall conform to the requirements of AASHTO M 303.
The anti -strip Manufacture shall submit product documentation, including the recommended dosage rate, to RMS for approval. Approved anti -strip additives shall be listed on the QCML. III.19 202 4 Edition Anti -stripping additives shall be an organic chemical compound free from inorganic mineral salts or inorganic mineral soaps. The anti -strip additive shall be chemically inert to asphalt binder and shall not appreciably alter the specified characteristics of the asphalt binder. When blended with asphalt binder, it shall be stable and withstand storage at a temperature of 400°F for extended periods without loss of effectiveness. M3.01.6: Asphalt Release Agents Approved asphalt release agents shall be tested in accordance with AASHTO T 383 and be listed on the QCML. The asphalt release agent shall not be detrimental to the HMA and shall not dissolve asphalt binder when applied to the truck bed. Dilution by diesel or other petroleum products will not be permitted. M3.02.0: Cutback Asphalts These materials shall be blends of asphalt cements and suitable solvents. They shall be homogeneous, free from water and conform to the requirements of AASHTO M 81 for the rapid curing type and AASHTO M 82 for the medium curing type. M3.03.0: Asphalt Emulsions Approved asphalt emulsions suppliers will be on the QCML. M3.03.1 : Anionic Emulsified Asphalt These materials shall conform to the requirements of AASHTO M 140. Anionic emulsion used for tack coat shall be grade RS -1h. When HMA paving takes place between November 1 st and March 31st the use of RS -1 is acceptable. When supplied in 5 -gallon buckets the anionic emulsion used for tack coat shall be grade RS -1. M3.03.2 : Cationic Emulsified Asphalt This material shall conform to the requirements of AASHTO M 208. Cationic asphalt emulsion used for tack coat shall be grade CRS -1h. When HMA paving takes place between November 1 st and March 31st the use of CRS -1 is acceptable. When supplied in 5 -gallon buckets the cationic emulsion used for tack coat shall be grade CRS -1. M3.03.3 : Polymer Modified Emulsified Asphalt This material shall conform to the requirements of AASHTO M 316. Polymer modified asphalt emulsion used for tack coat shall be grade CRS -1P. M3.05.0 : Pavement Crack Sealers and Joint Adhesives The material shall pour readily and penetrate a ¼ inch pavement crack or joint to a depth of at least 1 inch when the application temperature of the fully reacted mixture is 350 ℉ and the air temperature is 35℉ or higher. The material, when placed with conventional field installation equipment, shall readily melt to a pumping consistency after being heated to 400 ℉ for a maximum of 2 h r. The mixture shall remain III.20 202 4 Edition in a pumping consistency when the temperature of the field installation equipment is reduced to the normal operating temperature range of 300 ℉ to 350℉ . M3.05.1: Chemically Modified Crumb Rubber Crack Sealer Chemically modified crumb rubber crack sealer (CMFR) shall be a polymer modified performance graded asphalt binder which also incorporates crumb rubber and fibers.
rubber that meets the following specifications: • The SBS and Rubber modified binder shall meet a grade of PG64E- 28 with a JnR3.2 < 0.5. • The PGAB utilized in the CMCR shall be a PG58 -28 and shall comply with the requirements of M3.01.0: Performance Graded Asphalt Binder . • The modified binder shall contain a minimum of 3% SBS polymer. • The modified binders shall contain a minimum of 7% 80 mesh crumb rubber. • The asphalt binder supplier shall provide testing for the base asphalt binder and modified asphalt binder in accordance with AASHTO M 320 and M 332.
Table M3.05.1 -1.
Table M3.05.1- 1: Polyester Fiber Requirements Characteristic Test Method Requirement Length (See Note 1) 0.25 in.+0.02 Elongation at break ASTM D2256 38% Melting point ASTM D3418 > 475℉ Crimps per inch ASTM D3937 None Cross Section Round Denier ASTM D1577 4.5 Nominal dpf Tensile Strength ASTM D2256 >70,000 psi Diameter 0.0008 in. (See Note 2) Specific Gravity ASTM D792 1.32 to 1.40
M3.05.2: Hot Applied Crack Sealer This sealer shall meet the requirements of ASTM D6690 Type II. Products shall be listed on the QCML. III.21 202 4 Edition M3.05.3: Asphalt -Fiber Crack Sealer Asphalt -fiber crack sealer shall be a performance graded asphalt binder blended with fibers.
the requirements of M3.01.0: Performance Graded Asphalt Binder .
Table M3.05.1- 1.
M3.05.4: Hot Applied Pavement Joint Adhesive This material shall be a hot applied asphaltic product designed to adhere and seal HMA construction joints. The material shall meet the requirements of Table M3.05.4 -1. Table M3.05.4- 1 Hot Applied Pavement Joint Adhesive Property Test Method Requirement Flash Point AASHTO T 48 > 410 ℉ Ductility (See Note 1) AASHTO T 51 > 300 mm Ductility (See Note 2) AASHTO T 51 > 300 mm Softening Point AASHTO T 53 > 170°F Viscosity (See Note 3) ASTM D3236 4,000 – 10,000 cp Asphalt Compatibility ASTM D5329 Pass Cone Penetration (See Note 1) ASTM D5329 60 – 100 mm Resilience (See Note 1) ASTM D5329 > 30 % Tensile Adhesion (See Note 1) ASTM D5329 > 500 %
The manufacturer must supply all current product literature, including technical data sheets and Safety Data Sheets (SDS). This shall include information relevant to the material’s use, its limitations, material properties, instructions for storage, mixing, and application. As part of the evaluation, the Department will review the submitted laboratory test results. Qualified products will be listed on MassDOT’s QCML. M3.05.5: Preformed Bituminous Joint Filler for Concrete This material shall be a non -extruding and resilient bituminous type preformed expansion joint filler. It shall conform to the requirements of AASHTO M 213. M3. 06.0: Hot Mix Asphalt M3. 06.1: General All HMA mixtures shall meet the requirements of the Superpave volumetric mix design system as well as the following. Asphalt mixtures shall be composed of the following: III.22 202 4 Edition 1. Mineral aggregate
The use of recycled materials shall be at the Contractor's option in accordance with these specifications. And as permitted, recycled materials shall be limited to:
Each HMA pavement course placed shall be compromised of one of the mixture types listed in Table 450.10 -1. M3. 06.2: Aggregate for Hot Mix Asphalt
The coarse mineral aggregate shall be clean, hard, durable, crushed rock consisting of the angular fragments obtained by breaking and crushing shattered natural rock, reasonably free from thin and/or elongated pieces, free from dirt or other objectionable materials. It shall be surface dry and shall have a moisture content of not more than 0.5 percent after drying. Aggregates from multiple sources of supply shall not be mixed or stored in the same stockpile.
The fine aggregate shall consist of one of the following:
Engineer.
Natural sand shall consist of inert, hard, durable grains of quartz or other hard, durable rock, free from topsoil or clay, surface coatings, organic matter or other deleterious materials. Stone sand shall be a processed material prepared from stone screenings to produce a consistently graded material conforming to specification requirements. Stone screenings shall be the product of a secondary crusher and shall be free from dirt, clay, organic matter, excess fines or other deleterious material.
Aggregates utilized in HMA mixtures, including RAP if used in the mixture, shall be tested for conformance with the Consensus Property requirements outlined in AASHTO M 323 Sections 6.2 to 6.6 and Table M3.06 .2-1 below. III.23 202 4 Edition Table M3.06.2-1 : Aggregate Consensus Property Requirements Traffic Level Design ESALs (Millions) (See Note 1) Fractured Faces, Coarse Aggregate % Minimum (See Note 2) Uncompacted Content of Fine Aggregate % Minimum Sand Equivalent % Minimum Flat and Elongated % Maximum (See Note 2) All Courses (except Base Course) Base Course All Courses (except Base Course) Base Course 1 <0.3 55/-- --/-- -- (See Note 4) -- 40 -- 2 0.3 to <10 85/80 (See Note 3) 60/-- 45 40 45 10 3 ≥10 95/90 80/75 45 40 45 10
of the actual design life of the roadway, determine the design ESALs for 20 years.
fractured faces.
minimum Uncompacted Void Content is 40.
The coarse aggregate utilized in asphalt mixtures shall be clean, crushed rock consisting of the angular fragments obtained by breaking and crushing shattered natural rock. It shall be free from dirt or other objectionable materials. The coarse aggregate, including RAP if used in the mixture, shall be tested for conformance with the requirements indicated in Table M3.06.2 -2. The specific gravity of each aggregate component shall be determined as specified in Table M3.06 .2-3 below. To determine the bulk specific gravity of RAP aggregate the method outlined in FHWA Publication Number FHWA -HRT -11-021 “Reclaimed Asphalt Pavement in Asphalt Mixtures: State of the Practice” shall be used. The following excerpt is the method to be followed: If the source of RAP is known and original construction records are available, the bulk specific gravity (BSG) value of the virgin aggregate from the construction records may be used as the BSG value of the RAP aggregate. However, if original construction records are not available, the recommended procedure for estimating BSG of the RAP aggregate is a simple three -step process as follows: III.24 202 4 Edition 1. Determine the maximum theoretical specific gravity of the RAP mixture, 𝐺𝐺𝑚𝑚𝑚𝑚𝑅𝑅𝑅𝑅𝑅𝑅, according to AASHTO T 209.
content of the RAP mixture ( 𝑃𝑃𝑏𝑏) and an assumed asphalt specific gravity ( 𝐺𝐺𝑏𝑏) as follows: 𝐺𝐺𝑠𝑠𝑠𝑠𝑅𝑅𝑅𝑅𝑅𝑅=100− 𝑃𝑃𝑏𝑏 100𝐺𝐺𝑚𝑚𝑚𝑚�−𝑃𝑃𝑏𝑏𝐺𝐺𝑏𝑏� Where: 𝐺𝐺𝑏𝑏= 1. 030
of the RAP aggregate, 𝐺𝐺𝑠𝑠𝑏𝑏𝑅𝑅𝑅𝑅𝑅𝑅, from the calculated 𝐺𝐺 𝑠𝑠𝑠𝑠𝑅𝑅𝑅𝑅𝑅𝑅. 𝐺𝐺𝑠𝑠𝑏𝑏𝑅𝑅𝑅𝑅𝑅𝑅=𝐺𝐺𝑠𝑠𝑠𝑠𝑅𝑅𝑅𝑅𝑅𝑅 �𝑅𝑅𝑏𝑏𝑏𝑏×𝐺𝐺𝑠𝑠𝑠𝑠𝑅𝑅𝑅𝑅𝑅𝑅 100𝐺𝐺𝐵𝐵+1�� Table M3.06.2-2 : Aggregate Source Property Requirements Source Property Test Test Method Limit Toughness AASHTO T 96 Maximum Loss < 30% Soundness (See Note 1) AASHTO T 104 Maximum Loss < 10% Deleterious Materials AASHTO T 112 Maximum Permissible < 0.5%
Table M3.06.2-3 : Aggregate Specific Gravity Test Method Aggregate Type Test Method Coarse AASHTO T 85 Fine AASHTO T 84 or ASTM D7370 Mineral Filler AASHTO T 100 RAP From FHWA -HRT- 11-021
RAP shall meet the requirements of M3.06.2: Aggregate for Hot Mix Asphalt , Paragraphs C and D as well as the following. RAP shall consist of the material obtained from state highways or streets by crushing or milling existing HMA pavements. This material shall be transported to the HMA production facility yard and processed thro ugh an appropriate crusher so that the resulting material will contain no particles larger than the maximum aggregate size of the HMA mixture in which it will be used. The RAP shall be stockpiled on a free draining base and kept separate from the other aggregates. RAP stockpiles shall be covered by a framed structure which prevents the intrusion of water but also allows the flow of air to promote drying of the stockpile. The structure shall be capable of storing a minimum of 500 tons of RAP. The RAP stockpiles shall have a reasonably uniform gradation from fine to coarse and shall not be contaminated by foreign materials. The RAP used in III.25 202 4 Edition the HMA mix production shall have a moisture content such that the final HMA contains no more than 0.5% moisture. The proportion of RAP to virgin aggregate shall be in accordance with Table M3.06.2 -4 and M3.01.3: Asphalt Binder Grade for Recycled Asphalt Materials . Table M3. 06.2-4 : Maximum Allowed RAP Content by Mix Type Mix Type Maximum Amount of RAP Allowed (%) Maximum Amount of RAS Allowed (%) (see Note 1) Friction Course (OGFC) 0 0 Friction Course (ARGG) 10 0 Surface Course 15 0 Leveling Course 15 5 Bridge Surface Course 15 0 Bridge Protective Course 15 0 Intermediate Course 40 5 Base Course 40 5
considered as part of the overall allowable weight of recycled materials in the mixture.
RAS shall consist of only the by- product materials obtained from the roofing shingle manufacturing process. Post -consumer shingle waste and re -roofing shingle scrap will not be allowed. The Contractor or the plant shall provide certification from the roofing shingle manufacturer that RAS material provided is a by -product of the shingle manufacturing process. This material shall be transported to the HMA production facility yard and processed through an appropriate crusher so that the resulting material will contain no particles larger than 0.5 in. The mater ial shall be stockpiled on a free draining base and kept separate from the other aggregates. The material contained in the processed stockpile shall not be contaminated by foreign materials. RAS stockpiles shall be covered in a manner that prevents the int rusion of water but also allows the flow of air. RAS may be used in HMA leveling courses, HMA intermediate courses, and HMA base courses at a maximum rate of 5% by weight. When RAS is used in HMA mixtures containing RAP or other recycled materials, the RAS will be considered as part of the overall allowable weight of recycled materials in the mixture.
The use of PGA meeting the requirements of M2.01.8: Processed Glass Aggregate may be added at a maximum addition rate of 10% by weight. This addition will only be allowed in base and intermediate mixtures. PGA in mixes containing RAP will be considered as part of the overall allowable mass of RAP in the mix. If PGA is used in the mix, a separate aggregate bin shall be used and the use of lime as an anti -stripping agent shall be required. III.26 202 4 Edition M3. 06.3: Performance Graded Asphalt Binder The PGAB utilized in the HMA mixture shall be specified by the Contract and shall comply with the requirements of M3.01.0: Performance Graded Asphalt Binder . M3. 06.4: Hot Mix Asphalt Mixture Design The Contractor shall be responsible for development of all HMA mixture designs. All HMA surface courses, intermediate courses, base courses, leveling courses, bridge surface courses, and bridge protective courses shall be supported by volumetric mixture de signs using the Superpave mixture design system. All Superpave HMA designs shall be developed in accordance with the following AASHTO standards, as modified herein:
OGFC and ARGG mixtures shall be designed in accordance with Subsections M3. 06.4: Hot Mix Asphalt Mixture Design , Parts G and H , respectively
The Contractor shall develop and submit a LTMF for each HMA mixture type, which is to be proposed as a JMF, a minimum of 60 days prior to HMA production. Each LTMF shall be submitted with supporting documentation and adequate amount of blended aggregate material and PGAB in order to verify the LTMF. Once verified by the Department, the LTMF may become the JMF for a project. Two or more JMFs per HMA type may be approved for a particular plant, however, only mixture conforming to one JMF is permitted to be produced and placed on any given day.
The estimated traffic level to be used for HMA mix designs shall be specified by the contract. The traffic level shall be expressed in Equivalent Single Axle Loads (ESALs) for the design travel lane over a 20- year period in million 18 -kip ESALs.
The individual aggregate specific gravities shall be included with the LTMF. The Contractor shall provide samples of each aggregate material a minimum of 60 days prior to production for each LTMF to the Department for verification specific gravity of each stockpile.
The combined aggregate blend for each Superpave HMA mixture shall conform to the Gradation Control Point requirements specified in Table M3.06.4-1. The results of the selected optimum design aggregate structure shall be plotted on a 0.45 power chart and included with the LTMF. The combined aggregate gradation shall be classified as coarse -graded when it passes below the Primary Control Sieve (PCS) control point as defined in Table M3.06.4 -2. All other gradations shall be classified as fine graded. III.27 202 4 Edition When a Superpave Surface Course - 19.0 (SSC - 19.0) is specified in the contract, the LTMF aggregate gradation shall provide a fine -graded HMA mixture as defined in Table M3. 06.4-2.
Each asphalt mixture shall be designed and controlled during production using an approved gyratory compactor which meets the requirements of AASHTO T 312. Compaction shall be in accordance with the requirements of AASHTO T 312. The density of each HMA mixture shall be evaluated at the initial number of gyrations (N initial), the design number of gyrations (N design ), and the maximum number of gyrations (N max). The gyratory -compacted specimens for each LTMF shall meet the density requirements specified in Tabl e M3.06.4 -3 below.
Each Superpave HMA mixture shall be designed in accordance with the volumetric mixture design specifications contained in AASHTO M 323 and procedures contained in AASHTO R 35, as modified herein. Each HMA mixture LTMF shall be tested for conformance with the following volumetric properties:
design (Va)
The volumetric property test results shall be submitted with the LTMF for each Superpave HMA mixture. The required minimum or maximum criteria for each of the volumetric property tests are specified in Table M3.06.4 -3, Table M3. 06.4 -4, and Table M3.06.4-5. III.28 202 4 Edition Table M3. 06.4- 1: Superpave Aggregate Gradation Control Points Nominal Maximum Aggregate Size – Control Points (% Passing) Sieve #4 ⅜ in. ½ in. ¾ in. 1 in. 1 ½ in. (in.) Min Max Min Max Min Max Min Max Min Max Min Max 2 100 1.5 100 90 100 1 100 90 100 90 ¾ 100 90 100 90 ½ 100 100 90 100 90 ⅜ 95 100 90 100 90 #4 90 100 90 #8 32 67 28 58 23 49 19 45 15 41 #16 30 55 #30 #50 #100 #200 6 13 2 10 2 10 2 8 1 7 0 6 Table M3. 06.4- 2: Gradation Classification PCS Control Point for Mixture Nominal Maximum Aggregate Size (% Passing) Nominal maximum aggregate size ⅜ in. ½ in. ¾ in. 1 in. 1 ½ in. Primary Control Sieve #8 #8 #4 #4 ⅜ in. PCS control point, % passing 47 39 47 40 47 Table M3. 06.4- 3: Superpave Asphalt Mixture Design Laboratory Compaction Requirements Traffic Level Design ESALs
Asphalt Mixture Gyratory Specimen Nini Ndes Nmax Nini Ndes Nmax 1 <0.3 6 50 74 ≤91.5 96.0 ≤98.0 2 0.3 to <10 7 75 115 ≤90.5 96.0 ≤98.0 3 ≥10 8 100 160 ≤89.0 96.0 ≤98.0 III.29 202 4 Edition Table M3. 06.4-4 : Superpave Volumetric Requirements Nominal Maximum Aggregate Size #4 ⅜ in. ½ in. ¾ in. 1 in. 1 ½ in. Pb LTMF Value Gmb Gmm Va 4.0 VMA ≥17.0 ≥16.0 ≥15.0 ≥14.0 ≥13.0 ≥12.0 VFA See Table M3. 06.4-5 Dust/P be (See Note 1) 0.9 to 2.0 0.6 to 1.2 0.6 to 1.2 0.6 to 1.2 0.6 to 1.2 0.6 to 1.2 Mixture Temp. (See Note 2) Unmodified PGAB ≤325°F Modified PGAB ≤350°F
binder ratio range may be increased from 0.6 -1.2 to 0.8 -1.6 at the Engineer's discretion.
such as WMA, polymers, and rubber are introduced the mixing and compaction temperatures may be modified from the PGAB COA. Temperature modifications shall be recommended by the binder Supplier and approved at the Engineer's discretion. Table M3. 06.4-5 : Superpave Asphalt Mixture VFA Requirements Traffic Level Design ESALs
Based on Nominal Maximum Aggregate Size #4 ⅜ in. ½ in. ¾ in. 1 in. 1 ½ in. 1 <0.3 70 to 80 70 to 80 70 to 80 70 to 80 67 to 80 64 to 80 2 0.3 to <10 65 to 78 65 to 78 65 to 78 65 to 78 65 to 78 64 to 78 3 ≥10 75 to 78 73 to 76 65 to 75 65 to 75 65 to 75 64 to 75
Each OGFC asphalt mixture shall be designed in accordance with AASHTO R 113 , as modified herein. The combined aggregate gradation shall conform to Table M3.06.4-6 and the mixture shall conform to Table M3.06 .4-7.
Binder Grades , Part A.
Binder Grades , Part B. III.30 202 4 Edition Table M3. 06.4- 6: OGFC Aggregate Gradation Control Points Sieve ⅜ in. OGFC Control Points (% Passing) In. Min Max 1 - - ¾ - - ½ 100 - ⅜ 85 100 #4 20 30 #8 5 15 #200 0 4 Table M3. 06.4- 7: OGFC Mixture Requirements Property Requirement Ndes, gyrations 50 Pb, % (Polymer) ≥6.5 Pb, % (Asphalt Rubber) ≥7.5 Va, % 18 to 22 VCA mix, % <VCA DRC Draindown, % (See Note 1) ≤0.3 Abrasion Loss, % (See Note 2) ≤15 Moisture Susceptibility , % (See Note 3) ≥70 Permeability, in/sec (See Note 4) ≥0.0178
Each ARGG asphalt mixture shall be designed in accordance with the AASHTO M 323 and procedures contained in AASHTO R 35, as modified herein. The combined aggregate gradation shall conform to Table M3.06 .4-8 and the mixture shall conform to Table M3. 06.4-9. ARGG will utilize asphalt binder meeting the requirements of M3.01.2: Modified Asphalt Binder Grades , Part B. III.31 202 4 Edition Table M3. 06.4- 8: ARGG Aggregate Gradation Control Points Sieve ⅜ in. ARGG Control Points (% Passing) ½ in. ARGG Control Points (% Passing) Inches Min Max Min Max 1 - - - - ¾ - - 100 - ½ 100 - 90 100 #30 90 100 83 87 #50 38 52 28 42 #100 22 30 14 22 #200 - - 0 6 Table M3. 06.4- 9: ARGG Mixture Requirements Property Requirement 3/8 in. Requirement ½ in. Ndes, gyrations 75 100 Pb, % ( Asphalt Rubber ) ≥7.6 ≥7.6 Va, % 3 to 5 3 to 5 VMA, % 18 to 23 18 to 23 Draindown % (See note 1) ≤0.3 ≤0.3
M3. 06.5: Verification of Laboratory Trial Mix Formula The Contractor shall submit an LTMF in accordance with M3.06.4: Hot Mix Asphalt Mixture Design . The Engineer will perform laboratory verification of each LTMF. If the Engineer is unable to verify the Contractor’s LTMF in accordance with the applicable LTMF Verification Limits in Table M3. 06.5 -1, Table M3.06 .5-2, or Table M3.06.5-3, then the Engineer will work with the Contractor to resolve the verification issue(s). The Contractor shall not proceed with production and placement of a Control Strip under Subsection 450: Hot Mix Asphalt Pavement until the LTMF is verified by the Engineer.
III.32 202 4 Edition Table M3. 06.5- 1: Superpave LTMF Verification Limits Properties Test Method LTMF Verification Limit Asphalt Binder Content (P b) AASHTO T 308 Target ± 0.3% Gradation Passing #4 and Larger Sieves AASHTO T 30 Target ± 6.0% Gradation Passing #8 Sieve AASHTO T 30 Target ± 5.0% Gradation Passing #16 to #50 Sieve AASHTO T 30 Target ± 3.0% Gradation Passing #100 Sieve AASHTO T 30 Target ± 2.0% Gradation Passing #200 Sieve AASHTO T 30 Target ± 1.0% Bulk Specific Gravity (G mb) AASHTO T 166 Target ± 0.022 Max. Theo. Specific Gravity (G mm) AASHTO T 209 Target ± 0.020 Air Voids (V a) AASHTO R 35 Target ± 1.0% Voids in Mineral Aggregate (VMA) AASHTO R 35 Target ± 1.0% Voids Filled w ith Asphalt (VFA) AASHTO R 35 Target ± 5.0% Rutting and Moisture Susceptibility AASHTO T 324 See Table M3. 06.5-4 Table M3. 06.5- 2: OGFC LTMF Verification Limits Properties Test Method LTMF Verification Limit Asphalt Binder Content (P b) AASHTO T 308 Target ± 0.3% Gradation Passing #4 and Larger Sieves AASHTO T 30 Target ± 6.0% Gradation Passing #8 Sieve AASHTO T 30 Target ± 4.0% Gradation Passing #16 to #50 Sieve AASHTO T 30 Target ± 4.0% Gradation Passing #100 Sieve AASHTO T 30 Target ± 2.0% Gradation Passing #200 Sieve AASHTO T 30 Target ± 1.0% Bulk Specific Gravity (G mb) AASHTO T 331 Target ± 0.022 Max. Theo. Specific Gravity (G mm) AASHTO T 209 Target ± 0.020 Air Voids (V a) AASHTO R 35 Target ± 2.0% Voids in Mineral Aggregate (VMA) AASHTO R 35 Target ± 2.0% Voids Filled w ith Asphalt (VFA) AASHTO R 35 Target ± 5.0% Draindown AASHTO T 401 ≤0.3% Abrasion Loss AASHTO T 283 ≤15% Tensile Strength Ratio ≥70% III.33 202 4 Edition Table M3. 06.5- 3: ARGG LTMF Verification Limits Properties Test Method LTMF Verification Limit Asphalt Binder Content (P b) AASHTO T 308 Target ± 0.3% Gradation Passing ¾ in. Sieve AASHTO T 30 Target ± 0.0% Gradation Passing #4 to ½ in. Sieve AASHTO T 30 Target ± 6.0% Gradation Passing #8 Sieve AASHTO T 30 Target ± 5.0% Gradation Passing #16 to #50 Sieve AASHTO T 30 Target ± 3.0% Gradation Passing #100 Sieve AASHTO T 30 Target ± 2.0% Gradation Passing #200 Sieve AASHTO T 30 Target ± 1.0% Bulk Specific Gravity (G mb) AASHTO T 166 Target ± 0.022 Max. Theo. Specific Gravity (G mm) AASHTO T 209 Target ± 0.020 Air Voids (V a) AASHTO R 35 Target ± 1.0% Voids in Mineral Aggregate (VMA) AASHTO R 35 Target ± 1.0% Voids Filled with Asphalt (VFA) AASHTO R 35 Target ± 5.0% Draindown AASHTO T 305 ≤0.3% Rutting and Moisture Susceptibility AASHTO T 324 See Table M3. 06.5-4 Evaluation of Rutting and Moisture Sensitivity Each HMA mixture, with the exception of Base Courses and OGFC, shall be tested by RMS for rutting and moisture sensitivity in accordance with the requirements of AASHTO T 324 using the Hamburg Wheel -Tracking Device (HWTD). The Engineer may also require that mixtures meet the requirements of AASHTO T 283 with a minimum tensile strength ratio of 80%. Table M3. 06.5- 4: Hamburg Wheel Tracking Device Requirements Traffic Level Maximum Rut Depth (in.) Minimum number of passes before Stripping Inflection Point is observed 1 ½ 10,000 2 ½ 15,000 3 ½ 15,000 M3. 07.0: HMA for Driveways, Sidewalks, Berm, and Curb HMA mixtures for driveways, sidewalks, berm, and curb shall conform to the master ranges in Table M3. 06.6 -1. The PGAB shall conform to M3.01.1: Standard Asphalt Binder Grade. The aggregate shall conform to M3.06.2: Aggregate for Hot Mix Asphalt . The Contractor shall submit a JMF prior to production which shows the target aggregate gradation and PG asphalt binder content for each HMA mixture for driveways, sidewalks, berm, and curb. III.34 202 4 Edition With the approval of the Engineer, the Contractor may substitute a MassDOT approved 9.5 mm or 12.5 mm Superpave Surface Course mixture (Traffic Level 1 or 2) for Driveways and Sidewalks. The composition limits in Table M3. 07.0 -1 are HMA mix design master ranges for aggregate gradation and asphalt binder content. The JMF for each HMA mixture type shall establish a single percentage of aggregate passing each required sieve size, and a single percentage of asphalt binder material to be added to the aggregate. The JMF shall be submitted in writing by the Contractor to the Engineer at least 30 days prior to the start of paving operations and shall include the following as a minimum:
AASHTO T 195 (Ross Count) with a coating factor of 98% will be used when necessary to evaluate proper mixing time. The use of recycled materials will be permitted at the option of the Contractor and provided that the end product is in conformance with the designated JMF. The proportion of reclaimed materials (including RAP, PGA, and RAS) in the total mix shall be limited to a maximum of 15%. All HMA JMFs for sidewalks, pedestrian curb ramps, driveways, and berm will be submitted to the Engineer for approval. The JMF for each mixture shall be in effect until modified in writing by the Contractor and approved by the Engineer. Should a change in sources of materials be made, a new JMF must be approved by the Engineer before the new material is used. III.35 202 4 Edition Table M3. 07.0- 1: Master Ranges for HMA for Driveways, Sidewalks, Berm, and Curb Control Points (% Passing) Mix Type Driveways, Sidewalks, and Berm Berm and Curb Only Sieve (in.) Min Max Min Max 1 - - - - ¾ 100 - - - ½ 95 100 100 - ⅜ 87 93 87 93 #4 57 69 62 73 #8 41 45 52 55 #16 30 36 40 45 #30 21 25 28 34 #50 14 17 18 23 #100 9 12 10 14 #200 4 5 6 6 Pb, % 6.0 6.6 7.4 7.6 M3. 08.0 : Cold Patch for Temporary Patching When HMA is not available due to seasonal limitations the Contractor shall use stockpiled cold patch mixtures approved by the Research & Materials Section . M3.10.0: Surface Preservation Treatment M3. 10.2 : Stress Absorbing Membrane & Stress Absorbing Membrane Interlayer All Stress Absorbing Membrane (SAM) and Stress Absorbing Membrane Interlayer (SAMI) mixtures shall meet the requirements as specified below. SAM & SAMI mixtures shall be composed of the following:
The aggregate shall conform to M3. 06.2: Aggregate for Hot Mix Asphalt . Crushed gravel stone will not be permitted. The aggregate shall be pre -heated to a temperature between 200 ℉ and 300 ℉, and be pre -coated with 0.4% to 0.8% asphalt binder (by weight of aggregate) prior to application. The aggregate shall meet the requirements in Tables M3. 10.2 -1 and M3. 10.2 2. III.36 202 4 Edition Table M3. 10.2- 1: SAM & SAMI Aggregate Control Points Nominal Maximum Aggregate Size – Control Points (% Passing) Type ⅜ in. ⅜ in. ½ in. ½ in. ⅜ in. (SAMI only) ⅜ in. (SAMI only) Sieve Min Max Min Max Min Max ⅝ in. 100 - 100 - 100 - ½ in. 100 - 90 100 100 - ⅜ in. 85 100 25 65 85 100 #4 0 8 0 8 0 30 #8 0 4 0 4 0 5 #200 0 2 0 2 0 2 Table M3. 10.2- 2: SAM & SAMI Aggregate Source Property Requirements Source Property Test Test Method Limit Toughness AASHTO T 96 <30% Flakiness Index (for SAM) TEX -224- F (see n ote 1) <20% Flakiness Index (for SAMI) TEX -224- F (see n ote 1) <30%
The PGAB binder to be applied to the pavement shall be in conformance with M3.01.2: Modified Asphalt Binder Grades , Part B. Asphalt binder that is pre- coated onto the aggregate shall be in conformance with M3.01.1: Standard Asphalt Binder Grade . M3. 10.5 : Ultrathin Bonded Overlay All Ultrathin Bonded Overlay (UTBO) mixtures shall meet the requirements as specified below. UTBO mixtures shall be composed of the following :
The use of recycled materials will not be permitted.
Coarse aggregate shall meet the requirement of M3.06.2: Aggregate for Hot Mix Asphalt , Part A as well as the following . Where coarse aggregates for these mixes are from more than one source or of more than one type of material, they shall be proportioned and blended to provide a uniform mixture. III.37 202 4 Edition Table M3.10.5-1: Coarse Aggregate Requirements Source Property Test Test Method Limit Flat and Elongated, 3:1 ASTM D4791 <25% Crushed Particles, Two Faced AASHTO T 335 >90% Water Absorption AASHTO T 85 ≤3.0%
Fine aggregate shall meet the requirement of M3.06.2: Aggregate for Hot Mix Asphalt , Part B as well as one of the following. Fine aggregate shall be 100% crushed and consist of one of the following:
Table M3. 10.5-2 : Fine Aggregate Consensus Property Requirements Source Property Test Test Method Limit Fine Aggregate Angularity AASHTO T 304 >40% Methylene Blue AASHTO T 330 ≤10 mg/g Water Absorption AASHTO T 84 ≤3.0%
Hydrated lime, fly ash, and baghouse fines are acceptable as mineral filler. The material shall conform to the following: • Lime – AASHTO M 303 • Fly Ash – AASHTO M 295 • Baghouse fines – AASHTO M 17 Typical acceptable gradation: • #30 - 100% passing • #200 - 75-100% passing
The PGAB utilized in the HMA mixture shall be specified by the Contract and shall comply with the requirements of M3.01.2: Modified Asphalt Binder Grades .
The Contractor shall be responsible for development of all UTBO mixture designs. All UTBO designs shall be developed in accordance with the requirements specified below.
The Contractor shall develop and submit an LTMF for each UTBO mixture type, which is to be proposed as a JMF, a minimum of 60 days prior to UTBO production. Each LTMF shall be submitted III.38 202 4 Edition with supporting documentation and adequate amount of blended aggregate material and PGAB in order to verify the LTMF. Once verified by the Department, the LTMF may become JMF for a project.
The individual aggregate, mineral filler, and PGAB specific gravities shall be included with the LTMF. The Contractor shall provide samples of each material a minimum of 60 days prior to production for each LTMF to the Department for verification specific gravity of each stockpile.
The combined aggregate blend for each UTBO mixture shall conform to the Gradation Control Point requirements specified in Table M3.10.5 -3. The results of the selected optimum design aggregate structure shall be plotted on a 0.45 power chart and included with the LTMF. Table M3. 10.5-3 : UTBO Aggregate Control Points Nominal Maximum Aggregate Size – Control Points (% Passing) Type 1 Type 1 Type 2 (see Note 1) Type 2 (see Note 1) Type 3 (see Note 1) Type 3 (see Note 1) Sieve Min Max Min Max Min Max ¾ in. 100 - 100 - 100 - ½ in. 100 - 92 100 85 100 ⅜ in. 85 100 55 90 45 85 #4 24 40 24 41 24 41 #8 21 32 21 33 21 33 #16 16 26 15 26 15 26 #30 12 20 11 20 11 20 #50 8 16 8 16 8 16 #100 5 10 5 10 5 10 #200 5 7 4 7 4 7 Pb, %
Pb, % (Asphalt Rubber) (See note 2) - - 5.7 6.2 5.6 6.2
approval from the Research & Materials Section.
The combined mixture for each UTBO mixture shall conform to the mixture requirements specified in Table M3.10.5 -4. The results of the selected optimum design shall be included with the LTMF. III.39 202 4 Edition Table M3. 10.5-4 : UTBO Mixture Requirements Property Requirement Unit Weight Per LTMF Draindown, % (see Note 2) ≤0.1 Moisture Susceptibility, % (see Note 3) ≥80
AASHTO T 283. The tensile strength ratio, TSR, shall meet or exceed 80 % when tested in accordance with AASHTO T 283. Specimens for T 283 shall be 6 in. in diameter by 3 ¾ ± ¼ in. in height and compacted in accordance with AASHTO T 312, except the specimens shall be compacted to 100 gyrations a nd resultant air voids reported for information purposes only. The compaction temperatures shall be 300 ± 10 ℉ or as recommended by the binder supplier. Follow T 283 with the following exceptions:
the difference in tensile strength between duplicate specimens is greater than 25 lb/in.2.
The Contractor shall submit an LTMF in accordance with Subsections M3. 10.5 , Part A to Part I. The Engineer will perform laboratory verification of each LTMF. If the Engineer is unable to verify the Contractor’s LTMF in accordance with the applicable LTMF Verification Limits in Table M3. 10.5-4 , then the Engineer will work with the Contractor to resolve the verification issue(s). The Contractor shall not proceed with production and placement of a Control Strip until the LTMF is verified by the Engineer. III.40 202 4 Edition Table M3. 10.5- 4: UTBO LTMF Verification Limits Properties Test Method LTMF Verification Limit Asphalt Binder Content (P b) AASHTO T 308 Target ± 0.3% Gradation Passing ¾ in. S ieve AASHTO T 30 Target ± 0. 0% Gradation Passing #4 and Larger Sieves AASHTO T 30 Target ± 6.0% Gradation Passing #8 Sieve AASHTO T 30 Target ± 5.0% Gradation Passing #16 to #50 Sieve AASHTO T 30 Target ± 3 .0% Gradation Passing #100 Sieve AASHTO T 30 Target ± 2.0% Gradation Passing #200 Sieve AASHTO T 30 Target ± 1.0% Draindown AASHTO T 305 ≤0.1% Moisture Susceptibility AASHTO T 283 ≥80% M3.1 2.0: Hot Mix Asphalt Production Facility All facilities producing HMA must be approved on an annual basis by the Department. All sources of materials used for the production of HMA must be approved by the Department prior to their use. Such materials shall include:
HMA production operations shall follow industry accepted best management practices including:
The plant shall meet the requirements of AASHTO M 156 as well as the following provisions. HMA plants meeting these requirements and which have been approved by RMS shall be listed on the QCML. An adequate quantity of each size aggregate, mineral filler and asphalt binder shall be maintained at the HMA plant site at all times while the plant is in operation to ensure that the plant can continuously produce mixtures that meet these specifications. The quantity of such materials shall never be less than one day’s production capacity. III.41 202 4 Edition A. Production Facility Quality Control System The production facility shall provide a Quality Control System (QC System) adequate to ensure that all materials and workmanship meet the required quality levels for each specified Quality Characteristic. The QC System shall be documented in a Quality System Manual (QSM). The Contractor shall provide qualified QC personnel and QC laboratory facilities and p erform Quality Control inspection, sampling, testing, data analysis, corrective action (when necessary), and documentation. The QSM shall conform to the requirements of AASHTO R 38 and the MassDOT Model QSM. The pages of the QSM shall be sequentially numbered and shall address, in sufficient detail, the specific information requested under each section and subsection contained in the MassDOT Model QSM.
Plant and truck scales shall be certified:
The plant’s systems shall be calibrated:
repaired, replaced, or adjusted.
Recordation equipment shall be provided. Each recorder shall include an automatic printer system. The printer shall be so positioned that the digital display and the printer can be readily observed within the plant’s control room by the Engineer and the plant operator, simultaneously. The delivery ticket shall be printed with an original and at least one copy. The original shall be furnished to the Engineer at the paving site and the copy to the Engineer at the plant. The delivery ticket format shall be app roved by RMS and will include the following information:
The following mixture production information shall also be provided: III.42 202 4 Edition For Batch Plants
net ingredients.
Note: This information shall be included on the delivery ticket when the mix is batched directly into a truck. When the mix is batched and stored in a silo the information may be separate from the delivery ticket however it must be provided to the Engineer at the plant. For Drum Plants
component including:
Note: This information is not required to be included on the delivery ticket however it must be provided to the Engineer at the plant.
The mixtures shall not be stored in surge and storage bins longer than the following:
Note: In order to prevent excessive draindown, OGFC shall not be stored in a surge or storage bin for longer than 2 hours. ARGG shall not be stored for more than 6 hours.
The plant shall have a method of applying MassDOT approved asphalt release agents to the haul units in accordance with the Manufacturer’s recommendations. Spray systems may either be manual or automated but application of the release agent must be at the rate specified by the Manufacturer. III.43 202 4 Edition G. Air Quality The plant shall be designed and operated to meet all current Federal and State air quality requirements.
If at any time the automatic proportioning or recording system becomes inoperative, the plant will cease all HMA production. Work will only be allowed to restart once all automatic controls and recording systems are functional. M3.1 2.1: HMA Plant Facility Inspection The Engineer shall have access at any time to all parts of the plant for:
M3.1 3.0: Hot Mix Asphalt Materials Testing Laboratory and Equipment M3.1 3.1: Contractor Quality Control Laboratory All Contractor QC testing shall be performed in laboratories that are approved by RMS and qualified through the NETTCP LQP or accredited through the AAP. All laboratories shall maintain a QSM in accordance with the outline maintained by RMS .
Asphalt Pavement shall at a minimum be qualified as a NETTCP LQP Category 2 laboratory.
laboratory. Contractors who do not produce mixtures under Subsection 450: Hot Mix Asphalt Pavement will not be required to have their own laboratory at the production facility but will be required to either test at their central laboratory or hire a consultant testing company to perform the QC testing required in the specification. The Contractor will still be required to maintain a QSM. The Contractor’s QC laboratory shall be qualified to perform all testing required by Table M3.1 3.2-1 as well as contract specifications. Laboratories meeting these requirements, and which have been approved by the RMS , shall be listed on the QCML. The Contractor's QC Manager shall have overall responsibility for ensuring that all laboratories utilized for QC are in compliance with the requirements of the NETTCP LQP. This includes providing required AASHTO, ASTM, and NETTCP reference documents and ensuring that all required equipment and tools are properly functioning and calibrated. The Engineer shall be permitted unrestricted access to inspect and review the Contractor’s laboratory facility. III.44 202 4 Edition Along with the required testing capabilities the laboratory facilities shall meet the following:
able to maintain an inside temperature of 68 ℉ to 86 ℉ during working hours.
shifts. The restroom facilities shall be enclosed in a separate room with proper ventilation and comply with applicable sanitary codes as well as:
M3.1 3.2: Department Acceptance Laboratory at HMA Production Facility The Engineer shall be provided laboratory working space meeting the requirements of M3.13.1: Contractor Quality Control Laboratory as well as the following. A desk must be located in close proximity to the laboratory but be separated from the ovens, sieve shakers, and anything else that can cause poor air and sound quality. The Engineer’s desk and laboratory space will not be shared with any other entity. Contractors who do not produce mixtures under Subsection 450: Hot Mix Asphalt Pavement will not be required to have a Department Acceptance Laboratory at the production facility , but will be required to allow the Engineer to perform Acceptance testing at their central laboratory or Consultant testing company laboratory. These laboratories are still required to meet M3.13.1: Contractor Quality Control Laboratory . If the Engineer is unable to perform their duties either due to lack of working space, poor working conditions, or access to equipment it will be considered a laboratory facility deficiency. The Engineer will advise the Contractor in writing of any noted deficiencies concerning the laboratory facility, equipment, supplies, or testing personnel and procedures. Deficiencies shall be grounds for the Engineer to order an immediate stoppage of work until the deficiencies are corrected. The plant, silos, and sample rack shall be in view of laboratory when performing testing under Subsection 450: Hot Mix Asphalt Pavement. The Engineer shall be provided with the following:
For plants producing HMA in accordance with Subsection 450: Hot Mix Asphalt Pavement, the Engineer shall be furnished with a computer with high speed internet access which conforms to the requirements determined by RMS. The minimum requirements shall include:
III.45 202 4 Edition 2. Computers shall be required to have the latest MS Office Professional with all security updates, Antivirus software with all current security updates maintained, and any other software required by RMS.
connected to the laboratory’s computer.
The Contractor shall supply the Engineer with the following equipment. This equipment shall only be utilized by the Engineer and shall be labeled as such. It shall be the Contractor’s responsibility to maintain and replace equipment as needed.
Category A Lots).
Lots).
Pavement Category A Lots).
(only for Subsection 450: Hot Mix Asphalt Pavement Category A Lots).
III.46 202 4 Edition Table M3.1 3.2-1: Required Test Methods by Laboratory Test Method Description Mix Design Laboratory QC Laboratory Department Acceptance Laboratory AASHTO M 323 Superpave Volumetric Mix Design X AASHTO R 30 (See note 1) Mixture Conditioning of HMA X AASHTO R 35 Superpave Volumetric Design for Asphalt Mixtures X AASHTO R 47 Reducing Samples of HMA to Testing Size X X X AASHTO R 66 Sampling of Asphalt Materials X AASHTO R 76 Reducing Samples of Aggregate to Testing Size X X AASHTO R 79 (See note 3) Vacuum Drying Compacted HMA Specimens X AASHTO R 90 Sampling of Aggregate X AASHTO R 97 Sampling of Bituminous Paving Mixtures X X AASHTO T 11 Material Finer Than #200 Sieve by Washing X X X AASHTO T 27 Sieve Analysis of Fine and Coarse Aggregates X X X AASHTO T 30 Sieve Analysis of Extracted Aggregate X X X AASHTO T 84 Specific Gravity and Absorption of Fine Aggregate X AASHTO T 85 Specific Gravity and Absorption of Coarse Aggregates X AASHTO T 96 Coarse Aggregate L.A. Abrasion X AASHTO T 104 Soundness of Aggregates X AASHTO T 166 Bulk Specific gravity of HMA X X X AASHTO T 176 Sand Equivalence X AASHTO T 209 Theoretical Maximum Specific Gravity of HMA X X X AASHTO T 255 Moisture Contents of Aggregates X AASHTO T 283 (See note 4) Resistance of Compacted Asphalt Mixtures to Moisture -Induced Damage X AASHTO T 304 Un-compacted Void Content of Fine Aggregate X III.47 202 4 Edition Test Method Description Mix Design Laboratory QC Laboratory Department Acceptance Laboratory AASHTO T 305 (See note 3) Draindown in Uncompacted Asphalt Mixtures X AASHTO T 308 Asphalt Binder Content by Ignition Oven X X AASHTO T 312 Density of HMA by Superpave Gyratory X X X AASHTO T 329 Moisture Control of HMA X X AASHTO T 331 (4) Bulk Specific Gravity and Density of Compacted Asphalt Mixtures Using Automatic Vacuum Sealing X X X AASHTO T 335 Determining the Percentage of Fracture in Coarse Aggregate X ASTM D3549 Thickness of Compacted HMA Specimens X ASTM D4791 Flat & Elongated Particles in Coarse Aggregate X ASTM D7370 (See note 2) Relative Density and Absorption of Aggregate Using Combined Vacuum Saturation and Rapid Submersion X
and one to condition the loose mixture at the compaction or conditioning temperature.
III.48 202 4 Edition SECTION M4 : CEMENT AND CEMENT CONCRETE MATERIALS M4.00 .00: General All cement, cement concrete, and related materials shall be sampled and tested in accordance with the applicable AASHTO, ASTM or other designated methods. Cement as defined in this specification shall mean cementitious material as specified in the followin g sections. M4.01.0 : Portland Cement Portland Cement shall conform to the requirements of AASHTO M 85. M4.01.1 : Blended Hydraulic Cements Blended hydraulic cements shall conform to the requirements of AASHTO M 240 M/M 240. M4.01.2 : Fly Ash Fly ash shall conform to AASHTO M 295. M4.02.00: Cement Concrete Producers shall report proposed mix design formulations onto the Department issued mix design sheet in its entirety and submit to the Department for review. Mix design formulations shall meet the requirements specified in the construction standard specifications, contract document special provisions, design plans, and herein. Mix design formulations shall be approved by the Department prior to construction. Mix design formulations shall be designed with precise proportions of constituent materials, yielding 27.0 ft ³ (1 cubic yard) of cement concrete. All required mix design targets shall be reported on the Department issued mix design sheet for each proposed mix design. Mill certifications and technical data sheets of the constituent materials incorporated into the p roposed mix design formulation shall accompany the mix design formulation submission. Cement concrete shall be classified and reported according to the mix design formulation’s 28 -day compressive strength (f’ c), nominal maximum aggregate size (NMAS), total cementitious content (lb), air content (%), water- cementitious (w/cm) ratio, paste content (%), paste content- void content (PC/VC) ratio, slump (in.), unit weight (lb/ft³ ), and mix type. Nominal maximum aggregate size (NMAS) shall be determined from the combined aggregate system of the proposed mix design formulation and is defined as the sieve size immediately above the first sieve size that cumulatively retains more than 10% by mass. III.49 202 4 Edition Table M4.02.00- 1: Classifications of Concrete Mixes Class 28 -Day Compressive Strength Minimum Total Cementitious Content (Pounds per Cubic Yard of Concrete) 1-½ in. ¾ in. ⅜ in. 2,500 psi 425 470 520 3,000 psi 470 520 565 3,500 psi 520 565 610 4,000 psi 565 610 660 5,000 psi 660 705 760 M4.02.01: Cement Cement for concrete shall be the kind and type designated on the plans or in the specifications for the particular work. If no type is specified either Type I, IA, IP, IP -A or Type II, IIA shall be furnished except that cement for exposed bridge deck concr ete or concrete exposed to sea water shall be Type II or IIA. Cement shall not exhibit a flash set or cause an abnormal initial rise of temperature when mixed with water. It shall maintain its full plasticity and fluidity during the period required for placing the concrete. The temperature of the cement at the time of mixing shall not exceed 150°F. When tested at the mill, no cement shall be shipped to the work until it has passed the 7-day test. At least 12 days from the time of sampling shall be allowed to the completion of the required 7-day test. Each shipment, regardless of quantity, shall be accompanied by a certified Mill Test Report, three copies of which shall be furnished to the Engineer before the cement may be incorporated in the work. Cement furnished without a current Mill Analysis Report shall not be used in the work until the Engineer has had sufficient time to make appropriate tests and has approved the cement for use. A current Certificate of Compliance for concrete admixtures, fly ash, silica fume, and slag based on test results shall be available for the inspector prior to production. Cement of a uniform color shall be used in all exposed concrete of any structure. M4.02.02: Aggregates Aggregate shall exhibit acceptable quality characteristics and material properties, including particle size distribution, shape, surface texture, absorption, compressibility, effect on modulus of elasticity of concrete, moisture -related volume changes, coefficient of thermal expansion, wetting and drying, and resistance to abrasion, alkali aggregate reaction, and d -cracking, popouts, and sulfate attack due to freezing, thawing, and de- icing. Aggregate shall be sufficiently limited of potentially deleterious amounts of constituents that may negatively affect cement concrete performance, including workability, setting, hardening, aggregate -cement bond, strength, color, long -term durability, and other properties. III.50 202 4 Edition Aggregate sources with limited historical field and test data shall be subjected to ASTM C295 Petrographic Examination for Potential Akali Aggregate Reactive Constituents and Deleterious Materials in Aggregate. Examinations and reporting shall be conducted by accredited independent laboratories. The Producer shall submit ASTM C295 examination reports to the Department for review.
Fine aggregate shall meet AASHTO M 6 Standard Specification for Fine Aggregate for Hydraulic Cement Concrete.
Coarse aggregate shall meet AASHTO M 80 Standard Specification for Coarse Aggregate for Hydraulic Cement Concrete and AASHTO M 43 Sizes of Aggregate for Road and Bridge Construction. M4.02.03: Lightweight Aggregates Lightweight aggregates for Structural Concrete shall meet AASHTO M 195 . M4.02.04: Water Water for use in cement concrete shall be clean, clear and free from deleterious amount of oil, acid, alkali, salts and organic matter. The water shall exhibit no deleterious effect upon the strength, setting, or soundness of the cement. It shall conform to the following requirements:
Testing of the water shall be in accordance with AASHTO T 26. M4.02.05: Chemical Admixtures Chemical admixtures shall be defined as constituent materials in both liquid or powder form that are incorporated into the material immediately prior or during mixing, to enhance mix properties and maintain consistency during mixing, transporting, placing, finishing, and curing. Chemical admixtures shall be considered any ingredient added to a concrete mixture other than cement, supplementary cementitious materials (SCMs), aggregate, water, and fiber reinforcement. Chemical admixtures shall exhibit acceptable quality characteristics and material properties, including chemical composition, performance, and uniformity. Chemical admixtures shall be listed on the QCML as of the date of placement and meet the requirements specified herein.maintain valid listin g on the Department Qualified Construction Materials List (QCML) and meet the requirements specified herein.
Standard admixtures shall meet AASHTO M 194 Standard Specification for Chemical Admixtures for Concrete. III.51 202 4 Edition B. Air-Entraining Admixtures. Air-entraining admixtures shall meet AASHTO M 154 Standard Specification for Air -Entraining Admixtures for Concrete.
Corrosion inhibiting admixtures shall meet ASTM C1582 Standard Specification for Admixtures to Inhibit Chloride -Induced Corrosion of Reinforcing Steel in Concrete. M4.02.06: Proportioning Concrete shall be proportioned with the specified minimum cement content for each class and shall be mixed to the required consistency as determined by standard slump test AASHTO T 119 M/T 119 .
Cement and aggregates shall be proportioned by weight in an approved manner. Scales shall be calibrated and sealed by the proper authority within the preceding year, or following any reassembly, or as the Engineer may direct.
The responsibility of the Department is confined to the inspection of the following four factors controlling the mix:
The cement proportion is subject to adjustment and approval by the Engineer in order to insure compliance with minimum strength requirements. Standard field test specimens (AASHTO T 23) shall be taken on the job and the Contractor shall be required to add additional cement as directed by the Engineer if the test specimens fail to meet the requirements of M4.02.13: Test Specimens . No claims shall be allowed for extra cement or extra concrete due to variations in materials, proportioning, dimensions, shrinkage, waste and similar causes. The Contractor is advised to anticipate a normal loss in yield of 1% or 2% due to the foregoing ca uses. The volume of plastic concrete in a given batch shall be determined from the total weight of the batch divided by the actual weight per cubic foot of the concrete. The total weight of the batch shall be calculated as the sum of the weights of all materials including water. The weight per cubic foot shall be determined in accordance with the Method of Test for Weight per Cubic Foot Yield and Air Content (Gravimetric) of Concrete (AASHTO T 121 M/T 121).
The Contractor shall uniformly regulate the consistency of the mix to the slump directed by the Engineer. The slump target shall be identified on the approved cement concrete mix design sheet. For approved slump targets less than or equal to 3 in ., slump test results shall not exceed the allowable tolerance of ±1.0 in . from the approved target. For approved slump targets greater than 3 in., slump test results shall not exceed the allowable tolerance of ±1.5 in. from the approved target. III.52 202 4 Edition Modifications to the approved slump target shall be prohibited. If slump test results are not within the specified design target ranges, the Contractor is permitted to request for Department review and approval, on -site adjustments of chemical admixture dosages and the use of water held back at the plant. The Engineer may reject non -conforming batches and the Contractor shall receive no additional compensation.
The Engineer may vary the proportion of fine aggregate in order to regulate the workability or density of the mix, making an equivalent change in the coarse aggregate to keep the yield constant.
The air void system shall contain a stabilized air bubble distribution and promote quality concrete properties, including enhanced workability, cohesion, strength, and resistance to freezing, thawing, de-icing, and sulfate reaction. Cement concrete shall meet the air content targets identified in Table M4.02.06- 1. A tolerance of ±1.5% in the percentages will be allowed. Table M4.02.06- 1: Air Content Target Nominal Maximum Aggregate Size (in.) Reinforced Concrete (%)[1] Non - Reinforced Concrete (%)[1] ⅜ 7.5 7.5 ½ 7.0 7.0 ¾ 6.0 7.0 1 6.0 6.5 1½ 5.5 6.5 [1]A 1.0% reduction from the air content target is permitted for f’ c ≥ 5000 psi.
All plants shall be equipped with an approved automatic weighing, cycling and monitoring system installed as part of the batching equipment. Each plant shall include equipment for accurate proportioning batches containing the various components by weight o r by volume for admixtures and water in the proper sequence and for controlling the sequence and timing of mixing operation. The automatic proportioning system shall be capable of consistently delivering each constituent within the tolerances indicated in M4.02.07: Measuring Materials . Interlocks shall be provided which will hold or delay the automatic batch cycling whenever the batched quantity of any component is not within the specific weight tolerance, when any aggregate bin becomes empty or when there is a malfunction in any porti on of the control system. The weight setting and time controls shall be so equipped that they may be locked when directed by the Engineer. The weighing equipment shall be so arranged that the batch plant operator can conveniently observe all scales from their operation station. The Controls shall be set so that:
III.53 202 4 Edition 2. The batcher discharge gates cannot be opened:
Measuring Materials .
all scales have returned to zero. Discharge chutes shall be so arranged that they are not suspended from any part of the weighing system and so that no materials will lodge therein or be lost on discharge. Each weighing unit shall include a springless dial which shall indicate the scale load at all stages of the weighing operation from zero to full capacity. If at any time the automatic proportioning system becomes inoperative, the plant will be allowed to batch materials manually for a period not in excess of 2 working days. Manual batching for longer periods will require written permission of the Engineer. All plant scales shall be tested at the expense of the producer by a competent scale technician as follows:
Plants shall be equipped with a separate dispensing system necessary to incorporate each of the required admixtures into the concrete. At least two admixture dispensing systems shall be required for plants supplying structural concrete.
All concrete batching plants equipped with automatic proportion systems shall have digital recording instruments approved by the Engineer which shall be so located as to be readily accessible and readable to the operator from their normal work station. The recording instruments shall be designed to record the quantities of each aggregate component, cement, fly ash (when used), water and the presence of admixture for each batch of concrete produced. All records of batches shall show the batch number, the day, the month, year, and time of day to the nearest minute for each batch and they shall be imprinted on the record so that each batch may be permanently identified. The Department shall be provided with a clear and legible copy of all batch records. Cement, fly ash, and aggregate component weight quantities shall be recorded separately. Water may be recorded by weight or volume. Weights and/or volumes shall be recorded as indicated on the batching scale or meter within an accuracy of ±1 scale or meter gradation. The minimum recorder resolution shall be equivalent to or less than minimum gradation on the scale or meter. When the automation system is capable of producing other than standard size batches (full, half or quarter cubic yard increments), the recordation requirements shall be in accordance with written directives from the Engineer. Each plant site shall be equipped with an approved instrument capable of automatically applying a time -date stamp to each delivery ticket as the delivery vehicle departs from the plant site. III.54 202 4 Edition M4.02.07: Measuring Materials Materials shall be measured in accordance with AASHTO M 157, Section 8, with the following exceptions: All wash water shall be removed from truck mixers and truck agitators prior to charging with a fresh load. Water may be held back at the plant by up to 5.0 gallons per cubic yard of concrete mixed. The use of this water on the project is at the direction of the Engineer and must be verified through sight glass increments or in -line meter readings and then the amount will be written on the ticket. Absolutely no additional water may be utilized on site for slump adjustment purposes. If after placing all the allowable hold- back water and mixing the proper time, the concrete mixture still does not attain the proper slump, the Engineer will reject the truckload. M4.02.08: Plant and Equipment The plant and equipment shall be subject to approval by the Engineer to insure satisfactory prosecution of the work without delay.
coarse aggregate shall be provided in the batching plant. Each compartment shall be designed to discharge efficiently and freely into the weighing hopper. Means of control shall be provided so that, as the quantity desired in the weighing hopper is being approached, the material may be added slowly and shut off with precision. Weighing hoppers shall be constructed so as to eliminate accumulation of tare materials and to discharge fully.
load cell type and shall indicate the load at all stages of the weighing operation from zero to full capacity. They shall conform to the applicable sections of the current edition of the National Bureau of Standards Handbook 44, Specifications, Tolerances and other Measuring Devices, except as may be otherwise specified. They shall be accurate within one half of 1 % under operating conditions. Ten 50 -lb weights shall be available at the plant at all times for checking accuracy. All exposed fulcrums, clevises, and similar working parts of scales shall be kept clean. When beam -type scales are used, provisions shall be made for indicating to the operator that the required load in the weighing hopper is being approached; the device shall indicate within the last 200 lb of load and within 50 lb overload. All weighing and indicating devices shall be in full view of the operator while charging the hopper and the operator shall have convenient access to all controls.
installed in an area enclosed for protection against dust and inclement weather.
A weatherproof building or room shall be furnished at the site of the producing plant suitable for the housing and use of equipment necessary to carry on the various tests required and for III.55 202 4 Edition recording and processing test results. This building shall be for the exclusive use of the Engineer or their representative for testing and recording purposes. The building or room shall have a least dimension of 7 ft and a minimum of 220 ft² . Windows and doors shall be adequately screened and satisfactory lighting and heating shall be provided for a 24 hour day and be supplied with water. The room shall have adequate ventilation and be air conditioned in the warm months to provide a minimum of 75°F. A table, chairs, desk, work bench, file cabinet, electronic calculator, and a minimum of two 5 -lb fire extinguishers shall be provided. If the Engineer permits, the testing facility may be part of another building in which case it shall be entirely partitioned off from the remainder of such building. Testing equipment conforming to current AASHTO standards and meeting the approval of the Engineer shall be furnished as follows and installed in the building for use in testing the materials (and mixtures) supplied by the Plant for the work: • 1 Fine Aggregate Sieve Shaker, power driven, for 8 -in. minimum diameter sieves. • 1 Each of the following standard 8 -in. minimum diameter square opening sieves: No. 4, No. 8, No. 16, No. 30, No. 50, No. 100, and No. 200, with pan and cover. • 1 Sample Splitter with a minimum capacity of 1 ft ³. It shall be of the clam shell type and the chute width shall be adjustable from a minimum of ½ in. up to 2 in. • 1 Solution Balance, 20 -kg capacity, weighing directly to 1 g, with two weighing beams and a taring beam; tare capacity to be 2 kg; weight beams to read 1,000 g by 100 g divisions and 100 g by 1 g divisions. Additional matching weights (one 1 -kg, two 2 -kg, one 5 -kg, and one 10-kg) shall be provided to fulfill the capacity of 20 kg. The platform to be 11 -in. diameter. An electronic, direct reading, top loading, 20 -kg minimum capacity, balance with a precision of 0.1 g may be substituted for the solution balance. • 1 Approved Scale with a minimum capacity of 2,000 g and with a sensitivity of 0.50 g . An electronic, top -loading, balance, with a capacity of 2,000 g minimum, and reading to 0.1 g may be used in place of the scale. • 1 Approved Dial Thermometer, range of 50°F to 500°F. • 1 Approved Hot Plate. Approval of a plant will be contingent upon approval of the aforementioned requirements for Plant Laboratory, including the building and appurtenances, furnishings, facilities including heat, light, power and water, the testing equipment and any other inci dentals. M4.02.09: Mixers and Agitators
agitators. Each mixer and agitator shall have attached thereto, in a prominent place by the manufacturer, a metal plate or plates on which is plainly marked the various uses for which the equipment is designed, the volume of the drum, the capacity of the drum or container in terms of the volume of mixed concrete and the speed of rotation of the mixing drum or blades. Stationary mixers shall be equipped with an acceptable timing device that will not permit the batch to be discharged until the specified mixing time has elapsed. Truck mixers shall be equipped with counters by which the number of revolutions of the drum or blades may readily be verified. The counters shall be read at the time of starting and ending of mixing at mixing speeds. III.56 202 4 Edition B. The truck mixer when loaded with concrete shall not contain more than 63 % of the gross volume of the drum. The mixer shall be capable of combining the ingredients of the concrete into a thoroughly mixed and uniform mass and of discharging the concrete with a satisfactory degree of uniformity.
the concrete with a satisfactory degree of uniformity. M4.02.10: Mixing and Delivery
by means of one of the following combinations of operations.
of delivery in a truck agitator or in a truck mixer operating at agitator speed or in non - agitating equipment when approved by the Engineer.
Engineer , who shall certify on a delivery slip that they observed the complete mixing of the concrete.
agitating as designated by the manufacturer of the equipment. A truck mixer or truck agitator used for transporting concrete that has been completely mixed in a stationary mixer shall be operated within the limits of capacity and speed of rotation designated by the manufacturer for agitating, except that the agitator capacity in no event exceed 80% of the gross drum volume.
more than 10 yd ³ capacity, the mixing time shall be determined by the Engineer. The time is valid provided mixer efficiency tests prove the concrete is satisfactory for uniformity and strength. Mixing time shall be measured from the time all cement and aggregates are in t he drum. The batch shall be so charged into the mixer that some water will enter in advance of cement and aggregates, and all water shall be in the drum by the end of the first one -fourth of the specified mixing time.
speed. Additional mixing, if any, shall be at the speed designated by the manufacturer of the equipment as agitating speed. All materials including mixing water shall be in the mixer drum before actuating the revolution counter for determination of number of revolutions of mixing.
when all ingredients including water have been added to the truck mixer at the batching plant, the drum shall be constantly rotated at the agitating speed designated b y the III.57 202 4 Edition manufacturer of the equipment, both during transport and while on the project prior to discharge, except during the period required for mixing.
85°F or above, the time between the introduction of the cement to the aggregates and discharge shall not exceed 1 hour. When a truck mixer is used for the complete mixing of the concrete, the mixing operation shall begin within 30 minutes after the cement has been added to the aggregate. When it is determined that more than 90 minutes will be required to batch and completely discharge the load, an alternate method of delivery and mixing will be permitted. The truck mixer will be charged at the batching plant with reasonably dry aggregates and cement but no mixing water. The required amount of mixing water shall be carefully introduced into the truck mixer at the job site and the batch of concrete mixed as outlined above. Under such conditions one hour shall be allowed for the discharge of t he load, computed from the time the mixing water has been added to the batch and the mixing begun. The concrete when discharged from truck mixers and truck agitators, shall be of the consistency and workability required for the job. The rate of discharge of the plastic concrete from the mixer drum shall be controlled by the speed of rotation of the drum in the discharge direction with the discharge gate fully open. All wash water shall be removed from truck mixers and truck agitators prior to charging with a fresh load.
may be transported in suitable non- agitating equipment.
gates that will permit control of the discharge of the concrete. Covers meeting the approval of the Engineer shall be provided for protection against the weather.
water to the cement and aggregates.
specification. The concrete shall be mixed thoroughly according to the manufacturer’s recommendation. Concrete shall not be re- tempered by adding water. Any batch of concrete that does not conform to the specification with respect to delivery time, temperature, slump or entrained air content shall be rejected. III.58 202 4 Edition M4.02.11: Storage and Handling of Materials All materials shall be stored and handled in an approved manner.
Cement shall be fully protected against moisture and any cement damaged by exposure shall not be used. Cement shall be emptied directly from the shipping packages into the skip of the mixer, except when bulk cement is used. The cement discharge chute at the aggremeter shall be so arranged that there will be no possibility of loss of cement in passing throug h it.
Aggregates in stockpiles shall be placed on firm well -drained ground. The piles shall be of such shape and size that materials may be handled and stored without becoming dirty or mixed with deleterious substances. Aggregates from different sources or of different grading shall be kept in separate stockpiles. Coarse aggregate will be handled and stored to produce minimum segregation of sizes. Fine aggregate will be handled in such a way as to prevent the loss of fines. Aggregate shall be induced into the aggremeter in an approved manner complying with required gradation. Storage and handling of aggregates shall be done in a manner to ensure a uniform moisture content satisfactory for proper control of the consistency of the mix. Frozen aggregates shall not be used. Aggregates shall be taken continuously from one source in filling the compartments of the batcher bin, and no change of source of any of the aggregates shall be permitted without the consent of the Engineer. The Department reserves the right to prohibit the use of aggregates from any plant, pit quarry or deposit where the character of the material method of operation or rate of production is inadequate. When aggregate is proportioned in the batching plants and transported by trucks to the paving mixer, the compartments in the trucks shall be of sufficient size to prevent spilling from one compartment to another either in transit or when emptying the load into the skip of mixer. M4.02.13: Test Specimens
and temperature shall be measured and recorded when concrete cylinders are fabricated.
Engineer reserves the right to cast test beams or cylinders as they deem necessary. The Contractor shall furnish concrete and such assistance as the Engineer may require. After the fabrication of concrete cylinders by the Engineer, the concrete cylinders shall be protected and cured on the project by the Contractor in accordance with AASHTO T 23 and as directed by the Engineer without additional compensation. The Contractor shall furnish and maintain, without extra compensation, a protected environment to provide initial curing of all concrete cylinders at the project. The protective environment shall be available III.59 202 4 Edition at each site where concrete is placed and then maintained by the Contractor until such time that all concrete cylinders have been transported to the laboratory for testing. The Engineer shall approve each protective environment prior to the beginning of any project concrete placement. The protective environment shall be shielded from direct sunlight and radiant heating devices. The protective environment shall be capable of maintaining the temperature for the stored concrete cylinders in the range between 60°F and 80°F and loss of moisture from the cylinders shall be prevented. When moving the concrete cylinders into the protective environment, precautions shall be taken to avoid any damage to the freshly made concrete cylinders. If the top surface is marred during movement to the protective environment, refinish immediately. The protective environment for the concrete cylinders shall consist of tightly constructed, firmly braced wooden boxes, damp sandpits, temporary building at construction sites, wet burlap covered in plastic in favorable weather, or heavyweight closed plast ic bags. Other suitable methods may be used, upon approval by the Engineer, provided that the foregoing requirements limiting concrete cylinder temperature and moisture loss are met. Storage temperature shall be regulated by means of ventilation, or thermostatically controlled cooling devices, or by using heating devices such as stoves, light bulbs, or thermostatically controlled heating elements. A temperature record of the concrete cylinders shall be established by means of maximum- minimum thermometers. After finishing the concrete cylinders, they shall be covered and placed immediately into the protective environment where they will remain undisturbed for the initial curing period. Concrete cylinders that are to be transported to the laboratory for standard curing before 48 hours shall remain in the molds in a moist environment until they are received in the laboratory, demolded and placed in standard curing. Concrete cylinders that will be transported to the laboratory for standard curing after 48 hours age may be cured in the protective environment provided that the loss of moisture is prevented until the time of transportation and testing. Concrete cylinders shall be demolded no la ter than 48 hours. 28-day and 56 -day concrete cylinders shall be transported to the laboratory for standard curing and testing by the Department personnel within six days of the time of cylinder fabrication. 7 -day cylinders shall be transported to the laboratory as soon as p ossible but not until at least 8 hours after final set (Setting Time may be measured by AASHTO T 197 M/T 197). When the sequence of the construction operation is dependent upon the development of strength in concrete previously placed the specimens taken for this purpose shall be further cured after 24 hours as required in Section 9 of AASHTO T 23 by the Contractor , without additional compensation, under the direction of the Engineer.
entraining admixture is used. If the measured consistency or air -content falls outs ide the III.60 202 4 Edition limits specified, a check test shall be made. In the event of a second failure, the Engineer may refuse to permit the use of the load of concrete represented.
methods:
controlled conditions as described in Article 9.3 of AASHTO T 23 and tested at the age of 28 days and/or other ages as specified. A test is defined as the average strength of two concrete cylinders of the same age, fabricated from a sample taken from a single batch of concrete.
shall be accepted as proof of reasonably close conformity with the sp ecification. If the 56 - day cylinder breaks fail to meet the specified strength, the Contractor may request permission to core the concrete to verify its strength. Coring may only be done with the permission of the Department, at locations chosen by the Department and within 2 weeks of being notified that the 56 -day cylinder breaks have failed. The Department shall specify a minimum of 3 core locations. Core results shall be evaluated in accordance with ACI procedures whereby the average of all core breaks must exceed 85% of the specified design strength and no single core break may be less than 75% of the specified design strength. The Contractor may request permission to core the concrete immediately after the failure of 28-day cylinder breaks, rather than waiting for 56 -day cylinder tests, if waiting for later tests will compromise the project’s schedule. All concrete represented by the compression test that indicates a compressive strength of more than 500 psi below the specified 28 -day strength will be re jected and shall be removed and replaced with acceptable concrete. However, the Contractor may, at their own expense, obtain and submit evidence as outlined below, acceptable to the Engineer, that the strength and quality of the concrete placed in the work is acceptable, then the concrete will be permitted to remain in place and the contractor will be paid at a reduced price as outlined below.
III.61 202 4 Edition source of the problem can be identified and corrected, or new trial batches can be performed. When the average of three consecutive tests, falls to less than 150 psi above the specified strength or any single test falls more than 200 psi below the specifie d strength, the plant shall make corrective changes in the materials, mix proportions or in the concrete manufacturing procedures before placing additional concrete of the same mix design. Such changes shall be subjected to the approval of the Engineer pri or to use.
same concrete mix equal to or exceed the required specified strength fć, and no individual test result falls below the specified strength fć by more than 500 psi. Non -destructive testing will not be permitted in lieu of compressive strength tests of concrete cylinders, air content tests by the pressure method, slump or other test for evaluation and acceptance on concrete placed on the projects. Coring is the only acceptance method to determine the in -situ characteristics of concrete. The size of the core shall be 4 -in. finished diameter for concrete with ¾- in. or less aggregate and 6 -in. finished diameter for concrete with aggregate greater than ¾ in. The length of the concrete core, when capped, shall be as nearly as practicable twice its diameter and a strength correction factor in accordance with AASHTO T 24 must be determined based on the ratio of Length to Diameter (L/D). Cores with L/D ratio less than 1 shall not be tested. Wipe off the surface of the drilled cores and allow the remaining surface moisture to evaporate. When the surfaces appear dry but not more than an hour after drilling, place cores in separate plastic bags or non -absorbent containers and seal to prevent moisture loss. Allow the cores to remain in the sealed plastic bags or non -absorbent containers for at least 5 days after last being wetted before making the compression test. A request for strength analysis by coring shall be approved by the Engineer prior to beginning the work. Coring will not be permitted if the Department determines it would be harmful to the integrity of the structure, Cores shall be obtained by the Contractor and witnessed by the Engineer in accordance with AASHTO T 24 M/T 24 and delivered to RMS for testing in accordance with AASHTO T 22. The test results will be considered proof of in -situ concrete strength and will supersede all other strength data for the concrete represented by that placement. Cores shall be obtained no later than two weeks after the 56 day cylinder breaks have failed. All reinforcing steel shall be located with a pachometer around the proposed coring locations prior to the coring operation. The Department shall approve the location to be cored. And all cost associated with th e coring operation including the repair of cored area shall be the responsibility of the contractor. The Contractor shall patch the core holes with low slump mortar, similar to that used in the concrete, immediately after coring, to the satisfaction of the Engineer. Acceptance by core method requires that the average compressive strength of three cores from the same concrete placement exceeds 85 percent of the specified design strength with no single core less than 75 % of the specified design strength. These cores may be subjected to petrographic analysis, if deemed necessary by the Engineer and at the expense of the Contractor, to determine if there is microscopy evidence that identifies the constituents of concrete, possible reasons for the strength deficiency of the in -situ concrete, if any, and to provide a basis for assessing the quality and long term durability of the in -situ concrete. The results of the petrographic analysis will be considered in conjunction with the results of concrete cylinders t o determine if the concrete can remain in place or has to be removed. III.62 202 4 Edition Concrete that meets the strength requirements through the 28 -day, the 56 -day break or the core break shall be considered in reasonably close conformance with the specifications and no credit shall be taken. Concrete with cylinder or core compressive strength (fc) which fails to meet acceptance level requirements shall be evaluated for structural adequacy at the Contractors’ expense. The Department shall review all production records, the concrete test records, petrographic analysis report, field notes, and the placement records for the concrete in question. If the Engineer determines the material is found to be adequate to remain in place, payment shall be adjusted in accordance with the following formula: 𝑃𝑃=2(𝑓𝑓𝑓𝑓−𝑓𝑓𝑓𝑓́ )(𝑈𝑈𝑃𝑃)(𝑄𝑄) 𝑓𝑓𝑓𝑓́ Where: 𝑃𝑃=𝑝𝑝𝑝𝑝𝑝𝑝 𝑝𝑝𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑓𝑓𝑓𝑓𝑓𝑓 𝑎𝑎𝑎𝑎𝑠𝑠𝑎𝑎𝑎𝑎𝑝𝑝𝑎𝑎𝑎𝑎𝑝𝑝𝑓𝑓𝑎𝑎 𝑓𝑓𝑓𝑓𝑎𝑎𝑓𝑓𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎 𝑓𝑓 𝑓𝑓́=𝑎𝑎𝑝𝑝𝑎𝑎𝑓𝑓𝑠𝑠𝑓𝑓𝑠𝑠𝑎𝑎𝑎𝑎 𝑎𝑎𝑠𝑠𝑎𝑎𝑠𝑠𝑎𝑎𝑎𝑎𝑎𝑎 𝑓𝑓𝑓𝑓𝑎𝑎𝑝𝑝𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎𝑠𝑠𝑐𝑐𝑎𝑎 𝑎𝑎𝑎𝑎𝑓𝑓𝑎𝑎𝑎𝑎𝑠𝑠𝑎𝑎ℎ 𝑝𝑝𝑎𝑎 28 𝑎𝑎𝑝𝑝𝑝𝑝𝑎𝑎 𝑓𝑓𝑓𝑓=𝑎𝑎𝑎𝑎𝑠𝑠𝑎𝑎𝑎𝑎𝑝𝑝𝑎𝑎𝑎𝑎𝑝𝑝𝑓𝑓𝑎𝑎 𝑓𝑓𝑓𝑓𝑎𝑎𝑓𝑓𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎 𝑓𝑓𝑝𝑝𝑐𝑐𝑠𝑠𝑎𝑎𝑎𝑎𝑎𝑎𝑓𝑓 𝑓𝑓𝑓𝑓𝑎𝑎𝑝𝑝𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎𝑠𝑠𝑐𝑐𝑎𝑎 𝑎𝑎𝑎𝑎𝑓𝑓𝑎𝑎𝑎𝑎𝑠𝑠𝑎𝑎ℎ 𝑝𝑝𝑎𝑎 28 𝑎𝑎𝑝𝑝𝑝𝑝𝑎𝑎 𝑓𝑓𝑓𝑓 𝑓𝑓𝑓𝑓𝑎𝑎𝑝𝑝𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎𝑠𝑠𝑐𝑐𝑎𝑎 𝑎𝑎𝑎𝑎𝑓𝑓𝑎𝑎𝑎𝑎𝑠𝑠𝑎𝑎ℎ 𝑓𝑓𝑓𝑓 𝑓𝑓𝑓𝑓𝑎𝑎𝑓𝑓𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎 𝑓𝑓𝑓𝑓𝑓𝑓𝑎𝑎𝑎𝑎 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑓𝑓𝑎𝑎𝑠𝑠𝑎𝑎𝑎𝑎𝑎𝑎 𝑠𝑠𝑝𝑝 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝐴𝐴 22 𝑄𝑄=𝑞𝑞𝑎𝑎𝑝𝑝𝑎𝑎𝑎𝑎𝑠𝑠𝑎𝑎𝑝𝑝 𝑓𝑓𝑓𝑓 𝑓𝑓𝑓𝑓𝑎𝑎𝑓𝑓𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎 𝑓𝑓𝑎𝑎𝑝𝑝𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑠𝑠𝑝𝑝 𝑎𝑎ℎ𝑎𝑎 𝑝𝑝𝑓𝑓𝑓𝑓𝑎𝑎𝑝𝑝𝑎𝑎𝑝𝑝𝑎𝑎𝑓𝑓𝑎𝑎 𝑓𝑓𝑝𝑝𝑐𝑐𝑠𝑠𝑎𝑎𝑎𝑎𝑎𝑎𝑓𝑓𝑎𝑎 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑈𝑈𝑃𝑃=𝑎𝑎𝑎𝑎𝑠𝑠𝑎𝑎 𝑓𝑓𝑓𝑓𝑎𝑎𝑎𝑎𝑓𝑓𝑝𝑝𝑓𝑓𝑎𝑎 𝑝𝑝𝑓𝑓𝑠𝑠𝑓𝑓𝑎𝑎 𝑓𝑓𝑓𝑓 𝑎𝑎ℎ𝑎𝑎 𝑐𝑐𝑎𝑎𝑎𝑎𝑝𝑝 𝑎𝑎𝑎𝑎𝑎𝑎 𝑠𝑠𝑓𝑓𝑎𝑎𝑝𝑝𝑏𝑏𝑎𝑎𝑓𝑓𝑏𝑏𝑎𝑎 𝑝𝑝𝑓𝑓𝑠𝑠𝑓𝑓𝑎𝑎 𝑝𝑝𝑎𝑎𝑓𝑓 𝑓𝑓𝑎𝑎𝑠𝑠𝑠𝑠𝑓𝑓 𝑝𝑝𝑝𝑝𝑓𝑓𝑎𝑎 𝑓𝑓𝑓𝑓𝑓𝑓 𝑎𝑎ℎ𝑎𝑎 𝑓𝑓𝑐𝑐𝑝𝑝𝑎𝑎𝑎𝑎 𝑓𝑓𝑓𝑓 𝑓𝑓𝑓𝑓𝑎𝑎𝑓𝑓𝑓𝑓𝑎𝑎𝑎𝑎𝑎𝑎 𝑠𝑠𝑎𝑎𝑐𝑐𝑓𝑓𝑐𝑐𝑐𝑐𝑎𝑎𝑎𝑎 𝑓𝑓𝑓𝑓𝑎𝑎𝑝𝑝𝑐𝑐𝑎𝑎𝑎𝑎𝑎𝑎 𝑠𝑠𝑎𝑎 𝑝𝑝𝑐𝑐𝑝𝑝𝑓𝑓𝑎𝑎 M4.02.14: Precast Concrete Highway Units The following Precast Concrete Highway Units shall meet the requirements specified herein: (a)Standard Temporary Barriers (b)Standard Permanent Barriers (c)Box Culverts (Spans ≤ 10 ft) (d)Catch Basins (e)Drainage Pipes (Non -Dry Cast) (f)Manholes (g)Retaining Wall Systems (h)Traffic Light Pole Bases (i)Luminaire Bases A.Materials. Materials shall meet the requirements specified in Section M4: Cement and Cement Concrete Materials , the following Subsections of Division III, Materials, and specified herein: III.63 202 4 Edition Self- Consolidating Concrete for Precast Products ......................................................... M4.02.17 High Performance Cement Concrete ................................................................................... M4.06.1 Reinforcing Bars ........................................................................................................................... M8.01.0 Epoxy Coated Reinforcing Bars ............................................................................................. M8.01.7 Galvanized Reinforcing Bars ................................................................................................... M8.01.8 Primer and Damp -Proofing ..................................................................................................... M9.09.0 Liquid Penetrant/Sealant ......................................................................................................... M9.15.0
Fabricators shall report proposed mix design formulations onto the Department issued mix design sheet in its entirety and submit to the Department for evaluation. Mix design formulations shall be designed with precise proportions of constituent materials, yielding 27.0 ft³ (1 cubic yard) of cement concrete. All required mix design targets shall be reported on the Department issued mix design sheet for each proposed mix design. Cement concrete mix designs shall be classified and reported according to the specified compressive strength of the concrete structure (f’ c), nominal maximum aggregate size (NMAS), and mix type. The specified compressive strength of the concrete structure (f’ c) shall be identified from the construction standard specifications, contract document special provisions, and design plans. Nominal maximum aggregate size (NMAS) shall be determined from the combined aggregate system of the proposed mix design formulation and is defined as the sieve size immediately above the first sieve size that cumulatively retains more than 10% by mass. Proposed mix design formulations will be evaluated for quality and conformance to the requirements specified herein.
Precast concrete barrier shall be fabricated with cement concrete meeting M4.06.1: High Performance Concrete.
Precast concrete highway units fabricated with self- consolidating concrete shall meet M4.02.17: Self- Consolidating Concrete for Precast Concrete Products .
Upon Department Acceptance of the mix design evaluation, Fabricators proposing new mix design formulations shall select an AASHTO accredited independent laboratory to conduct mix design verification testing. The sampling and testing conducted by the independent laboratory shall be witnessed by the Department. Fabricators shall report the source, type, quantity, and design target for each constituent material incorporated into the p roposed mix design onto batch tickets meeting AASHTO M 157. Fabricators shall provide Batch tickets to the Department for review. Mix design verification test results shall be within the limits specified in Table M4.02.14 -1. Proposed mix design formulations for high performance concrete shall meet the additional requirements specified in M4.06.1: High Performance Concrete and self -consolidating concrete shall meet the additional requirements specified in M4.02.17: Self- Consolidating Concrete for Precast Concrete Products. III.64 202 4 Edition Table M4.02.14- 1: Mix Design Verification Testing Requirements Property Method Quality Characteristic Limits Min. Max. Uniformity T 119[1] Slump (in.) < 4 in. Target -1.0 Target +1.0 4 – 8 in. Target -1.5 Target +1.5 T 121[1] Unit Weight (lb/ft3) For Information Workability T 119[2] Segregation Resistance Pass Thermal T 309 Concrete Temperature (°F) 50 90 Strength T 22[1][3][4] Compressive Strength (psi) 3 Days – – 7 Days – – 28 Days f’c – 56 Days – – Durability T 358[3] Surface ChlorideIon Penetration Resistance ( kΩ-cm) 7 Days – – 28 Days 15 – T 121[1] T 152[1] T 196[1] Freezing, Thawing, and De- Icing Resistance: Air Content (%) Target -1.0 Target +1.0 C 1567 Alkali Silica Reaction Resistance: Expansion of Accelerated Mortar Bar (%) 14 Days M4.02.00 [1] Prior to mix design verification testing, the Cement Concrete Producer shall identify and report the proposed mix design targets onto the Department issued cement concrete mix design sheet. Any adjustments made to the proposed mix design targets shall be based on the verification test results, and are subject to Department approval and the requirements specified herein. [2] Testing for segregation resistance shall be performed while the concrete is being discharged and during AASHTO T 119 Standard Method of Test for Slump of Hydraulic Cement Concrete. Visual signs of segregation include coarse particles advancing in fron t of or behind the fine particles and mortar and a tendency for coarse aggregate to separate from the mortar, particularly when the mixture is being consolidated. [3] Three (3) 4 x 8 in. cylinders shall be cast for each set specified for maximum aggregate size less than 1 - ½ inches. Two (2) 6 x 12 in. cylinders shall be cast for each set specified for maximum aggregate size greater than 1 inch.
Reinforcement for precast concrete barrier shall meet M8.01.7: Epoxy Coated Reinforcing Bars or M8.01.8: Galvanized Reinforcing Bars , and Grade 60 of the AASHTO M 31. The 1 -in. plain dowel bars shall conform to ASTM A36 and shall be galvanized according to AASHTO M 111M/M 111.
Precast Concrete Highway Units shall be fabricated by a Department approved precast or prestressed concrete Fabricator, under the controlled settings of the approved Fabricator’s facility, with a Department approved mix design formulation, as specified her ein. Fabricators and concrete III.65 202 4 Edition mix design formulations shall maintain valid listing on the QCML. Precast Concrete Highway Units shall be fabricated in conformance with:
for Precast Concrete Plants
for Plants and Production of Structural Precast Concrete Products
Circular vertical precast reinforced concrete manholes and structures used in sewer, drainage, and water works shall meet AASHTO M 199. Reinforced concrete draingage pipes intended to be used for the conveyance of sewage, industrial wastes, and storm water shall meet AASHTO M 170.
Prior to fabrication of precast concrete highway units, the Fabricator shall prepare shop drawings in accordance with:
Prior to fabrication of non -standard precast concrete highway units, the Fabricator shall prepare shop drawings in accordance with the relevant provisions of 5.02: Plans and Detail Drawings and shall, at a minimum, contain the following, where applicable:
splicers to be used for connecting products together in the field (if called for on plans).
amount of any additional reinforcing required for lifting. The Fabricator shall design all lifting devices based on the no cracking criteria in the latest edition of the PCI Design Handbook.
c), Nominal Maximum Aggregate Size (NMAS), and Mix Type. III.66 202 4 Edition Proposed shop drawings shall be drawn to scale and submitted to the Engineer of Record for review and approval. The shop drawings shall not include procedures for placement, finishing, and curing of concrete. These details shall be included in the Fabricat or’s Quality Control Plan as specified herein.
Fabricators shall verify the conformance of the constituent materials to specifications from Quality Control testing and Manufacturer certificates of compliance and meet the control, handling, and storage of constituent materials requirements specified herein.
Hydraulic cement and supplementary cementitious materials shall be sufficiently controlled, handled, and stored through prevention of moisture absorption, cement caking, and contamination. Hydraulic cement and supplementary cementitious materials shall be stored in weathertight, sufficiently ventilated structures to prevent absorption of moisture. The interior of a cement silo shall be smooth, with a minimum bottom slope of 50 degrees from the horizontal for a circular silo and 55 to 60 degrees for a rectan gular silo. Silos shall be equipped with non -clogging air -diffuser flow pads through which small quantities of dry, oil -free, low -pressure air can be introduced intermittently at approximately 3 to 5 psi to loosen cement that has settled tightly in the sil os. Storage silos shall be drawn down once per month to prevent cement caking. Each bin compartment from which cement is batched shall include a separate gate, screw conveyor, air slide, rotary feeder, or other conveyance that allows both constant flow and precise cutoff to obtain accurate batching of cement. Sources of contamination include incorrect sources placed into storage structures and dust contaminants. Storage structures shall be sufficiently labeled to avoid contamination. Contamination shall be sufficiently monitored and controlled during loading a nd transferring.
Aggregate shall be sufficiently controlled, handled, and stored through prevention of gradation variation due to segregation and undersized particles, moisture content variation, contamination, degradation, and fracture.
Aggregate gradation shall be sufficiently monitored to maintain control of the mix design. Aggregate shall be stockpiled in thin horizontal layers of uniform thickness to limit segregation. Storing aggregate in large conical stockpiles causes segregation a nd shall be prohibited. Segregation is limited when the coarse aggregate is further divided into several different sized sub -groupings with smaller ranges to be batched separately. Segregation in the coarse aggregate is controlled when the maximum aggregat e size to the minimum aggregate size for a given aggregate size grouping is limited to a 4 to 1 ratio for maximum aggregate size less than 1 in. and is limited to a 2 to 1 ratio for maximum aggregate size greater than or equal to 1 in. Undersized particles for a given coarse aggregate size grouping is defined as material passing the sieve size with an opening ⅚ of the nominal minimum size of the coarse aggregate size grouping. Coarse aggregate shall be rescreened as it is charged to the bins to remove undersized particles and III.67 202 4 Edition undesirable fines if handling and storage methods are unsatisfactory and variations in gradation exceed allowable tolerances. Storage bins (hoppers) shall be circular or nearly square and their bottoms shall slope more than 50 degrees from the horizontal on all sides to a center outlet. During bin loading, the aggregate shall be discharged directly above and fall vertically into the center of the bin. Discharging aggregate against the side of the bin or baffle wall causes segregation and shall be prohibited. Baffle plates or dividers can minimize segregation. Bins shall be filled to limit variation in gradation caused by withdrawa l of material, segregation, and breakage of aggregate particles. Dry fine aggregate when dropped from buckets or conveyors shall be sufficiently shielded from wind and other external forces to prevent loss of fines. Fine aggregate may require dampening to prevent segregation of material.
Aggregate moisture content shall be sufficiently monitored to maintain control of the mix design. Coarse aggregate shall be wetted to keep the aggregate in a constantly saturated condition, to compensate for aggregate absorption, and to provide cooling. Aggregate shall be sufficiently dewatered and drained to form a uniform moisture content and to prevent transfer of excessive free water to the bins. Fine aggregate, due to its surface area, contributes the largest amount of free water added to the mix desig n. Moisture meters can indicate variations in the moisture of aggregate and moisture compensators can be used for rapid batch weight adjustments, to limit moisture variations in the aggregate. Aggregates washed to remove contaminants shall be stockpiled well before use so that they can drain to a uniform moisture content.
Sources of contamination include overlapping of different aggregate sizes from adjacent stockpiles, aggregate leakage through or around bulkheads in storage bins, underlying soil, dislodged clay lumps and other contaminants from transporting unit, leaves and vegetation, freezing aggregate, incorrect delivery from aggregate manufacturer, and incorrect aggregate size placed into a bin or stockpile. Stockpiles shall be placed on a hard base with sufficient drainage to prevent contamination from underlying material. Bulkheads, dividers, and partitions with sufficient height and ample spacing between piles shall be utilized to avoid cross -contamination and overlapping of different aggregate sources, types, and size groupings between stockpiles. Storage areas shall be sufficiently labeled to avoid contamination. Clay lumps or clay balls shall be removed from the aggregate by placing a scalping screen over the batch plant bin. Aggregate may require washing to remove contaminants. During cold temperatures, bins shall be covered or underground to prevent the freezing of aggregate. Frozen aggregate shall be prohibited from use. Aggregates may require heating to maintain an acceptable aggregate temperature and prevent freezing. Trucks, loaders, dozers, and other heavy transport equipment shall not be operated on the stockpiles due to the potential for aggregate particle fracture and contamination of track dirt onto the piles. Additional measures, including storage area coverings, shall be instituted in cases where storage areas are subject to other sources of contamination.
Mixing water shall be sufficiently controlled, handled, and stored through prevention of contamination. III.68 202 4 Edition d. Chemical Admixtures. Chemical admixtures shall be sufficiently controlled, handled, and stored through prevention of contamination. Sources of contamination include freezing, evaporation, sunlight, and incorrect chemical admixture sources placed into chemical admixture tanks. Chemical admixtures shall be stored in heated environments to prevent freezing. Frozen chemical admixtures shall be reblended. Long -term storage of liquid admixtures in vented tanks shall be prohibited due to evaporation of the liquid negatively affecting the performance of the mix design. Certain chemical admixtures are prone to sunlight and shall be sufficiently protected in the storage tanks. Storage tanks shall be sufficiently labeled to avoid contamination. Chemical admixtures shall be stored in accordance with the chemical admixture manufacturer’s recommendations.
Concrete shall be batched, mixed, delivered, placed, finished, and cured with ambient temperatures greater than or equal to 40 ℉ and less than or equal to 85 ℉. The temperature of plastic concrete shall be greater than or equal to 50 ℉ and less than or equal to 90 ℉. At no point shall the temperature of the concrete exceed 158 ℉. Temperature measuring devices shall record and report to the nearest 1 ℉. The Fabricator shall continuously monitor, record, and report the ambient temperatures surrounding the concrete without interruption, at a minimum frequency of once per hour, until 100% of f’c is attained. The Fabricator shall confirm all temperature req uirements meet the specifications herein. Fabricator temperature monitoring records shall be provided to the Department upon request.
The concrete shall be protected from all adverse conditions, including precipitation, cold conditions, and hot conditions, until 100% of f’ c is attained, as specified 901.64: Protection from Adverse Weather.
Equipment, measurement, tolerances, procedures, sequencing, and batch ticketing used for the batching and mixing of cement concrete shall meet the applicable standards of AASHTO M 157, Concrete Plant Manufacturers Bureau (CPMB), Truck Mixer Manufacturers B ureau (TMMB), National Institute of Standards and Technology (NIST), and the requirements specified herein . Weigh batch equipment shall be categorized as manual, partially automatic, semiautomatic, and fully automatic. Scales and volumetric devices for measuring quantities of constituent materials shall be calibrated for accuracy through certified field standard weights and product substitute loading. Scales shall be accurate to the greater of ±0.15% of the scale capacity or ±0.4% of the applied test load in all quarters of the scale capacity through its range of use. The accuracy of scales and batching equipment shall be inspected routinely and adjusted when necessary. Equipment shall be isolated from plant vibration. Automatic controls shall be protected from dust and weather. Scale and beam pivot points shall be routinely inspected and cleaned. Equipment shall operate within the specified batch -weight tolerances specified in Table M4.02.14 -2. Equipment shall be made accessible to the Department for inspection. III.69 202 4 Edition Table M4.02.14- 2: Allowable Batching Tolerances of Mix Design Target Weights Specification Constituent Material Batch Weights > 30% of Scale Capacity Batch Weights ≤ 30% of Scale Capacity Individual Batching Tolerances Cumulative Batching Tolerances Individual Batching Tolerances Cumulative Batching Tolerances M 157 Hydraulic Cement (%) ±1.0 or ±0.3% of scale capacity, whichever is greater Not less than required weight or 4% more than required weight Hydraulic Cement + Supplementary Cementitious Materials (%) ±1.0 or ±0.3% of scale capacity, whichever is greater Not less than required weight or 4% more than required weight Aggregate (%) ±2.0 ±1.0 ±2.0 ±3.0 or ±0.3% of scale capacity whichever is less Mixing Water (%) ±1.0 Prohibited ±1.0 Prohibited Chemical Admixtures (%) ±3.0 Prohibited ±3.0 Prohibited Cement concrete shall be mixed by stationary mixers, truck mixers, volumetric (continuous) mixers, or portable mixers. Cement concrete shall be mixed thoroughly until the constituent materials are uniformly distributed. Mixers shall be adequately designed with blade or fin arrangements and drum shapes that ensure an end -to-end exchange of materials parallel to the axis of rotation or a rolling, folding, and spreading movement of the batch over itself as it is being mixed. Mixing blades shall be free of wear and hardened concrete. Modifications to Department approved mix design formulations, including source of constituent materials, design quantities, mix type, combined aggregate system targets, paste system targets, slump targets, air content targets, and compressive strength targ ets shall be prohibited. However, if slump or air content test results are not within the specified design target ranges, the Fabricator is permitted to submit to the Department a request to review and approve proposed adjustments of chemical admixture dos ages. At no point shall the total water or water -cementitious (w/cm) ratio exceed the approved mix design formulation targets. The Producer shall report the adjustments onto the batch ticket. Chemical admixture adjustments without Department approval shall be prohibited. Department approval is subject to performance at the plant, as well as conformance to the requirements specified herein.
Precast Concrete Highway Units shall meet 901.61: Forms, Falsework, and Centering and PCI Manual 116 -21, Section 2.4 Forms/Molds. Precast concrete barrier shall be cast with the forms in a 180° inverted position and compacted with an approved vibrator.
Precast Concrete Highway Units shall meet 901.62: Reinforcement and the reinforcement materials requirements specified herein. III.70 202 4 Edition 9. Handling and Placing of Concrete. Precast Concrete Highway Units shall meet 901.63: Handling and Placing Concrete.
As-cast formed surface finishes shall be acceptable in appearance, color, and texture. Exposed unformed surface finishes shall be finished by screeding or floating, unless otherwise noted. Under no circumstances shall bleed water or initial curing materials be worked into the surface. The addition of water, spreading of cement, or the use of unacceptable tools, including steel trowels and fresnos to the surface of the concrete shall be prohibited. The concrete shall not be overworked, to prevent premature d egradation from excess water and fine material rising to surface. Defects shall be addressed per M4.02.14: Precast Concrete Highway Units , B.15: Repairs and Replacement.
Final curing materials, methods, and procedures shall be applied to all exposed cement concrete surfaces immediately after the completion of finishing operations and final set to prevent the loss of moisture and surface drying. Exposed surfaces from form removal shall be wetted immediately and kept moist until final curing materials are applied. Final curing materials applied to the concrete shall allow the concrete to mature sufficiently to achieve its designed and desired properties, including strength, volume stability, permeability, durability, and resistance to freezing, thawing, and de- icing cycles. Curing water shall be free of deleterious impurities, causing staining and deterioration. The potential staining ability of curing water shall be evaluated by means of US Army Corps of Engineers CRD-C401 Method of Test For The Staining Properties of Water for instances where curing water quality is questioned. The Fabricator shall maintain a continuous application of moisture or moisture retention throughout the entire duration of the final curing method cycle and meet the minimum sustained ambient temperature, concrete temperature, duration, and strength requir ements as specified herein. Controlled, gradual, and uniform termination of the final curing method cycle shall begin only after all specified conditions are met. The concrete temperature shall be reduced at a rate not to exceed 36℉ per hour until the conc rete temperature is within 20 ℉ of the ambient temperature. Termination of final curing methods shall not occur until both the duration and compressive strength requirements are met, as specified in Table M4.02.14 -2. III.71 202 4 Edition Table M4.02.14- 3: Termination of Final Curing Method Product Categories Methods Duration Compressive Strength Precast Concrete Highway Products (Excluding Barrier) Form Cure[1] – ≥ 70% of f’ c Precast Concrete Barrier Liquid Membrane- Forming Compounds[2] Saturated Covers Sheet Materials ≥ 3 Days ≥ 80% of f’ c Curing Water Nozzles ≥ 5 Days [1] Final curing materials, methods, and procedures shall be applied to all exposed surfaces not being cured by the form. [2] If the liquid membrane -forming compound is to be removed due to compatibility or bonding concerns, removal shall not take place until the specified application duration is met. Concrete cured by way of curing water nozzles, saturated covers, sheet materials, or liquid membrane -forming compounds shall be cured with sustained ambient temperatures greater than or equal to 40 ℉ and less than or equal to 85 ℉. Curing water shall not exceed a temperature differential of more than 20 ℉ from the internal concrete temperature, to prevent cracking due to temperature gradients causing strain that exceeds the strain capacity of concrete. Curing water shall remain above freezing temperatures throughout the duration of the curing cycle. Compre ssive strength cylinders for termination of curing cycle shall be cast and field cured with the same environmental conditions that the concrete is subjected to throughout the entire d uration of the curing cycle. All procedures, operations, materials, and equipment required for adequate curing shall be present and ready for use prior to concrete production.
Curing water nozzles shall provide the surface of cement concrete with a continuous fine spray of water.
Saturated covers shall meet AASHTO M 182, Class 3. Saturated covers shall be in good condition, free from holes, tears, or other defects that would render it unsuitable for curing cement concrete. Saturated covers shall be dried to prevent mildew when storing. Saturated covers shall be of sufficient thickness to maximize moisture retention. Saturated covers shall be free of harmful substances that are deleterious or cause discoloration to cement concrete and cementitious materials. Saturated covers shall have the ability to retain sufficient moisture from continuous watering so that a film of water remains on the surface of cement concrete. Prior to application, saturated covers shall be thoroughly rinsed in water and free of harmful substances that are deleterious or cause discoloration to cement concrete. The Fabricator shall maintain sufficient moisture with continuous watering so that a film of water remains on the surface of the cement concrete throughout the entire duration of the final curing method cycle. Saturated covers shall be properly positioned, secured, and maintained on the surface of the III.72 202 4 Edition concrete to maximize moisture retention and to prevent moisture loss. The Fabricator shall prohibit saturated covers from drying out and prevent the absorption of curing water from the surface of the concrete. Polyethylene film may be applied over the saturated cover to limit the amount of continuous watering required for sufficient moisture ret ainage.
Sheet materials shall meet ASTM C171. Sheet materials shall inhibit moisture loss and reduce temperature rise in concrete exposed to radiation from the sun. Adjoining sheet materials shall overlap not less than 12 in. All edges of the sheet materials shall be secured to maintain a moist environment.
Polyethylene film shall be clear, white, or black in color and consist of a single sheet manufactured from polyethylene resins, be free of visible defects, including tears, wrinkles, and discontinuity. The film shall prohibit mottling and uneven spots from appearing on the surface of concrete, due to variations in temperature, moisture content, or both. Polyethylene film shall accommodate concrete surfaces with constant contact without damage. White polyethylene film shall minimize heat gain caused by absor ption of solar radiation. Clear and black polyethylene films shall inhibit absorption of solar radiation and be exclusively applied during cold conditions. The Fabricator shall prohibit mottling and uneven spots from appearing on the surface of concrete, due to variations in temperature, moisture content, or both. Application of additional curing water under the film or application of a polyethylene film bonded to absorbent fabric to the concrete surface may be required to prevent mottling and to retain and evenly distribute the moisture. The Polyethylene film shall be applied to concrete surfaces with constant contact without damage. The film shall extend bey ond the edges of the concrete surface. Edges of adjacent polyethylene film shall overlap a minimum of 6 in . and be tightly sealed with the use of sand, wood planks, pressure - sensitive tape, mastic, or glue to maintain close contact with the concrete surface, retain moisture, and prevent the formation of air pockets.
White burlap -polyethylene sheeting shall be securely bonded to the burlap so to avoid separation of the materials during handling and curing of the concrete.
Reinforced impervious paper shall be white in color, consist of two sheets of kraft paper cemented together with a bituminous adhesive, and reinforced with embedded cords or strands of fiber running in both directions. Reinforced impervious paper shall be free of holes, tears, and pin holes from deterioration of the paper through repeated use. Reinforced impervious paper shall be treated to prevent tearing when wetted and dried. Reuse of reinforced impervious paper shall be permitted so long as it is able t o retain moisture on the surface of concrete. The paper shall be discarded and prohibited from use when moisture is no longer retained in the material. III.73 202 4 Edition d. Liquid Membrane -Forming Compounds. Liquid membrane -forming compounds, including compounds with curing properties and compounds with both curing and sealing properties, shall maintain valid listing on the QCML and meet the requirements specified herein. Compounds shall form a continuous, non -yellowing, and durable film with quality moisture - retention properties. Compounds shall maintain the relative humidity of the concrete surface above 80% for greater than or equal to 3 days to sustain cement hydration. Compounds shall not affect the original color of the concrete surface. Compounds shall not degrade due to exposure to ultraviolet light from direct sunlight. Compounds shall meet the local and federal allowable Volatile Organic Compound (VOC) content limits. Liquid membrane -forming compounds shall be applied per the Manufacturer’s instructions and recommendations as specified herein. Prior to use, compounds shall be thoroughly mixed, stirred, and agitated. Compounds shall be applied immediately after final finishing and the disappearance of the surface water sheen, but before the free water on the surface has evaporated, to prevent the formation of cracks and loss of moisture at the surface. Careful considerations shall be made by the Fabricator to determine if the evaporation rate is exceeding the rate of bleeding, thus causing the surface to appear dry even though bleeding is still occurring. To diagnose and prevent this condition, the Fabricator shall place a transparent plastic sheet over a test area of the uncured and unfinished concrete surface and shall determine if any bleed water accumulates under the plastic. Under such conditions, the application of liquid membrane -forming compounds to the concrete surface shall be delayed to prevent bleed water from being sealed below the concrete surface, map cracking of the membrane films, reduction in moisture -retention capability, and the need for reapplication of the compound. When using compounds to reduce moisture loss from formed surfaces, the exposed surface shall be wetted immediately after form removal and kept moist until the compound is applied. The concrete shall be allowed to reach a uniformly damp appearance with no free water on the surface, and then application of the compound shall begin at once. Delayed application resulting in surface drying, absorption of the compound into the concrete, and forming of a discontinuous membrane shall be prohibited. The concrete surface shall be damp when the compound is applied. Power -driven spray equipment shall be used for uniform application of compounds on large paving projects. Spray nozzles recommended by the compound Manufacturer and use of windshields shall b e arranged by the Fabricator to prevent wind -blown loss of compound and to ensure proper coverage application rates are achieved. The compound shall be applied by power sprayer, using appropriate wands and nozzles with pressures between 25 and 100 psi. The Fabricator shall fill the power sprayer with curing compound from the Manufacturer’s original container in the presence of the Engineer. Any dilution as recommended by the Manufacturer shall take place in the presence of the Engineer. For very small areas such as repairs, the compound shall be applied with a wide, soft -bristled brush or paint roller. The Fabricator shall verify the application rate and procedures are in accordance with the Manufacturer’s instructions and recommendations. At least one uniform coat shall be applied at a rate of 150 to 200 ft 2/gallon. On very deeply textured surfaces, the surface area to be treated shall be at least twice the surface area of the surface. In such cases, two separate applications may be III.74 202 4 Edition needed, each at 200 ft2/gallon or greater if specified by the Manufacturer to achieve the desired moisture retention rate, with the first being allowed to become tacky before the second is applied. If two coats are necessary to ensure complete coverage, for effective protection the second coat should be applied at right angles to the first. Complete coverage of the surface shall be attained due to the potential for formation of small pinholes in the membrane, which will result in loss of moisture from the concrete. Compounds shall not sag, run off peaks, or collect in grooves. Compounds and procedures shall be compatible with concrete surfaces receiving subsequent applications or placements of concrete, overlays, coatings, paints, sealers, finishes or other toppings to ensure acceptable bonding to the concrete. Testing to establish compatibility among the curing compound, subsequent surface treatments, concrete moisture content and the actual finished surface texture of the concrete shall be conducted when compatibility is not known. The compound Manufacturer shall be consulted b y the Fabricator to determine the compatibility of the application. Compounds shall not be applied to concrete surfaces where bonding of subsequent applications or placements is incompatible or is of concern. The use of wax -based curing compounds shall be prohibited in instances where concrete surfaces are subject to additional toppings and vehicular, pedestrian, or other traffic. Deliberate removal of compounds in the presence of the Engineer and in accordance with Manufacturer’s instructions and recommendations shall be conducted as an alternative to compatibility testing, incompatibility, or in instances where bonding is of conce rn. Bonding of subsequent materials may still be inhibited by the presence of the compound even after the moisture retention characteristics of the compound have diminished. White -pigmented compounds shall be used in instances where solar -heat gain is concern to the concrete surface. White -pigmented compounds shall be agitated in the container prior to application to prevent pigment from settling out resulting in non -uniform overage and ineffective curing.
Liquid membrane -forming compounds for curing shall meet ASTM C309 and the requirements specified herein. Table M4.02.14- 4: Types Type Description Type 1 Clear or translucent without dye Type 1 -D Clear or translucent with fugitive dye Type 2 White pigmented Table M4.02.14- 5: Composition Classification Type Description Class A Unrestricted composition, generally wax -based products Class B ASTM D883 resin -based products III.75 202 4 Edition (2) Liquid Membrane -Forming Compounds for Curing and Sealing. Liquid membrane -forming compounds for curing and sealing shall meet ASTM and the requirements specified herein. The protective sealing requirements specified in M4.02.14: Precast Concrete Highway Units , B.16 do not apply to cement concrete surfaces previously applied with liquid membrane -forming compounds for curing and sealing. In addition to moisture -retention capabilities compounds shall exhibit specific properties, including alkali resistance, acid resistance, adhesion -promoting quality, and resistance to degradation by ultraviolet light. Table M4.02.14- 6: Types Type Description Type I Clear or translucent Type II White pigmented Table M4.02.14- 7: Classification Type Description Class A Non -yellowing
The Fabricator shall not remove forms from the concrete until compressive strength cylinders attain 70% of f’ c. Compressive strength cylinders for removal of forms shall be cast and field cured with the same environmental conditions that the concrete is subjected to throughout the entire duration of the operation. Immediately following form removal, all exposed concrete surfaces shall be prepared and cured per the requirements specified in.
Precast Concrete Highway Units shall not be handled until form removal strength has been attained. Concrete products shall be lifted at the designated points by approved lifting devices embedded in the concrete and in accordance with proper lifting and han dling procedures. Storage areas shall be smooth and well compacted to prevent damage due to differential settlement. Concrete products shall be supported on the ground by means of continuous blocking, in conformance with the approved dunnage plan. The conc rete shall be protected from all adverse conditions, including precipitation, cold conditions, and hot conditions, until 100% of f’ c is attained, as specified 901.64: Protection from Adverse Weather.
The Fabricator shall apply primer and damp -proofing materials, methods, and procedures to the outside surface of the tapered or cone section of precast concrete drainage structures. Precast concrete drainage structures shall be damp -proofed in accordance w ith 970: Damp -Proofing.
Defects identified during inspection shall be classified in the following categories and a non - conformance report (NCR) shall be initiated if required. The NCR shall be submitted to the III.76 202 4 Edition Department for review and approval of the Fabricator’s proposed NCR disposition. Defects shall be repaired per the approved NCR disposition, with approved materials listed on the QCML, according to the PCI Northeast Region Guidelines for Resolution of Non -Conformances in Precast Concrete Bridge Elements, Report Number PCINE -18-RNPCBE, at the expense of the Contractor. Defects requiring Non -Conformance Report (NCR) submission shall be repaired in the presence of Department personnel. All defects regardless o f category shall be documented by Quality Control personnel and made available to the Department upon request.
Category 1 defects do not require repair or Non -Conformance Report (NCR) submission. However, documentation of the identified defects is required by the Fabricator. Surface defects are defined as the following:
depth, except when classified as Category 3
Category 2 defects shall be documented. Repairs shall be documented, however, NCR submission is not required by the Fabricator. Minor defects are defined as the following:
dimension greater than 12 in .
sealed according to the PCI Repair Procedure #14 in PCINE -18-RNPCBE)
Category 3 defects may be cause for rejection, as determined by the Engineer. Category 3 defects shall be documented and reported on the NCR and submitted to the Department. The Fabricator may include proposed repair procedures on the submitted NCR for Dep artment review. However, if the proposed repair procedures are not accepted by the Department, the Precast Concrete Highway Unit shall be rejected. If accepted, proposed repair procedures shall not takeplace prior to Department approval. Rejectable defects are defined as the following, including, but not limited to:
square foot area.
greater than 12 in ., when measured along a straight line
c III.77 202 4 Edition 16. Protective Sealing Compounds for Precast Concrete Barrier. The protective sealing requirements specified herein do not apply to cement concrete surfaces previously applied with liquid membrane -forming compounds for curing and sealing. Protective sealing compounds meeting M9.15.0: Liquid Penetrant/Sealant shall be applied to precast concrete barrier per the Manufacturer’s instructions and recommendations as specified herein. Protective sealing compounds shall not be applied to concrete while conditions meeting
901.64: Protection from Adverse Weather are pr esent
Curing materials, methods, and procedures shall be applied to the concrete prior to the application of protective sealing compounds. The surface shall be sufficiently prepared, clean, and dry for at least 24 hours with ambient temperatures exceeding 60 ℉. Protective sealing compounds shall not be applied to the concrete for a minimum of 28 days after the concrete is poured, unless otherwise noted in the manufacturer’s instructions and recommendations. Periodic re -application shall be required for protecti ve sealing compounds requiring multiple applications and for concrete surfaces exhibiting wear to ensure long -term protection of the concrete surface.
Prior to loading the concrete product onto the truck for shipping, the Fabricator shall provide the MassDOT Plant Inspector and RMS a minimum seven -day notice of the Fabricator’s intent to load the concrete product. Inspection by the MassDOT Plant Inspector shall take place while the element is st ill on dunnage in the yard. The unit shall not be loaded onto the truck until the MassDOT Plant Inspector has performed the inspection.
Concrete products shall be loaded on a trailer with continuous blocking, in accordance with the approved dunnage plan. Shock -absorbing cushioning material shall be used at all bearing points. Blocking shall be provided at all locations of tie -down straps. Concrete products shall not be subjected to damaging torsional or impact stresses.
Prior to shipment, the Fabricator shall perform the following actions and provide the required documentation to the MassDOT Plant Inspector:
days after cast date.
c for the Precast Concrete Highway Unit’s representative Sublot shall be generated by the Fabricator and provided to the MassDOT Plant Inspector.
(NCR), shall be verified to have been completed by the MassDOT Plant Inspector and Quality Control Manager. III.78 202 4 Edition (f) All NCRs shall be signed off by the Quality Control Manager and the Department Inspector and/or MassDOT RMS.
Upon Delivery, the following documentation shall be provided to the Engineer:
Concrete Highway Unit’s representative Sublot.
The Contractor shall inspect the concrete product upon receipt at the site. Concrete products damaged during delivery shall be repaired or replaced per the Department direction, at the Contractor’s expense.
Quality Assurance is the planned and systematic actions necessary to provide confidence that a product or facility will perform satisfactorily in service. The Quality Assurance Program is comprised of the six core elements including Contractor Quality Cont rol, Department Acceptance, Independent Assurance, Dispute Resolution, Laboratory Accreditation and Qualification, Personnel Qualification and Certification. The Fabricator shall conduct Quality Control (QC) and the Department will conduct Acceptance throu ghout the fabrication process, independently from one another. The quality of the material or product shall be determined through quality measurements from sampling, testing, and inspection. The sampling population for quality measurements shall be comprised of lots and sublots. A lot shall be defined as a specific qu antity of material from a single source which is assumed to be produced or placed by the same controlled process. Lots shall be used to represent the population of the produced material and constructed product. The lot size shall be the specified quantity of material produced and placed. A sublot shall be defined as a subdivision of a lot. Sublots shall be used to assess the inspection attributes and quality characteristics of the lot. The sublot size shall be the specified subdivision of quantity for a giv en lot. The sampling population for testing and inspection shall be randomly sampled in accordance with ASTM D3665. Random sampling is defined as a small quantity of material or measurement obtained from a lot or sublot, whereby each sample obtained from the lot or sublot has an equal probability of being selected. Selective (non -random) sampling may also be conducted to provide supplemental information to assist in maintaining control of all production and placement processes. Selective sampling shall not replace random sampling and shall not be used in the Department Acceptance decision.
Quality Control (QC) shall be established, maintained, and performed by the Fabricator to monitor, assess, and adjust manufacturing, production, fabrication, and construction processes, to maintain continuous control of the process, and to ensure that the final material or product will meet the specified level of quality, through: III.79 202 4 Edition (a) Implementation of the Department approved Quality System Manual (QSM)
into the manufacturing, production, fabrication, and construction operations
conforming inspection results, uncontrolled processes, and materials with test results not within allowable limits
Quality Control operating documents shall be prepared, implemented, and maintained by the Fabricator and submitted to the Department for review and approval prior to the start of fabrication. The Fabricator shall adhere to all policies, practices, procedures, and activities identified in the following Department approved Quality Control operating documents.
The Fabricator shall submit a Quality System Manual (QSM) for Department review and approval. The QSM shall document the overall internal Quality Control operating procedures of the Producer’s Quality Control System and meet AASHTO R 18, AASHTO R 38, and the requirements specified by the Department.
When applicable, a Quality Control Plan (QCP) shall be prepared for each contract work item by the Fabricator to document all Quality Control personnel and procedures utilized to maintain control of all production and placement processes. The Quality Contr ol Plan for each contract work item shall meet the NorthEast Transportation Training and Certification Program (NETTCP) Model Quality Control Plan standard format and requirements specified by the Department.
At a minimum, the Fabricator shall maintain an active National Precast Concrete Association (NPCA) Plant Certification or Precast/Prestressed Concrete (PCI) Plant Certification.
The Fabricator shall have all required sampling, testing, and inspection equipment on site and available for use during all phases of fabrication. The equipment shall meet all applicable AASHTO III.80 202 4 Edition or ASTM standards, maintain required calibration schedules, and be in acceptable working condition. The Fabricator shall provide a room of sufficient size to house all equipment and to adequately perform all required testing. The room shall include a desk and file cabinet for proper record keeping and have good lighting and ventilation. This room shall b e kept for testing and quality control and not used for any other purpose. An additional desk and file cabinet shall be provided for exclusive use of the Engineer.
The Fabricator’s Quality Control organization shall be comprised of trained, experienced, and qualified Production Personnel, Quality Control Technicians, and Quality Control Managers at the Fabricator’s plant, per NPCA and/or PCI and as specified herein. Production Personnel, Quality Control Technicians, and Quality Control Managers shall maintain continuous communication to ensure conformance to specification requirements and to dictate corrective action for non - conformance.
Production Personnel that are directly responsible for the fabrication of Precast Concrete Highway Units shall be comprised of sufficiently trained, qualified, and experienced craftsmen, equipment operators, foremen, and superintendents. Best practices meeting Department recognized standards, organizations, and programs and requirements specified herein shall be performed by Production Personnel throughout the entire fabrication process. In addition to the fabrication activities, Production Personnel shall perform continuous self - inspection throughout the entire construction operation, to ensure quality workmanship is performed, through observation and verification of:
Production Personnel shall be capable of identifying unacceptable materials and products prior to completing the construction operation and shall notify potential non-conformances to the Quality Control Technicians and Quality Control Manager. The Fabricat or shall provide continual education, training, and qualification opportunities to Production Personnel to promote quality workmanship practices.
Each Quality Control Technician shall be sufficiently trained, qualified, and certified through Department recognized qualification and certification programs or through relevant experience acceptable to the Department. The Fabricator’s Quality Control organization shall include an acceptable number of experienced, trained, and qualified Quality Control Technicians at the Production Facility. The number of Quality Control Technicians shall be determined according to the s ize of the production operation and the III.81 202 4 Edition volume of material or product manufactured, produced, or fabricated for each work item. The principle responsibilities of each Production Facility Quality Control Technician include:
Production Personnel, Production Facility Quality Control Manager, and Prime Contractor Quality Control Manager At a minimum, Quality Control Technicians shall maintain an active American Concrete Institute
Technician certification. Quality Control Technicians shall be on site and present during all phases of fabrication.
The principal responsibilities of each Quality Control Manager shall include:
Manual (QSM)
At a minimum, the Fabricator’s Quality Control Manager shall meet the following requirements:
highway products Quality Control Managers shall be employed full -time (or engaged consultants), on site, and present during all phases of fabrication.
Quality Control inspection shall be performed by qualified Production Personnel and Quality Control Technicians to visually inspect equipment, environmental conditions, materials, and workmanship, per the Department approved Quality Control documents and specified herein. The results and findings of QC inspection shall be documented on the Fabricator’s Inspection Report Forms (IRFs). The Fabricator shall conduct immediate initiation of non -conformance reporting and corrective action for non -conforming inspe ction results and uncontrolled processes.
Quality Control sampling and testing shall be performed and reported by qualified Quality Control Technicians, to provide measurement of properties and quality characteristics of the material, to determine the degree of uniformity or the measured variabili ty of materials or products, to monitor III.82 202 4 Edition the quality and acceptability of the material or product, and to evaluate the control during the production or placement process, per the Department approved Quality Control documents and specified herein. The minimum QC sampling and testing activities sha ll be in accordance with the requirements specified herein. The results and findings of QC sampling and testing shall be documented on the Fabricator’s Test Report Forms (TRFs). The Fabricator shall conduct immediate initiation of non- conformance reporting and corrective action for materials with test results not within allowable limits.
The Fabricator shall conduct routine Quality Control sampling and testing of aggregate quality characteristics and properties, to ensure uniformity and consistency of the material per the requirements specified herein. Table M4.02.14- 8: QC Sampling and Testing Requirements for Aggregate Method Quality Characteristic T 27 Particle Size Distribution T 84 T 85 Bulk Specific Gravity Dry Bulk Specific Gravity SSD Apparent Specific Gravity Absorption (%) T 19 Unit Weight (lb / ft3) Aggregate Void Content (%) T 255 Moisture Content (%)
Quality Control sampling and testing shall be conducted during production per the minimum requirements specified herein. Production test results shall be within the limits specified herein. Table M4.02.14- 9: QC Sampling and Testing Frequency During Concrete Production Lot Size Sublot Size Frequency Total quantity of concrete (cy) produced in a year, per approved mix design formulation 50 cy 1 per sublot or fraction thereof, minimum 1 per day III.83 202 4 Edition Table M4.02.14- 10: QC Sampling and Testing Requirements During Production Property Method Quality Characteristic Limits Min. Max. Uniformity M 157[1] Batching Quantities of Constituent Materials Table M4.07.0 -4 T 119[2][3] Slump (in.) < 4 in. Target -1.0 Target +1.0 4 – 8 in. Target -1.5 Target +1.5 T 121[2] Unit Weight (lb/ft3) For Information Workability T 119[4] Segregation Resistance Pass Filling Ability T 347[2][5] Slump Flow (in.) 22.0 – 29.0 in.[6] Target -2.0 Target +2.0 Thermal T 309 Concrete Temperature (°F) 50 90 Strength T 22[2][7] Compressive Strength (psi) Form Removal 70% of f’c[8][9] – Storage in Adverse Conditions f’c[8] – 28 Days f’c[8] – 56 Days f’c[8][9] – Durability T 121[2] T 152[2] T 196[2] Air Content (%) Target -1.5 Target +1.5 [1] Batch tickets shall be provided to the Department by the Producer. Producers shall report the source, type, quantity, and design target for each constituent material incorporated into the proposed mix design onto batch tickets meeting AASHTO M 157. [2] Mix design target shall be identified on the Department issued cement concrete mix design sheet. [3] Required for non -self-consolidating concrete (SCC). [4] Required for non -self-consolidating concrete (SCC). Testing for segregation resistance shall be performed while the concrete is being discharged and during AASHTO T 119. Visual signs of segregation include coarse particles advancing in front of or beh ind the fine particles and mortar and a tendency for coarse aggregate to separate from the mortar, particularly when the mixture is being consolidated. [5] Required for Self- Consolidating Concrete (SCC). [6] Mix design target and production test results shall meet the specified range. [7] Three (3) 4 x 8 in. cylinders shall be cast and tested for each set specified for maximum aggregate size less than 1 -½ in. Two (2) 6 x 12 in. cylinders shall be cast and tested for each set specified for maximum aggregate size greater than 1 in. [8] The specified compressive strength (f’c) is defined as the minimum compressive strength required to be attained at a specified age for a given concrete structure, as specified in construction standard specifications, contract document special provisions, and design plans. [9] I n instances where the 28 -Day test results do not meet the specified limits, 56 -Day test results shall meet the 28 -Day limits.
The Fabricator shall organize, maintain, and retain Quality Control documentation, including the Quality System Manual, Quality Control Plans for contract work items, plant certification records, III.84 202 4 Edition personnel qualification and certification records, laboratory accreditation and certification records, daily diaries, record books, databases, Department and Contractor correspondence, random sampling location report forms, test report forms, inspection report forms, certificates of compliance, non -conformance report forms, corrective actions, control charts, quality level analysis, Quality Control test result summary sheets, material quantities produced or placed by lot and sublot, and other Quality Control documentation per the Department Approved Quality System Manual, Quality Control Plan, and specified herein. At a minimum, the Fabricator shall maintain a filing system for the following QC records and documentation:
materials, and steel reinforcement
each fabricated concrete product
All QC records and documentation shall be made available upon the request of the Department.
Acceptance shall be performed by the Department, including consultants under direct contract with the Department independent of the Fabricator, to evaluate the degree of compliance with contract requirements, to monitor the Fabricator’s Quality Control act ivities, to determine the corresponding value for a given product and the acceptability of all material produced and placed through Department acceptance sampling, testing, inspection, evaluation, and documentation.
The Department will review all Quality Control operating documents, including the Quality System Manual and Quality Control Plans for contract work items submitted by the Fabricator. Department approval shall be subject to conformance with the requirements specified herein. III.85 202 4 Edition b. Monitoring Fabricator Quality Control. The Department will monitor the adequacy of the Fabricator Quality Control System, to ensure Fabricator compliance to all items identified in Quality Control documents, including the Fabricator Quality System Manual and Quality Control Plans for contract work items. Failure to comply with these Quality Control documents may result in work suspension.
Acceptance inspection will be performed and reported by qualified Department (or designee) Acceptance Technicians, to visually inspect equipment, environmental conditions, materials, and workmanship, per the requirements specified herein. The results and findings of Acceptance inspection will be documented on the Department’s Inspection Report Forms (IRFs) . The Department will conduct immediate initiation of non -conformance reporting for non -conforming inspection results and uncontrolled processes.
Acceptance sampling and testing will be performed and reported by qualified Department (or designee) Acceptance Technicians, to provide quality characteristic data used for Department Acceptance determination, per the requirements specified herein. The res ults and findings of Acceptance sampling and testing will be documented on the Department’s Test Report Forms (TRFs). The Department will conduct immediate initiation of non -conformance reporting and corrective action for materials with test results not within allowable limits.
Acceptance sampling and testing will be conducted during production per the minimum requirements specified herein. Production test results shall be within the limits specified herein. Table M4.02.14- 11: Acceptance Sampling and Testing Frequency During Concrete Production Lot Size Sublot Size Frequency Total quantity of concrete (cy) produced in a year, per approved mix design formulation 50 cy 1 per sublot or fraction thereof, minimum 1 per day III.86 202 4 Edition Table M4.02.14- 12: Acceptance Sampling and Testing Requirements During Production Property Method Quality Characteristic Limits Min. Max. Uniformity M 157[1] Batching Quantities of Constituent Materials Table M4.08.0 -1 T 119[2][3] Slump (in.) < 4 in. Target -1.0 Target +1.0 4 – 8 in. Target -1.5 Target +1.5 T 121[2] Unit Weight (lb/ft3) For Information Workability T 119[4] Segregation Resistance Pass Filling Ability T 347[2][5] Slump Flow (in.) 22.0 – 29.0 in.[6] Target -2.0 Target +2.0 Thermal T 309 Concrete Temperature ( ℉) 50 90 Strength T 22[2][7] Compressive Strength (psi) 7 Days – – 28 Days f’c[8] – 56 Days f’c[8][9] – Durability T 121[2] T 152[2] T 196[2] Air Content (%) Target -1.5 Target +1.5 [1] Batch tickets shall be provided to the Department by the Cement Concrete Producer. Producers shall report the source, type, quantity, and design target for each constituent material incorporated into the proposed mix design onto batch tickets meeting AASHTO M 157. [2] Mix design target shall be identified on the Department issued cement concrete mix design sheet. [3] Required for non -self-consolidating concrete (SCC). [4] Required for non -self-consolidating concrete (SCC). Testing for segregation resistance shall be performed while the concrete is being discharged and during AASHTO T. Visual signs of segregation include coarse particles advancing in front of or behind the fine particles and mortar and a tendency for coarse aggregate to separate from the mortar, particularly when the mixture is being consolidated. [5] Required for Self- Consolidating Concrete (SCC). [6] Mix design target and production test results shall meet the specified range. [7] Three (3) 4 x 8 in. cylinders shall be cast for each set specified for maximum aggregate size less than 1-½ in. Two (2) 6 x 12 in. cylinders shall be cast for each set specified for maximum aggregate size greater than 1 in. [8] The specified compressive strength (f’
be attained at a specified age for a given concrete structure, as specified in construction standard specifications, contract document special provisions, and design plans. [9] I n instances where the 28 -Day test results do not meet the specified limits, 56 -Day test results shall meet the 28 -Day limits. M4.02.15: Cement Mortar Mortar shall be composed of 1 part Portland cement and 2 parts of sand by volume with sufficient water to form a workable mixture. Cement, sand and water shall conform to M4.01.0: Portland Cement , M4.02.02: Aggregates , Paragraph A , and M4.02.04: Water respectively. III.87 202 4 Edition M4.02.17: Self -Consolidating Concrete for Precast Concrete Products Self- Consolidating Concrete (SCC) may be used at the Fabricator’s discretion. SCC is a non - segregating concrete that is sufficiently flowable to fill formwork, spread into place, and encapsulate reinforcing steel, requiring minimal or no mechanical vibrati on to avoid segregation of the plastic concrete mixture. The following provision shall apply in addition to the other requirements specified in Section M4: Cement and Cement Concrete Materials .
The fine aggregate portion of a given mix shall not exceed 50 % by weight of the total aggregate in the mix.
Chemical admixtures shall be selected from the QCML, shall be used in accordance with manufacturer’s recommendations, and shall be compatible with all mix components. Any type of chemical admixture that is not included in the QCML (such as shrinkage reducing admixtures) shall be used in accordance with the manufacturer’s recommendations, shall be compatible with all mix components and shall conform to AASHTO M 194 M/M 194 and the following:
ASTM C 494 Type F (water- reducing, high range) or G (water -reducing, high range, and retarding) or ASTM C 1017. Such HRWRA can be used in combination with regular water - redu cing admixtures or mid -range water -reducing admixtures. High -Range Water -Reducing Admixture (HRWR).
Prior to concrete production, the Contractor shall submit a copy of the SCC mix design to RMS for review and approval. SCC Compressive strength specimens shall be fabricated in accordance to ASTM C1758. Multiple samples from the same batch shall be made simultaneously. Prior to testing for compressive strength, the de- molded cylinders shall be visually examined for evidenc e of segregation. The results of the observations shall be reported as part of the strength results. In addition to the testing provided in M4.02.00: Cement Concrete , the following tests shall be performed by qualified staff, in the presence of the Engineer and submitted to RMS for the prequalification of the SCC mix design; III.88 202 4 Edition Table M4.02.17- 1: Additional Material Acceptance Criteria for SCC Trial Batch Testing Property Test Method Target Value Filling Ability Slump Flow (AASHTO T 347) 22 to 29 in. Passing Ability Slump Flow (AASHTO T 347) J-Ring Flow (AASHTO T 345) The measured difference between the Slump Flow and the J -Ring Flow shall be <2 in. Static Stability Column Segregation (ASTM C1610) Percent static segregation (S) ≤15% Visual Stability Index (AASHTO T 351) 0 or 1 Note: Slump flow values outside of the above range will be considered, provided mock- ups performed during the trial batch process demonstrate full consolidation of concrete without segregation as approved by the Engineer.
In addition to production sampling and testing defined in M4.02.00: Cement Concrete, the following testing shall be performed during production. These tests shall apply whether performed by MassDOT for acceptance or by the Contractor for QC . Sampling and testing requirements shall be performed in accordance with the specifications for the precast concrete unit. Table M4.02.17- 2: Additional Material Criteria for SCC Production Testing Property Test Method Target Value Testing Frequency Filling Ability Slump Flow (AASHTO T 347) ±2 in. of Trial Batch Slump Flow Target Value and within Range of 22 to 29 in 1 per Sublot Static Stability Visual Stability Index (AASHTO T 351) 0 or 1 1 per Sublot M4.03.0: Concrete Produced by Volumetric Mixers Concrete produced by volumetric mixers shall meet AASHTO M 241 and the Volumetric Mixer Manufacturers Bureau (VMMB) Certification program. Quality Control (QC) shall be established, maintained, and performed by the Contractor (and/or Sub-Contractor Producer) to monitor, assess, and adjust manufacturing, production, fabrication, and construction processes, to maintain continuous control of the process, and to ensure that the final material or product will meet the specified level of quality, through:
or accredited through the AASHTO Accreditation Program (AAP)
workmanship III.89 202 4 Edition g) Routine QC sampling and testing of material quality characteristics and properties
control charts, and conformance to allowable limits
conforming inspection results, uncontrolled processes, and materials with test results not within allowable limits
Quality Control operating documents shall be prepared, implemented, and maintained by the Producer and submitted to the Department for review and approval at a minimum of 30 days prior to the start of construction. The Producer shall adhere to all policies , practices, procedures, and activities identified in the following Department approved Quality Control operating documents.
The Producer shall submit a Quality System Manual (QSM) to the Department for review and approval on an annual basis. The Quality System Manual (QSM) shall document the overall internal Quality Control operating procedures of the Producer’s Quality Control System and meet AASHTO R 18, AASHTO R 38, and the requirements of this section.
At a minimum of 30 days prior to construction, the Contractor shall submit a contract -specific Quality Control Plan (QCP) for each applicable contract work item to the Department for review and approval. The QCP shall document all Quality Control personnel and procedures utilized to maintain control of all production and placement processes. The QCP for each contract work item shall meet the NETTCP Model Quality Control Plan standard format and requirements specified by the Department.
The Contractor’s Quality Control Laboratory shall maintain active qualification through the NETTCP Laboratory Qualification Program or accreditation through the AASHTO Accreditation Program (AAP). The Contractor shall have all required sampling, testing, and inspection equipment on site and available for use during all phases of production. The equipment shall meet all applicable AASHTO or ASTM standards, maintain required calibration schedules, and be in acceptable working condition.
The Contractor’s Quality Control organization shall be comprised of trained, experienced, and qualified Production Personnel, Quality Control Technicians, and Quality Control as specified herein. Production Personnel, Quality Control Technicians, and Quali ty Control Managers shall maintain continuous communication to ensure conformance to specification requirements and to dictate corrective action for non -conformance. III.90 202 4 Edition 4. Quality Control Records, Documentation, and Analysis. The Contractor shall organize, maintain, and retain Quality Control documentation, including the Quality System Manual, Quality Control Plans for contract work items, plant certification records, personnel qualification and certification records, laboratory accreditation and certification records, daily diaries, record books, databases, Department and Contractor correspondence, random sampling location report forms, test report forms, inspection report forms, certificates of compliance, non -conformance report forms, corrective actions, control charts, quality level analysis, Quality Control test result summary sheets, material quantities produced or placed by lot and sublot, and other Quality Control documentation per the Department Approved Quality System Manual, Quality Control Plan, and specified herein. All QC records and documentation shall be made available upon the request of the Department. At a minimum, the Contractor shall maintain a filing system for the following QC records and documentation:
materials, and steel reinforcement
M4.04.0: Mortar for Prestressed Concrete Deck Beams The mortar shall conform to the following specification: General. The purpose of this specification is to describe a 2 -component, polymer -modified, cementitious, fast-setting, free flow mortar for filling keyways between adjacent box beams. III.91 202 4 Edition Materials. The polymer -modified cementitious system shall consist of a factory pre -proportioned, 2 - component system whose components conform to the following requirements:
This acrylic copolymer shall have the following properties: pH ................................................................................ 4.5 to 6.5 Minimum film forming temperature ............ Approximately 68°F Tear Strength .......................................................... Approximately 990 psi to 1,420 psi Elongation at break .............................................. 500% to 900% Particle size range ................................................ Less than 0.1 micron
organic accelerator, and admixtures for controlling setting time, water reducers for workability and a corrosion inhibiter.
combustible, either before or after cure. Typical Properties of Mixed Components.
Typical Properties of Cured System .
M4.05.0: Cement Concrete Brick Cement concrete brick shall be machine made solid segments conforming to the requirements of ASTM C139, except that the minimum average compressive strength for 5 representative bricks shall be 3,000 psi. The minimum compressive strength for one individual brick shall be 2,500 psi. Dimensional requirements shall be the same as for M4.05.2: Clay Brick . III.92 202 4 Edition M4.05.1: Cement Concrete Blocks Cement concrete blocks shall be machine made solid segments, conforming to the requirements for Concrete Masonry Units for Construction of Catch Basins and Manholes. ASTM C139, supplemented by the following requirements: The blocks shall be 6 in. in width for basins and manholes of 9 ft or less in depth, 8 in . in width below a depth of 9 ft when used in structures having a depth greater than 9 ft. The permissible dimensional variation for nominal size shall be in accordance with ASTM C139. The inside and outside surfaces of the blocks shall be carved to the necessary radius and so designed that the interior surfaces of the structures shall be cylindrical, except the top batter courses which shall be designed to reduce uniformly the inside section of the structure to the required top size and shape. The blocks used in the top courses shall be designed to produce a surface 8 in. in width upon which to seat the frame, and the curb inlet when one is used. Blocks shall be so designed that only full -length units are required to lay any one course. Blocks shall be sampled and tested in accordance with ASTM C140. The minimum average compressive strength for 5 representative blocks shall be 3,000 psi. The minimum compressive strength for one individual block shall be 2,500 psi. M4.05.2: Clay Brick Clay brick shall conform to the requirements of ASTM C32 with the following exceptions: The size of brick furnished shall be 7.75 in. long by 3.75 in . wide by 2.25 in . deep. All dimensions shall be nominal. The average of the absorption of 5 representative samples shall not exceed 15% and the individual absorption of any one sample shall not exceed 17.5%. The average compressive strength of 5 representative samples shall not be less than 3,000 psi and the compressive strength of any one sample shall not be less than 2,500 psi. M4.05.3: Precast Concrete Block for Slope Paving Precast blocks shall be solid segments, conforming to requirements for Concrete Masonry Units for Construction of Catch Basins and Manholes, ASTM -Cl39, supplemented by the following requirements: The thickness shall be 4 in ., the width shall be 12 in ., and the length 16 in . Blocks shall be sampled and tested in accordance with ASTM C140. Dimensional tolerances shall be in accordance with ASTM C139. M4.05.4: Sidewalk Brick Sidewalk brick shall conform to the requirements of ASTM C902 except that the absorption shall be 5% maximum when subjected to 5 hours of submersion in boiling water. III.93 202 4 Edition M4.05.5: Epoxy -Resin Base Bonding System for Concrete This specification covers two -component, epoxy -resin bonding systems for application to Portland cement concrete. The materials shall meet AASHTO M 235 M/M 235 Type III, IV, or V. The Type, Grade and Class shall be specified for each individual application. M4.06. 1: High Performance Concrete High Performance (HP) Concrete shall meet the requirements of M4: Cement and Cement Concrete Materials and the requirements specified herein. HP Concrete shall be designed and produced with precise proportions of constituent materials to form a homogenous composition with a well distributed, spaced, and sized air void system and quality concrete properties. HP Concrete shall exhibit acceptable quality characteristics and material properties, including uniformity, workability, bleeding and settlement, setting, thermal effects, shrinkage control, strength, modulus of elasticity, aesthetics, long -term durability , and resistance to premature deterioration due to freezing, thawing, and de -icing cycles, alkali silica reaction, corrosion of steel reinforcement, abrasion, erosion, sulfate reaction, salt crystallization, acid disintegration, carbonation reaction, delayed ettringite formation, and marine environments fo r the expected service life of the structure. The Contractor may elect to use fly ash, slag cement, silica fume, or a combination thereof provided that the dosage limits, permeability, and strength provisions contained herein are satisfied and the MassDOT Research and Materials Section (RMS) has approved the trial batches and mix design. Changing the mix design shall not be accepted and approved by RMS without the preparing, testing, and approval of trial batches for the revised mix design. HP Concrete shall meet AASHTO M 157. Table M4.06.1- 1: Classifications of HP Concrete 28 Day Compressive Strength Nominal Maximum Coarse Aggregate Size (in.) Maximum Total Cementitious Content (lb per yd ³) 5,000 psi ¾ 685 5,000 psi ⅜ 710 6,500 psi ⅜, ½, ¾ – 8,000 psi ⅜, ½, ¾ – Prior to concrete placement, the Contractor shall develop and forward a copy of the HP Concrete design mix to the Department for review and approval. Approval of the design mix must be obtained prior to placement of concrete. The mix design sent to the Department must be accompanied with trial batch information. Trial batches shall be performed in accordance with procedures outlined by the Department. Trial batch testing will be performed on samples of the same contents and proportions as the HP Concrete to be used in the proposed structures. AASHTO T 358 or AASHTO TP 119 shall be conducted and meet the requirements specified in Table M4.06.1 -2. III.94 202 4 Edition Table M4.06.1- 2: Durability Requirements Property Method Quality Characteristic Limits Min. Max. Durability T 358[1][2][3] Surface ChlorideIon Penetration Resistance (kΩ-cm) 7 Days Informational 28 Days 21 – Or TP 119[1][2][3] Uniaxial ChlorideIon Penetration Resistance (kΩ-cm) 7 Days Informational 28 Days 10.4 – [1] Three 4 x 8 in. cylinders shall be cast for each set specified. [2] This test method has been known to have compatibility issues with mix designs containing calcium nitrite chemical admixtures or steel fibers. As a result, inclusion of these materials into the test specimens may negatively affect test results. An additional set of cylinders shall be cast an d tested without the noted materials. The calcium nitrite shall be replaced by an equivalent quantity of water. A correction factor shall be determined by the following equation: CF = PR REMOVED / PR MIX DESIGN where PR REMOVED = Penetration Resistivity with noted materials removed, PR MIX DESIGN = Penetration Resistivity of original mix design with noted materials included, and CF = Correction Factor. The correction factor established during the mix design verification shall be applied to the penetration resistivity test results to compensate for the noted materials. The corrected penetration resistivity (PR CORRECTED ) shall be determined by the following equation and meet the specified limits identified in the tabl e: PR CORRECTED = PR MIX DESIGN * CF [3] Specimens shall be moist cured in accordance with AASHTO T 22 and shall be in saturated surface dry
High Performance Concrete shall meet the supplementary cementitious materials (SCM) requirements specified in Section M4: Cement and Cement Concrete Materials and the content target requirements specified in Table M4.06.1 -3. SCMs shall be incorporated into the mix design formulation to successfully mitigate alkali silica reaction (ASR) without exceeding the SCM content requirements. High Performance Concrete sh all meet the ASR requirements specified in M4.02.00: Cement Concrete. SCM content is defined as the percent by mass replacement of hydraulic cement. III.95 202 4 Edition Table M4.06.1- 3: SCM Content Target Supplementary Cementitious Material SCM Content Blended Hydraulic Cement Content[1] [2] Fly Ash (Class F) Content 15 – 30 Slag Content 20 – 50 Silica Fume Content 7 – 15 Total Fly Ash and Silica Fume Content ≤ 35 Total SCM Content ≤ 50 [1] The SCM content of blended hydraulic cement shall be identified on the Manufacturer’s certified mill test report. [2] SCMs in blended hydraulic cement shall meet the total cementitious material requirements for fly ash, slag, and silica fume specified in the table.
The water -cementitious ratio shall be 0.40 maximum. The water content of all additives shall be included in the water -cementitious ratio.
Cement concrete shall meet the air content targets specified in M4.02.00: Cement Concrete, Table M4.02.06- 1: Air Content Target.
Chemical admixtures incorporated into cement concrete shall meet M4.02.05: Chemical Admixtures and be precisely dosed per admixture manufacturer recommendations to meet the required properties of HP Concrete. HP Concrete shall be formulated with 3.0 gal of corrosion inhibiting admixture per yd ³ of concrete in order to increase the active corrosion threshold to 9.9 lb of chloride per yd ³ of concrete at the reinforcing bar level. Acceptance will depend upon the material's conformance, as documented by certified test results, to all applicable sections of AASHTO M 194M/M 194. The calcium nitrite solution shall contain 30 ± 2% calcium nitrite by weight. The calcium nitrite material shall have neutral set characteris tics.
HP Concrete shall be designed with a paste content that decreases the tendency of shrinkage cracking, while also adequately filling the voids of the concrete to provide sufficient separation and effective bonding between the aggregate particles. HP Concrete shall meet Table M4.06.1 -4. III.96 202 4 Edition Table M4.06.1- 4: Paste and Void Content Target Property Design Parameter Target Shrinkage Resistance Paste Content Target (%) ≤ 30[1][2] Workability Paste Content to Void Content (PC/VC) Ratio 1.1 – 1.75[2] [1] Not applicable to mix design formulations incorporating sufficiently designed dosages of S -SRA Shrinkage Reducing or TypeS -CRA Crack Reducing chemical admixtures meeting M4.05.0: Cement Concrete Brick . [2] Not applicable to specialized mix design formulations, including self -consolidating concrete. M4.06.2: High Early Strength Concrete High Early Strength Concrete shall meet the requirements of Section M4: Cement and Cement Concrete Materials and the requirements specified herein. High Early Strength Concrete shall meet the requirements specified in Table M4.06.2 -1. Table M4.06.2- 1: Verification Testing Requirements Property Method Quality Characteristic Limits Min. Max. Strength AASHTO T 22[1] Compressive Strength (psi) 12 Hours Informational 24 Hours 2500 – 3 Days 4000 – 7 Days 5000 – 28 Days Informational AASHTO T 97[2] Flexural Strength (psi) 12 Hours Informational 24 Hours 400 – 3 Days 550 – 7 Days 650 – 28 Days Informational ASTM C882[3] Slant Sheared Bond Strength (psi) 24 Hours 1200 – 7 Days 1900 – 28 Days 2200 – Setting AASHTO T 197 Initial Set (min.) Informational Final Set (min.) Informational Shrinkage Cracking Resistance [5] AASHTO T 160[4] Unrestrained Volume Change (µε) 28 Days – 420 ASTM C1581[6] Restrained Shrinkage 28 Days No Cracking[7] Or AASHTO T 363[8] Restrained Shrinkage (psi) 7 Days – 0.6T[9] III.97 202 4 Edition Table M4.06.2- 1: Verification Testing Requirements (cont.) Property Method Quality Characteristic Limits Min. Max. Durability AASHTO T 358[1][10] Surface ChlorideIon Penetration Resistance ( kΩ-cm) 7 Days Informational 28 Days 21 – Or AASHTO TP 119[1][10] Uniaxial ChlorideIon Penetration Resistance ( kΩ-cm) 7 Days Informational 28 Days 10.4 – [1] Three (3) 4 x 8 in. cylinders shall be cast and tested for each age specified for maximum aggregate size less than 1 -½ in. Two (2) 6 x 12 in. cylinders shall be cast and tested for each age specified for maximum aggregate size greater than 1 in. [2] For applications where the concrete is subject to flexural stresses: Two (2) 6 x 6 x 20 in. beams shall be cast for each age specified. [3] For applications where bond strength is desired. [4] For applications where the concrete is not subject to restraining stresses. [5] Not applicable to mix design formulations incorporating sufficiently designed dosages of TypeS -SRA Shrinkage Reducing or TypeS -CRA Crack Reducing chemical admixtures meeting M4.02.05: Chemical Admixtures . [6] For nominal maximum aggregate sizes less than or equal to ½ in . and for applications where the concrete is subject to restraining stresses. [7] Cracking is defined as the sudden decrease in compressive strain greater than 30 µε. [8] For any nominal maximum aggregate size and for applications where the concrete is subject to restraining stresses. c The circumferential residual stress in the specimen at the inner face of the specimen (σθ(RIC)) shall be calculated according to AASHTO T 363. [9] The splitting tensile strength (T) at 28 days shall be determined by AASHTO T 198. [10] Specimens shall be moist cured in accordance with AASHTO T 22 and shall be in saturated surface dry (SSD) condition during testing. M4.06.3: Rapid Hardening Concrete Rapid Hardening Concrete shall meet the requirements of Section M4: Cement and Cement Concrete Materials and the requirements specified herein. Rapid Hardening Concrete shall meet the requirements specified in Table M4.06.3 -1. III.98 202 4 Edition Table M4.06.3- 1: Verification Testing Requirements Property Method Quality Characteristic Limits Min. Max. Strength AASHTO T 22[1] Compressive Strength (psi) 2 Hours Informational 4 Hours 2500 – 6 Hours Informational 24 Hours 4000 – 7 Days 5000 – 28 Days Informational AASHTO T 97[2] Flexural Strength (psi) 2 Hours Informational 4 Hours 400 – 6 Hours Informational 24 Hours 550 – 7 Days 650 – 28 Days Informational ASTM C882[3] Slant Sheared Bond Strength (psi) 24 Hours 1200 – 7 Days 1900 – 28 Days 2200 – Setting AASHTO T 197 Initial Set (min.) Informational Final Set (min.) Informational Shrinkage Cracking Resistance AASHTO T 160[4] Unrestrained Volume Change (µε) 28 Days – 420 ASTM C1581[5] Restrained Shrinkage 28 Days No Cracking[6] Or AASHTO T 363[7] Restrained Shrinkage (psi) 7 Days – 0.6T[8 III.99 202 4 Edition Table M4.06.3- 1: Verification Testing Requirements (cont.) Property Method Quality Characteristic Limits Min. Max. Durability AASHTO T 358[1][9] Surface ChlorideIon Penetration Resistance ( kΩ-cm) 7 Days Informational 28 Days 21 – Or AASHTO TP 119[1][9] Uniaxial ChlorideIon Penetration Resistance ( kΩ-cm) 7 Days Informational 28 Days 10.4 – [1] Three (3) 4 x 8 in. cylinders shall be cast and tested for each age specified for maximum aggregate size less than 1 -½ in. Two (2) 6 x 12 in. cylinders shall be cast and tested for each age specified for maximum aggregate size greater than 1 in. [2] For applications where the concrete is subject to flexural stresses: Two (2) 6 x 6 x 20 in. beams shall be cast for each age specified. [3] For applications where bond strength is desired. [4] For applications where the concrete is not subject to restraining stresses. [5] For nominal maximum aggregate sizes less than or equal to ½ in . and for applications where the concrete is subject to restraining stresses. [6] Cracking is defined as the sudden decrease in compressive strain greater than 30 µε. [7] For any nominal maximum aggregate size and for applications where the concrete is subject to restraining stresses. The circumferential residual stress in the specimen at the inner face of the specimen (σθ(RIC)) shall be calculated according to AASHTO T 363. [8] The splitting tensile strength (T) at 28 days shall be determined by AASHTO T 198 . [9] Specimens shall be moist cured in accordance with AASHTO T 22 and shall be in saturated surface dry
M4.06.4: Lightweight Concrete Lightweight Concrete shall meet the requirements of Section M4: Cement and Cement Concrete Materials and the requirements specified herein. Lightweight Concrete shall be formulated with lightweight aggregate meeting M4.02.03: Lightweight Aggregates . Lightweight Concrete shall meet the requirements specified in Table M4.06.4 -1. Table M4.06.4- 1: Verification Testing Requirements Property Method Quality Characteristic Limits Min. Max. Unit Weight ASTM C567 Calculated Equilibrium Density, E c (lb/ft3)[1] – 115.0 [1] Measured Oven Dry Density (O m) shall be used for Calculated Equilibrium Density (E c). M4.07.0: Elastomeric Concrete Elastomeric concrete for use in strip seal bridge joint systems, shall consist of a two -component polyurethane material that shall be mixed and placed at the job site. The cured elastomeric concrete shall have the following physical properties: III.100 202 4 Edition Table M4.07.0- 1: Physical Properties of Elastomeric Concrete Property Test Method Requirement Compressive Stress @ 5% deflection ASTM D 695 800 psi minimum Resilience @ 5% deflection ASTM D695 70% minimum Impact Resistance @ -20°F, 32° F and 158°F ASTM D3209 No cracks M4.08.0: Controlled Low -Strength M aterials Controlled Low Strength Materials shall meet the requirements of Section M4: Cement and Cement Concrete Materials and the requirements specified herein. Controlled Low Strength Materials (CLSM) shall be designed and produced with precise proportions of hydraulic cement, supplementary cementitious materials (SCM), aggregate, mixing water, air - entrainment, and chemical admixtures to form a self -compacting, self -leveling, flowable, excavatable or non -excavatable, low strength, rigid setting, and unshrinkable material. Controlled Low Strength Materials mix design formulations shall be classified and reported according to the 90 -day ultimate compressive strength target, nominal maximum aggregate size (NMAS), and CLSM mix type. Classification is subject to meeting the requ irements specified herein. Table M4.08.0- 1: Classification Type 90-Day Ultimate Compressive Strength Target (psi) CLSM – Manual Excavatable[1][2] 0 – 100 CLSM – Mechanical Excavatable[1][2] 101 – 300 CLSM – Structural Non -Excavatable[1][3] > 300 [1] In addition to the ultimate compressive strength target requirements, the Controlled Low Strength Materials shall meet the removability modulus (RE) requirements specified in Table M4.08.0 -2. [2] The coarse aggregate content of the mix design shall also be considered. Mixtures using high coarse aggregate quantities may be difficult to excavate. [3] Structural non-excavatable Controlled Low Strength Materials are intended for permanent installation. Controlled Low Strength Materials shall meet the requirements specified in Table M4.08.0 -2. III.101 202 4 Edition Table M4.08.0- 2: Minimum Verification Testing Requirements Property Method Quality Characteristic Limits Min. Max. Uniformity ASTM D6023[1] Unit Weight (lb/ft3) Target -
2.0Target
+2.0 Air Content (%) Target -
Target
+2.0 ASTM D6103[1] Slump Flow (in.) ≥ 8 in. Target -
Target
+2.0 Workability ASTM D6103[2] Visual Inspection for Segregation Pass Thermal AASHTO T 309 Concrete Temperature ( ℉) 50 90 Excavatability ASTM D4832[1][3] Ultimate Compressive Strength (psi) Manual Excavatable 28 Days Informational 56 Days Informational 90 Days – 100 Mechanical Excavatable 28 Days Informational 56 Days Informational 90 Days 101 300 Structural Non - Excavatable 28 Days Informational 56 Days Informational 90 Days 301 – ACI 229R ASTM D4832 Removability Modulus (RE)[4] Excavatable – 1.0 Non -Excavatable 1.1 – Permeability[5] ASTM D5084 Coefficient of Water Conductivity (cm/s) 0.004 – [1] Prior to mix design verification testing, the Cement Concrete Producer shall identify and report the proposed mix design targets onto the Department issued cement concrete mix design sheet. Any adjustments made to the proposed mix design targets shall be based on the verification test results, and are subject to Department approval and the requirements specified herein. [2] Visual inspection for segregation shall be performed while the CLSM is being discharged and during ASTM D6103. Visual signs of segregation include coarse particles advancing in front of or behind the fine particles and mortar and a tendency for coarse aggregate to separate from the mortar, particularly when the mixture is being consolidated. [3] Two (2) 6 x 12 in. cylinders shall be cast and tested for each age specified. [4] The Removability Modulus is determined by the equation RE = [(W 1.5 x 104 x C0.5) / 106], where RE = Removability Modulus, W = Hardened Unit Weight (lb/ft3), and C = 28 Day Compressive Strength
[5] For excavatable applications only. The permeability of excavatable Controlled Low Strength Materials shall be greater than or equal to the surrounding soil. For design purposes, the criteria shall meet or exceed the permeability of uniform fine sand (0.004) as specified in the table. III.102 202 4 Edition SECTION M5 : PIPE, CULVERT SECTIONS AND CONDUIT M5.00.0 : Pipe, Culvert Sections and Conduit These shall consist of individual sections of the kinds and sizes shown on the plans and as directed. They shall conform to the requirements of the applicable following subsections. All pipes shall be subject to inspection at the point of manufacture as well as the site of the work. The purpose of the inspection shall be to cull and reject pipes which, independent of the physical tests, fail to con-form to the specification in the particulars of dimension, workmanship, finish, blisters, cracks or fractures. M5.01.0: Joint Materials for Pipe
common usage.
such size and shape as to ensure satisfactory pipe joints when incorporated in the work and shall conform to ASTM C443.
hemp or untarred twisted jute, clean and dry and free from oil, grease, or any other deleterious matter. M5.02.1 : Reinforced Concrete Pipe Reinforced concrete pipe shall conform to the requirements of AASHTO M 170 for the class of pipe specified in the contract documents. • All pipe 24 in. in diameter or smaller shall be of the bell- and-spigot type. • Pipes larger than 24 in. in diameter shall be tongue and groove or bell and spigot. M5.02.2 : Reinforced Concrete Pipe Flared Ends Flared end sections shall be fabricated to comply with the Construction Standard Details . The method of fabrication and materials used shall conform to the requirements of AASHTO M 170, Class III, except that the three edge bearing tests shall not be required. The flare shall be of the same thickness and materials as the barrel and have steel reinforcement equaling or exceeding the amount shown on the table for AASHTO M 170, Class III, except that a double row of steel will not be required . M5.03.0: Corrugated Metal Pipe This pipe shall consist of metallic coated (galvanized or aluminized) corrugated metal pipe and couplings. The coating shall completely cover the inside and outside of all pipe and couplings. Galvanizing shall conform to M7.10.0: Galvanized Coatings . Aluminizing shall conform to M7.15.0: Metallized Coatings . Aluminized and galvanized pipe components shall not be used together in a pipe run. III.103 202 4 Edition The pipe shall conform to AASHTO M 36. Pipe 8 in. or less in diameter shall be constructed of sheets not less than 0.052 in . thick. End sections shall be 16 gage for all pipes 24 in . in diameter and under, 14 gage for all 30 - and 36 -in. diameter pipes and 12 gage for all diameters greater than 36 in. The coating on end sections shall match the coating on the pipe connected to it. M5.03.1: Perforated Corrugated Metal Pipe This pipe shall meet the requirements of M5.03.0: Corrugated Metal Pipe and contain perforations conforming to AASHTO M 36, Type III. The pipe shall conform to AASHTO M 36 except that reinforcing the ends of the pipe will not be required. M5.03.6: Metal End Sections Metal End Sections shall be fabricated to conform with the Construction Standard Details. The method of fabrication and materials used shall conform to the applicable requirements of AASHTO M 36. M5.03.7: Plastic (PVC) Pipe Plastic (PVC) Pipe shall meet ASTM D1785 Standard Specification for Poly Vinyl Chloride (PVC) and Chlorinated Poly Vinyl Chloride (CPVC) Plastic Pipe, Schedule 40, 80, and 120. The pipe shall be PVC, Type I Schedule 80. Fittings, such as adapters, couplings, etc. shall be the same material as the pipe. Joints shall be made in accordance with ASTM D2855 Recommended Practice for Making Solvent -cemented Joints with Poly (Vinyl Chloride) (PVC) Pipe and Fittings. Cements shall meet ASTM D2564. M5.03.8 : Polymeric Precoated Corrugated Metal Pipe Polymeric precoated corrugated metal pipe shall conform to the requirements of AASHTO M 246, Type B with the thinner polymeric coating a minimum of 3 mils. M5.03.9 : Slot -Perforated Corrugated Plastic Pipe This pipe or tubing shall consist of slot -perforated corrugated polyethylene tubing, couplings and fittings. Materials, dimensions, physical properties and fabrication shall be in conformance with AASHTO M 252. M5.03.10: Corrugated Plastic Pipe Pipe shall consist of corrugated polyethylene or polypropylene tubing, flare ends, couplings and fittings. Materials, dimensions, physical properties and fabrication shall be in accordance with AASHTO M 294, TypeS or D or AASHTO M330 TypeS or D. Perforated pipe shall meet Type SP, DP or CP. M5.03.11: Porous Concrete Pipe Porous Concrete Pipe shall meet the requirements of AASHTO M 176 M/M 176 for Extra -Strength Porous Concrete Pipe. Aggregates for the concrete may consist of inert carbon material. M5.04.0: Asphalt Coated Corrugated Metal Pipe Arches Asphalt coated corrugated metal pipe arches shall consist of corrugated metal pipes which have been reformed to multi -centered pipe having arch shaped tops with a slight outwardly curved III.104 202 4 Edition integral bottom. The pipe shall be fabricated from standard length culvert sheet and factory riveted to form a continuous length pipe arch. Asphalt coated corrugated metal pipe arches, including coupling bands, shall conform to the requirement of AASHTO M 36 or AASHTO M 196 for corrugated metal pipe meeting the requirements for base metal, rivets, sampling, testing, brands, corrugations, end finish, weight, bands and workmanship. FABRICATION
Dimensions, tolerances, and areas shall be in accordance with AASHTO M 36. The lapped longitudinal seams shall be factory riveted and shall be placed in the top arch and be staggered so as to alternate on each side of the center of the top of the arch by approximately 15% of the periphery.
The insert of the pipe arch shall be coated with asphalt conforming to AASHTO M 190. Type C Coating, so as to form a smooth pavement to widths of 40% of the circumference of the pipe arch. These widths are determined by 40% of the circumference of equivalent diameters. It shall be applied in such a manner that the corrugations are completely filled and that, excepting where the upper edges intersect the corrugations, the pavement has a minimum thickness of ⅛ in. above the crests of the corrugations. The remainder of the inside of the pipe arch and the entire outside shall be uniformly coated with asphalt cement to a minimum thickness of 0.05 in . The thickness shall be measured on the crests of the corrugations. All coupling bands shall be coated to same requirements as the pipe arch except the pavement shall be omitted.
The asphalt cement used for coating shall conform to the requirements in M5.03.0: Corrugated Metal Pipe , Paragraph B . M5.04.2: Structural Plate for Pipe and Pipe Arches All materials, including base metal analysis, galvanizing, bolts, nuts, corrugations, gauge determination and acceptance of plates, forming and punching holes, bearing shapes, fabrication and incidental items shall conform to AASHTO M 167 M/M 167 and the following:
M5.04.3: Asphalt Coated Smooth Steel Liner Helically Corrugated Shell Metal Pipe This pipe shall conform to AASHTO M 36, 8.1.1, Type 1A pipe. The coating shall conform to AASHTO Designation M 190, Type A. III.105 202 4 Edition M5.05.3: Ductile Iron Pipe and Fittings Ductile iron pipe shall conform to the requirements of AWWA C150, C151, C111 and shall be double cement lined and asphalt seal coated in accordance with AWWA C104. The wall thickness shall be Class 52. Ductile iron fittings for pipes 3 in . through 24 in . in diameter shall be of the compact type and conform to the requirements of AWWA C153 American National Standard for Ductile -Iron compact Fittings, 3 in. through 24 in. , for w ater and o ther liquids. Ductile iron fittings for pipes greater than 24 in . and up to 48 in . in diameter shall conform to the requirements of AWWA C110 American National Standard for Ductile -Iron and Gray -Iron Fittings, 3 in. through 48 in. , for w ater and o ther liquids.
Hydrants shall conform to the requirements of AWWA Standard C502, and/or to the type used by the particular municipality involved as specified in the Special Provisions.
Gate valves shall conform to the requirements of AWWA Standard C500 and/or to the type used by the particular municipality involved as specified in the Special Provisions. M5.05.4 : Acrylonitrile - Butadiene - Styrene (ABS) Pipe This type of pipe shall conform to the requirements of AASHTO M 265. M5.06.0 : Copper Tubing Copper Tubing shall conform to the requirements of ASTM B88, Type k, “annealed .” M5.07.0: Electrical Conduit -Rigid Nonmetallic (Type NM) Rigid Nonmetallic Electrical Conduit and associated fittings shall conform to Article 352 of the NEC, NEMA TS2, UL 514B and UL 651. Unless encased in concrete, all Type NM conduit installed underground shall be Schedule 80 (Electric Polyvinyl Chloride -80). The walls of the conduit shall have a smooth interior surface free from all substances which may injure any wire or cable covering such as is used on rubber covered or thermoplastic insulated wire or cable. The bore of the conduit shall be circular in cross section and straight and true so as to pass freely a mandrel 3 ft long and ¼ in. less in diameter than the nominal inner diameter of the conduit. The bore of bends, elbows, and other fittings shall pass freely a ball of ¼ in . less in diameter than the nominal inner diameter of the conduit. Couplings, elbows, bends, adapters, reducers, increasers and bell ends, shall be of the same material as the conduit. The minimum acceptable radii dimensions for elbows and bends shall conform to the requirements of the NEC. Joints shall be machined to an accurate taper on both ends to permit a tight joint when assembled with suitable couplings or fittings. III.106 202 4 Edition One tapered joint coupling shall be supplied with each length of conduit and each elbow or bend. At least 85% of the conduit in any lot shall be furnished in standard length; sections of conduit less than 5 ft will not be accepted. A tolerance of ±1 in . is permissible in the conduit lengths specified. Each length of conduit and all associated fittings shall be clearly and durably marked at least every 10 ft with the manufacturer’s name, trademark, or other descriptive marking by which the fabricator can be identified. The material type, trade size, and UL labelling shall also be included in the marking. M5.07.1: Electrical Conduit -Rigid Metallic (Type RM) Rigid Metallic Electrical Conduit and associated fittings shall conform to Article 344 of the NEC and the following: Class 1 – Type A –UL Standard 6 – Rigid Metal Electrical Conduit. Class 2 – Type A – UL Standard 1242 – Intermediate Metal Conduit. Class 1 and 2 – Types B, C, and D – UL Standard 514B – Fittings for Conduit and Outlet Boxes. Each length of conduit and all associated fittings shall be clearly and durably marked at least every 10 ft with the manufacturer’s name, trademark, or other descriptive marking by which the fabricator can be identified. The material type, trade size, and UL labelling shall also be included in the marking. M5.07.2: Electrical Conduit -Flexible Metallic (Type FM) Flexible Metallic Electrical Conduit and associated fittings shall be liquid -tight and conform to Article 350 of the NEC and UL -360. Each length of conduit and all associated fittings shall be clearly and durably marked at least every 10 ft with the manufacturer’s name, trademark, or other descriptive marking by which the fabricator can be identified. The material type, trade size, and UL labelling shall also be included in the marking. Type FM conduit suitable for direct burial shall also be so marked. M5.0 8.0: Pull and Junction Boxes – Metallic Metallic pull and junction boxes made of cast iron, welded sheet steel or cast aluminum shall conform to UL 514A Metallic Outlet Boxes. III.107 202 4 Edition SECTION M6 : ROADSIDE DEVELOPMENT MATERIALS M6.00.0 : General This section describes requirements for materials used for soil amendments, seed, plant material, mulches, and other materials required for the care and establishment of plants. M6.01.0 : Inorganic Amendments Limestone shall consist of pulverized limestone obtained by grinding either calcareous or dolomitic limestone such that 95% of the material will pass a 20 mesh sieve and at least 50% will pass a 100 mesh sieve. The limestone shall meet the applicable provisions of State and Federal laws which relate to commercial fertilizers. Sulfur for adjustment of loam pH shall be elemental or flours of sulfur, unadulterated, and shall be delivered in containers with the name of the manufacturer, material, and net weight appearing on each container. Gypsum for soil structure amendment and de -icing salt mitigation shall be agricultural grade, 80 percent calcium sulphate (CaSO 4 × 2H 2O), in granular or slurry form, with 100% passing a 2 mm screen, and 90% passing through 150 µm screen. Gypsum may be derived from natural sources or from recycled wallboard. Soil wetting agent shall be a synthetic, non -toxic acrylic polyacrylamide or natural soluble plant extract. Application rates shall be per manufacturer’s recommendations. Submit supplier specifications and certification. M6.02.0 : Fertilizer Fertilizer shall meet the applicable provisions of State and Federal laws and be furnished in containers plainly marked with the chemical analysis of the product. Fertilizer for general planting shall be slow release and shall be commercial grade 10 -10-10, or sufficient to meet the recommendations for soil amendment. At least 40% of the nitrogen content shall be slow release, phosphorus shall be available phosphoric acid, and potassium shall be water- soluble potash. M6.03.0: Long Term Seed Mixes for Lawns and Slopes The seed mixture specified for slopes and shoulders consists of a tough hardy type for use on slopes graded at the rate of 1 vertical to 4 horizontal, and steeper slopes, and on shoulders adjacent to the roadway pavement or as otherwise directed. The mixture for lawn grass plots is of a finer type that will produce finer turf. Grass seed shall be of the previous year’s crop and in no case shall the weed seed content exceed 1% by mass. All Bluegrass, Fescue, and Ryegrass shall be within top 25% of either of two most recent National Turfgrass Evaluation Program reports. The grass seed shall conform to the requirements of the following tables: III.108 202 4 Edition Table M6.03.0- 1: Grass Seed Requirements for Lawn Grass Areas Grass Type Proportion Germination Minimum Purity Minimum Creeping Red and/or Chewings Fescue 59% 85% 95% Kentucky Blue 30% 85% 90% Perennial Rye 5% 90% 98% Redtop 5% 85% 92% Dutch White Clover 1% 85% 96% Table M6.03.0- 2: Grass Seed Requirements for Slopes and Shoulders Grass Type Proportion Germination Minimum Purity Minimum Creeping Red, Chewings, and/or Hard Fescue 50% 85% 95% Tall Fescue 35% 85% 90% Perennial Rye 5% 90% 98% Redtop 5% 85% 92% Dutch White Clover 5% 85% 96% The seed shall be furnished and delivered premixed in the proportions specified above. All seed shall comply with State and Federal seed laws. Clover shall be pre -inoculated. Contractor will supply a manufacturer’s Certificate of Compliance to the specifications shall be submitted by the manufacturers with each shipment of each type of seed mix. Certificates will be attached to the seed bags for inspection. These certificatess hall include the guaranteed percentages of purity, weed content and germination of the seed, and also the net mass and date of shipment. No seed may be sown until the Contractor has submitted the certificates. M6.03.1: Short Term Erosion Control Seed This seed shall consist of a mixture of the previous year’s crop and shall contain the following mixture by weight with 98% purity: III.109 202 4 Edition Table M 6.03.1- 1: Requirements for Short -Term Erosion Control Seed Seed Type % by Weight Germination Minimum Winter Rye 80 minimum 85% Red Fescue (Creeping) 5 minimum 80% Perennial Rye Grass 5 minimum 90% Dutch White Clover 3 minimum 90% Other Crop Grass 0.5 maximum Noxious Weed Seed 0.5 maximum Inert Matter 1.0 maximum A manufacturer’s certificate of compliance will be required as specified in M6.03.0: Long Term Seed Mixes for Lawns and Slopes . M6.04.0: Mulch Materials to be used in mulching shall conform to the following requirements: M6.04.1: Hay Mulch Hay Mulch shall consist of mowed and properly cured grass, clover or other acceptable plants. M6.04.2: Straw Mulch Straw Mulch shall be seed free, consisting exclusively of stalks or stems of grain after threshing. M6.04.3: Wood Chip Mulch Wood chip mulch shall consist of wood chips produced by cutting branches, limbs of trees, brush or shrubs with chippers or from the chipping of stumps, and shall be free of topsoil, stones, and other extraneous material. The chippers shall be approved for use by the Engineer. Wood chip mulch must be free from long stringy material over 4 in. in length and from live, rot -free wood and bark, except that 35% or less by volume of the wood chip mulch may consist of “slab wood,” chipped to an acceptable size by chippers equipped with a ¼ in. knife set and thoroughly mixed with the live material. Wood Chip Mulch containing an excess of fine particles, such that mulch will blow or wash away, decay too quickly, or percolate too slowly, will not be acceptable. Wood Chip Mulch may be produced on the project from acceptable cuttings. Wood chip mulch containing remnants of invasive species such as Japanese Knotweed and Bittersweet shall not be used. M6.04.4: Wood Fiber Mulch Wood Fiber Mulch shall consist of wood fiber produced from clean, whole uncooked wood, formed into resilient bundles having a high degree of internal friction and shall be dry when delivered on the project. Recycled material may be evaluated for acceptance based on evaluation of submitted sample, specifications and certified test results from an approved laboratory, per the requirements of M1.06.0: Organic Soil Additives . III.110 202 4 Edition M6.04.5: Aged Pine Bark Mulch This mulch shall consist of the outer bark of pine trees and a minimum of hardwood bark. Bark shall be processed by removal from the limbs and trunks of trees. Bark mulch shall be shredded pine bark aged a minimum of 6 months. The mulch shall be dark brown in color, free of chunks and pieces of wood thicker than ¼ in. and shall not contain, in the judgment of the Engineer, an excess of fine particles. Do not use wood chips, recycled, dyed, wood product, or crumb rubber mulch. Mulch must be free from long stringy material. M6.05.0: Sod Sod shall be composed of the grass mixture recommended by the New England Sod Producer’s Association and shall be specified as: Table M6.05.0- 1: Sod Type 1 for Full Sun Turf Areas (6 or More Hours Direct Sunlight in Growing Season) Species Percent by Turf Area* Kentucky Bluegrass 50% to 80% Fine Fescues 10% to 30% Perennial Ryegrass 0 to 20% * All species with >70% of the mix shall have at least 3 varieties; >40% shall have at least 2 varieties. Table M6.05.0- 2: Sod Type 2 for Partial Shade Turf Areas (4 to 6 Hours Minimum Direct Sunlight in Growing Season)** Species Percent by Turf Area* Fine Fescues 75% to 90% Kentucky Bluegrass 10% to 25% Perennial Ryegrass 0 to 10% * All species with >70% of the mix shall have at least 3 varieties; >40% shall have at least 2 varieties. ** Areas receiving less than 4 hours per day of direct sun during growing season should not receive sod. Table M6.05.0- 3: Sod Type 3 for Multi -Use Turf Areas (and 4 to 6 Hours Minimum Direct Sunlight in Growing Season) Species Percent by Turf Area* Tall Fescue 50% to 90% Fine Fescues 20% to 50% Kentucky Bluegrass 0 to 20% Perennial Ryegrass 0 to 20% * All species with >70% of the mix shall have at least 3 varieties; >40% shall have at least 2 varieties. ** Areas receiving less than 4 hours per day of direct sun during growing season should not receive sod. III.111 202 4 Edition Lawn sods shall have been nursery grown on cultivated agricultural land used specifically for sod purposes. Grasses shall be drought tolerant cultivars. The sods shall be free of objectionable grassy and broadleaf weeds. Sods shall be considered free of such weeds if less than 5 such plants are found per 10 yd ² of area. The sod shall be machine cut at a uniform minimum thickness of ¾ in. at the time of cutting. Measurement for thickness shall exclude top growth and thatch. Individual pieces of sod shall be cut to the supplier’s standard width and length. Maximum allowable deviation from standard widths and lengths shall be 5%. Broken pads and torn or uneven ends will not be acceptable. Sod that has dried out, or that has been unplanted over 3 days (including weekends) since harvest, will be rejected. M6.06.0 : General Planting The Contractor shall furnish all plants as shown on the plans. M6.06.1: Nursery Stock – General All scientific and common plant names of the items specified shall conform to the current edition of Hortus Third, compiled by the staff of the L.H. Bailey Hortorium, Cornell University. These standards shall determine all requirements of acceptable shrub and seedling nursery stock names. All plants will have durable, non -fading labels applied at the nursery that clearly bears the correct botanical name, including cultivar, as well as common name and size. Caliper or spread shall govern over height specifications. The Contractor must obtain written permission from the Engineer for any substitutions of types or sizes specified. All plants shall be grown in a certified nursery. All plants shall be typical of their species or variety in growth habit. Plant sizes, habit, rootball dimensions, stem and cane count shall conform to the requirements of the American Standards for Nursery Stock (ASNS) standards as a minimum requirement for acceptance. Container sizes shall also be consistent with the guidance per plant size per the ASNS. Each plant shall have plenty of fibrous roots, healthy buds, and shall be free of disease and insect pes ts. No plant material from cold storage will be accepted. All plant parts shall show active green cambium when cut and shall be densely foliated when in leaf. Deciduous shrubs shall have 4 to 6 canes coming from the roots and shall have a well- branched root system. Vines and ground cover shall be minimum 2 -year No. 1 stock. Herbaceous plants shall be minimum 1-year No. 1 stock, and clumps shall have not less than 6 buds, eyes, or crowns. The trunk of each tree shall be free from sunscald, frost cracks, or wounds resulting from abrasions, animal pest, fire or other causes. Pruning wounds shall be no larger than 2 in. and shall show vigorous scar tissue. No trees with double -leaders or twin -heads will be acceptable without the written approval. The plants must be in a vigorous condition and free from dead wood, bruises and other root or branch injuries. Deficient plants may be rejected at any time. III.112 202 4 Edition Any species (including all cultivars) listed on the Massachusetts Department of Agricultural Resources Prohibited Plant List shall not be used including but not limited to the following: Norway Maple ( Acer platanoides ) Sycamore Maple ( Acer pseudoplatanus ) Japanese Barberry ( Berberis thunbergii) Autumn Olive ( Eleagnus umbellata ) Burning Bush or Winged Euonymus ( Euonymus alatus ) Glossy or European Buckthorn ( Frangula alnus ) Dames Rocket ( Hesperis matronalis ) Yellow Iris ( Iris pseudoacoris ) Border Privet ( Ligustrum obtusifolium ) Honeysuckle -- Japanese, Amur, Morrow’s, Tatarian, Bell’s ( Lonicera japonica, L. maackia, L. morrowii, L. morrowii x tartarica) Plume grass ( Miscanthus sacchariflorus ) Forget -me-not ( Myosotis scorpoides ) Reed Canarygrass ( Phalaris arundinacea) Amur Cork Tree ( Phellodendron amurense ) Common Buckthorn ( Rhamnus cathartica ) Black Locust ( Robinia pseudoacacia ) Wild Rose ( Rosa multiflora ) M6.06.2 : Nursery Stock – Balled and Burlapped All plants that are to be balled and burlapped previous to shipment are designated “B&B.” B&B plants shall be dug so as to retain as many fibrous roots as possible. All B&B plants shall come from soil that will hold a firm root ball and the solidity of the ball shall be carefully preserved. B&B plants shall be wrapped with untreated 8 -oz burlap, firmly held in place by a stout cord or wire. Wire containers shall be of adequate size to allow root development for the plant size as per ASNS requirements. Plants prepared with plastic or other non -biodegradable wrappings will not be accepted. Rootballs shall remain intact during all operations. No plant will be accepted if the rootball has been cracked or broken prior to, or during, the process of planting. All p lant materials shall be dug with reasonable care and skill immediately prior to shipment. M6.06.3: Nursery Stock – Container Grown All container grown plants shall be healthy, vigorous and well rooted in the container in which they are sold. They shall have tops that are of good quality and are in healthy growing condition. No single -stemmed shrubs or sparsely leafed plants will be accepted. The side branches must be generous and well twigged, and the plant as a whole must be well -branched to the ground or typical of the species or cultivar. Container -grown stock shall have been grown in the container long enough for the root system to develop sufficiently to hold the soil together firmly. No plants shall be loose in the container. Container- grown plants shall not be pot bound with spiraling roots or roots growing densely against the sides of the container. The container shall be suffic iently rigid to protect the root mass during shipment and sizes shall be provided in accordance with the ASNS standards. The size of plant, as well as minimum number of stems or canes, will conform to the type of plant per ASNS standards. III.113 202 4 Edition The soil medium for container -grown plant material shall be a uniformly blended, stable medium free from weeds, weed seeds, disease organisms, insects, herbicide residue, and all other harmful organisms or materials. The soil shall fill the container to at least 85% of its height, serving as a stable base for the anchorage and support of the plant growing in it. It shall be well- aerated sandy loam or fine sandy loam, per USDA Soil Classification, and of sufficient structure to provide adequate moisture to p lants. The certificate of compliance for container grown plants shall contain, in addition to the requirements listed in 771.40: General, the guaranteed composition of the potting mixture and the date of planting in the container. Plants shall have been grown in the container for a minimum of 12 weeks. A random sample is required from each delivery for soil and root inspection upon request of the Engineer. M6.06.4: Nursery Stock – Bare -Root Bare -root material shall be dug during dormancy within 72 hours of shipping and shall be kept moist and stored in a cool, shaded location until planting. All bare -root material shall be accompanied by certification of digging date. The roots of bare -rooted material shall be dipped in soil wetting agent and carefully protected with wet straw, moss or other suitable material that will ensure the arrival of the plants at the site of the work in good condition. All bare- root material shall be installed within 4 8 hours of arrival on the construction site, and shall be kept moist and out of wind or direct sunlight until planting. Maximum time between digging for shipping and installation shall be one week. M6.06.5: Nursery Stock – Seedlings Seedlings shall have well developed root systems and shall be acclimated and suitable in all respects for field planting. All conifers must have dormant buds and secondary needles. Evergreen seedlings shall be two year transplants, bare rooted. Lining out stock seedlings shall be two year seedlings. Root cuttings shall be established in peat pots 2.5 in. deep by 2 in . wide at the open end and tapered to 1 in . wide at the closed end (inside measure). M6.06.6: Nursery Stock – Trees Per the requirements of the ASNS, the sizes of trees shall be as called for on the plans and measurements shall be determined by caliper at a point 6 in. above the ground for plants specified up to 4 in . in caliper. Larger minimum caliper shall be measured 12 in . from ground. Trees for streetscape plantings ( i.e., in or adjacent to walkways) shall have a single straight leader not cut back. They shall have a symmetrical development of strong, healthy branches beginning at least 7 ft from the ground; and below this point, the trunk shall be clean for street trees. Coniferous Evergreens shall be dug before spring “candling” of new growth. Grafted and budded trees may branch lower and be pruned off 2 ft from the ground where directed. Flowering trees shall be balled and burlapped and kept moist for delivery. III.114 202 4 Edition M6.06.7: Nursery Stock – Shrubs, Vines, Groundcover and Perennials Shrubs shall have the form required per ASNS. Specified spread shall govern over height requirements. Vines and ground cover in this group shall be 2 year, No. 1 stock. Herbaceous plants in this group shall be minimum 1 year, No. 1 year stock, and clumps shall have not less than 6 buds, eyes or crowns. M6.07.0: Delivery and Protection All plants shall be packed so as to arrive at the delivery point in good growing condition and shall be kept moist for delivery and during transit. Special precautions shall be taken to avoid any unnecessary injury to, or removal of, fibrous roots. Each sp ecies or variety shall be handled and packed in the approved manner for that particular plant having regard to the soil and climatic conditions at the time and place of digging, transit and delivery, and to the time that will be consumed in transit. All pr ecautions that are customary in good trade practice shall be taken to ensure the arrival of the plants at the site of the project in good condition for successful growth. Shipment of plant material shall be scheduled to minimize the time between arrival and installation at the construction site. Plants may be stored at the construction site for up to 3 days on in an approved location that is out of direct sunlight and wind. Contractor shall store plants in wood chips and shall provide watering to maintain containers and root balls in moist condition at all times prior to installation. M6.07.1: Wrapping for Transport Wrapping material shall be used for transport only. Wrapping material for root balls shall be 8 - ounce jute burlap; plastic is not acceptable. Material for tree trunks shall be 4 to 6 in. wide strips of burlap, paper, cardboard, or plastic manufactured for this purpose. Fastening for the wrapping material shall be either adhesive weather resistant tape or a minimum of 3 -ply jute twine. Wrapping must be removed once tree has been installed. M6.08.0: Materials for Guying and Staking The stakes shall be unpainted spruce or other suitable wood free from large knots, dimensioned 2x2 by 8 ft in length and sharpened at one end. Binding and guying shall be biodegradable webbing. Stake fastenings shall be 10 penny galvanized nails. Trees shall not be wrapped. M6.08.1: Temporary Fencing for Tree Protection Temporary Tree Protection Fence shall be brightly colored polypropylene barricade or wooden snow fencing for tree protection or safety fencing. Fencing shall be a minimum of 4 ft high and supported by steel or hardwood stakes spaced at a maximum of 8 ft on center or by other means acceptable to the Engineer. M6.08.2: Trunk Cladding for Tree Protection. Cladding for trunk protection shall be 2x4 or 2x3 nominal lumber, at least 6 ft in length, sufficiently tall to protect tree trunk from construction activities, and bound together with wire. Alternatively, trunks may be shielded with sections of corrugated plastic pipe of sufficient diameter and height to III.115 202 4 Edition shield trunk from construction activities. Trunk protection shall include burlap, which shall be untreated 8 -oz burlap. M6.08.3: Sheeting for Tree Root Protection Sheeting for tree root protection shall be minimum ¾-in. thickness plywood, cut and trimmed to required sizes and configurations. M6.09.0: Water for Irrigation Water used for irrigation of plant materials shall be free from any substance injurious to vegetation, such as oil, acids, alkalis and salts. Water shall be free from impurities injurious to vegetation. Submittal shall be required, including anticipated demand, irrigation method, watering schedule, sources of water, and any incidental work required to provide water for the plants. III.116 202 4 Edition SECTION M7 : PAINTS, PROTECTIVE COATINGS AND PAVEMENT MARKINGS M7.00.0 : General Requirements for Paints and Protective Coatings All paint shall conform to the following general requirements.
The r aw materials used in the following specifications for paints and protective coatings shall conform to the specification designed by ASTM or AASHTO specifications.
Paint proportions and percentages given in the following specification are expressed by weight.
Paint and protective coatings shall be homogeneous, free of contaminant and of a consistency suitable for use in the capacity for which it is specified. The finished product shall be well ground and the pigment shall be properly dispersed and suspended in the vehicle according to the requirements of the paint or protective coating. The dispersion shall be of such nature that the pigment does not settle badly, does not cake or thicken in the container, and does not become granular, jelled or curdled. Any settlement of pigment in the paint or protective coating shall be a thoroughly wetted soft mushy mass permitting the complete and easy vertical penetration of a paddle. Settled pigment shall be easily dispersed, with a minimum resistance to the sidewise manua l motion of the paddle across the bottom of the container, to form a smooth uniform product of the proper consistency.
The finished paint or protective coating shall be furnished in new 5- gal, round, n on-tapered containers . The containers shall meet U.S. Department of Transportation Hazardous Materials Shipping Regulations. The following information shall be labeled on each can in a clear legible manner:
Precautions concerning the handling and the application of the paint or protective coating shall be shown on the label.
Testing of paints will be done by the Department in accordance with the methods of Federal Test Method Standard Number 141, AASHTO and ASTM methods described below. III.117 202 4 Edition In addition, the Department reserves the right to make use of any information or methods of testing to determine the quality of paint and paint materials. M7.01.0 : Pavement Markings • M7.01.05 White Traffic Paint • M7.01.06 Yellow Traffic Paint • M7.01.08 White High Heat Rapid Drying Traffic Marking Material • M7.01.09 Yellow High Heat Rapid Drying Traffic Marking Material • M7.01.10 Fast Drying White Traffic Paint • M7.01.11 Fast Drying Yellow Traffic Paint • M7.01.12 Striping Powder • M7.01.14 Black Non- Reflective Lane Tape • M7.01.15 Black Traffic Paint • M7.01.16 White and Yellow Temporary Reflective Lane Tape • M7.01.18 Preformed Permanent Plastic Pavement Markings or Legends • M7.01.21 Green Pavement Coatings • M7.01.23 Fast Drying White Water -borne Traffic Paint • M7.01.24 Fast Drying Yellow Water -borne Traffic Paint M7.01.3 Liquid Thermoplastic Striping Material
This specification covers a reflectorized thermoplastic pavement striping material that is extruded onto the pavement in a molten state by mechanical means with the application of glass beads. When applied properly and at the designated thickness and width the stripe shall, upon coo ling, be reflectorized and be able to resist deformation by traffic. The material shall be placed on bare pavement or existing thermoplastic markings. Materials Prequalified batches of acceptable thermoplastic materials are listed on the QCML. All thermoplastic material shall meet the requirements of AASHTO M 249 and tested in accordance with AASHTO T 250 and the following: 1) Glass Beads (Pre -Mix) used in the manufacture of thermoplastic shall be uncoated and meet the requirements of AASHTO M 247, Type I and M7.01.07 and have a minimum of 80% true spheres. 2) The resin shall be alkyd or hydrocarbon and meet the requirements of table M7.01.3 -1. Table M7.01.3 -1 Thermoplastic Resin Requirements Properties Hydrocarbon Alkyd % Binder, Minimum 22 20 Indentation Resistance @ 115 ℉, ASTM D7735 -- 40-75 units (Type A) Bond Strength, Minimum, psi 180 200 III.118 202 4 Edition The material manufacturer shall have the option of formulating a hydrocarbon resin -based or an alkyd resin -based system. However, the physical and chemical properties contained in this specification shall apply regardless of the type of formulation used. T he binder must consist of a mixture of resins, at least one of which is a solid at room temperature, and high boiling point plasticizers. At least one third of the binder composition of an alkyd -based system must be maleic -modified glycerol ester of rosin and must be no less than 8% of the entire material formulation. Material of either binder type upon heating to the application temperature shall not evolve fumes which are toxic, or injurious to persons or property. The pigment, beads and filler shall be w ell dispersed in the resin. The material shall be free from all skins, dirt, and foreign objects. The thermoplastic pavement marking material may be supplied in block or granular form. Block material shall be packaged in suitable containers to which it will not adhere to during shipment or storage. The blocks shall be approximately 12 in. x 36 in. x 2 in. Granular material shall be packaged in bags that when introduced to the mix hopper of the application equipment, it will become part of the mix with no adverse effect to the performance of the thermoplastic material. The packages of either type shall weigh approximately 50 lb. Each container label shall designate the color, manufacturer’s name, batch number and date of manufacture. Each batch manufactured shall have its own separate number. The label shall warn the user that the material shall be heated in the range of 400 ℉-425 ℉ during application.
Provide one bag of thermoplastic material for verification testing per batch. A batch is a unit of production that is consistent in appearance, formulation, proportions and can be identified by a unique number know as a Batch Number. Each batch shall cons ist of a minimum of 3,000 lb and a maximum of 44,000 lb.
Tests on White and Yellow Thermoplastic Striping Material shall be reported by an Independent Testing Laboratory and performed in accordance with these Specifications and AASHTO T 250. The Independent Test Results shall be for each batch and shall identify the material by manufacturer including name and address, batch number(s), date and place of manufacture and any other information that will assist in identifying the product. It shall also note the test method used for each test. The report shall include the date tested and shall be signed by a person responsible for authenticating the veracity of the test. Below the signature shall be the person’s printed name and title. Request for prequalification for each thermoplastic material batch shall be submitted to RMS, accompanied by: a) Certificate of Compliance stating that the material complies with AASHTO M 249, AASHTO T 250, this specification and all applicable MassDOT requirements.
III.119 202 4 Edition c) One bag of thermoplastic striping material per batch in sample bags meeting the specifications above for verification testing. The bag shall be sent to the attention of the Director of Research & Materials, MassDOT/Highway, 5 Macadam Road, Hopkinton, MA 01748. M7.01.07: Glass Beads This specification covers the requirements for glass beads which are to be dropped or sprayed on pavement markings. Glass bead suppliers and approved batch numbers are listed on the QCML . All glass beads shall meet the requirements of AASHTO M 247, and be tested in accordance with AASHTO T 346 and the following:
ASTM D1155, Procedure A.
shall meet the AASHTO concentration for heavy metals, 200 ppm maximum, as tested in accordance with EPA test methods 3052, 6010B and 6010c, or AASHTO T 392. The silica content shall be 60% minimum (ASTM C169).
proof coating and be moisture resistant as tested by AASHTO T 346, Referee Method.
enhance embedding in, and adherence to, the applied binder film. The coated beads shall emit a yellow -green fluorescence when tested by the Dansyl Chloride test proc edure.
optional.
The glass beads shall be tested in accordance with ASTM D1214 (By use of U.S. Standard Sieves). Standard gradation beads shall meet the requirements of AASHTO M 247, Type 1. Large gradation beads shall meet the requirements of AASHTO M 247, Type 4.
The beads shall be packaged in 50 -lb or greater polyethylene- lined burlap bags or equal container; such containers guaranteed to furnish dry and undamaged beads. The following information shall be indelibly labeled in a clear and legible manner on each container:
III.120 202 4 Edition C. Approval Procedure. Requests for approval shall be submitted to the Department accompanied by:
in accordance with AASHTO T 346 and all applicable MassDOT requirements;
verification testing. M7.02: Structural Paint
New coatings systems shall be a low VOC that meets current VOC regulations. Coating systems shall be selected from the MassDOT QCML -NEPCOAT Qualified Products List “B .” Structural paint will be tested according to the following: • ASTM D 562 Consistency • ASTM D 1475 Density • ASTM D3723 Pigment • ASTM D 2369 Volatile Content • AMS STD 595 Federal Color Index
Each year manufacturers shall send samples of each product for each color to be used to The Department for testing. Approved paint products and colors will be posted on the QCML. If Paint products are not listed on QCML but are Nepcoat qualified products, samples shall be obtained from the project site. Samples must be taken in clean, dry, airtight, widemouthed metal quart cans. The sample container must be filled within 2 in. from the top of the can and sealed properly. Each sample must be labeled with the name of the manufacturer, brand, coat, and color prior to shipping to the Department.
Samples from project sites are not required if the paint to be used on the project is on the QCML. If samples are obtained from the project, paint must be agitated by the contractor before sampling. Contractors shall not combine individual paint components prior to sampling. One quart sample shall be taken in containers described below. All samples shall be from the same batch. Samples must be taken in clean, dry, airtight, widemouthed metal quart cans. The sample container must be filled within 2 in. from the top of the can and sealed properly. Each sample must be labeled with the name of the manufacturer, brand, coat, and color prior to shipping to t he Department. Project paint quantities of 40 total gallons or less shall not require sampling and testing. In lieu of sampling and testing, the contractor shall submit a letter stating the total amount of paint to be used on the project will be 40 gallons or less. A man ufacturer’s certificate of compliance shall be submitted with the letter. III.121 202 4 Edition M7.03: Enamels • M7.03.02 Sign and Equipment Enamel M7.04 : Miscellaneous Coatings • M7.04.01 Coal Tar Protective Coatings • M7.04.02 Primer, Paint, Exterior, (Undercoat for Wood, Ready Mixed White and Tints) • M7.04.03 Paint, Zinc Yellow, Iron Oxide Base Ready Mixed (Type II) • M7.04.04 Paint, Ready Mixed, International Orange • M7.04.05 Paint, Exterior, Black Ready Mixed • M7.04.06 Primer Coating, Basic Lead Silico Chromate, Ready Mixed • M7.04.07 Primer Coating, Zinc Dust -Zinc Oxide (for galvanized surfaces) • M7.04.08 Enamel Undercoat Interior, Tints and White • M7.04.09 Paint, Outside, Dull- Black (Formula 104) • M7.04.10 Primer, Pretreatment (Formula 117 for Metals) • M7.04.11 Paint, High Zinc Dust Content, Galvanizing Repair M7.05 : Epoxy Protective Coating • M7.05.01 Epoxy - Polyamide Red Lead Paint • M7.05.02 Epoxy - Polyamide Green Paint • M7.05.03 Epoxy - Polyamine Concrete Coating • M7.05.05 One Coat High Build Epoxy Mastic Coating • M7.05.11 Epoxy - Polyamide Primer Paint (non -lead) • M7.05.12 Brown Epoxy - Polyamide Top Coat (non -lead) • M7.05.13 Green Epoxy - Polyamide Top Coat (non -lead) • M7.05.15 One Coat Hi Build Mastic Coating • M7.05.21 Coal Tar Epoxy Polyamide Paint • M7.05.31 Self- Priming Epoxy Coating Or those coatings listed in the QCML. M7.10.0 : Galvanized Coatings Galvanized coatings shall conform to the following requirements: • ASTM A143 – Standard Practice for Safeguarding Against Embrittlement of Hot -Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement. • ASTM A384 – Standard Practice for Safeguarding Against Warpage and Distortion During Hot- Dip Galvanizing of Steel Assemblies. • ASTM A385 – Standard Practice for Providing High -Quality Zinc Coatings (Hot -Dip). • ASTM B6 – Standard Specification for Zinc. A range of 0.05% to 0.09% nickel (by weight) shall be added to the galvanizing bath. • ASTM B695 Standard Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel. • AASHTO M 111 M/M 111 –Zinc (Hot -Dip Galvanized) Coatings on Iron and Steel Products. • AASHTO M 232 M/M 232 – Zinc Coating (Hot -Dip) on Iron and Steel Hardware. III.122 202 4 Edition M7.15.0: Metallized Coatings The wire used for metallizing shall be zinc or 85/15 zinc/aluminum per ASTM B833, Standard Specification for Zinc Wire for Thermal Spraying (Metallizing). All thermal spray wire must be manufactured domestically. M7.20.0: Anodized Coatings Aluminum extrusions to be anodized shall be finished in a dark bronze Architectural Integral -Color Anodized finish conforming to Aluminum Association designation AA -M10 -C22 -A44. The anodic coating shall be Aluminum Association Architectural Class 1 with a minimum thickness of 0.7 mils and a minimum weight of 35 mg/in 2. Prior to production, the finisher shall submit surface smoothness samples and color range samples to RMS for the Engineer's approval, to establish inspection limits of allowable surface smoothness and allowable color shade range. Samples of anodized extrusions from production lots, as selected by the Engineer, shall be tested in accordance with ASTM B137, ASTM B244 and ASTM B136. M7.25.0: Powder Coatings Aluminum to be powder coated shall be finished in a dark bronze powder coat finish to match the color of the anodized extrusions. The coating shall be a polyester -TGLC (triglycidyl isocyanurate) resin system conforming to the following: III.123 202 4 Edition Table M7.25.0- 1: Physical and Mechanical Properties of Powder Coatings Quality Test Limits Abrasion ASTM D4060 Taber Abraser CS -10, 1,000 gram load, 1,000 cycles 100 mg maximum weight loss Adhesion ASTM D3359 Initial - 1,000 hours - 5A 5A Gloss ASTM D523 60°F - 600 hours 60°F - 1,000 hours 82% Retention 90% Retention (washed) Hardness ASTM D3363 2H – No Gouge Impact ASTM D2794, Direct Pass 80 in. -lb. Salt Spray Resistance ASTM B117, ASTM D1654 1,000 hours unscribed - 400 hours Scribed - Table 2 - 10 Table 1 - 10 Weather ASTM G23 1,000 hours, 18 minutes Waterspray , 102 minute Light No film failure Color Dark Bronze, to match color of anodized aluminum framework n/a Identify Infrared Fingerprint Match Flexibility 180° bend with ½-in. diameter mandrel within 10 seconds No breaks, flaking or cracks Tested with a Q- panel with 2 mils or less of coating Humidity ASTM D2247, 1,000 hours No blister or film failure Thickness n/a 4 ±1 mils Mar Resistance n/a Good Aluminum to be powder coated shall be bare and free of oil or any mill coating. The aluminum shall be caustic cleaned to standard near white. A chromic conversion coating shall be applied after caustic cleaning. The finish coating shall be applied immediately after chromic coating as an electrostatically charged dry powder, sprayed onto the grounded aluminum using an electrostatic spray gun. The coated aluminum shall be heated in accordance with the powder manufacturer's recommend procedure to provide a fully cured finish. The coating thickness after cure shall be a minimum of 3 mils. Prior to production, the coater shall submit a 3 ft by 1 ft coated sample and color range samples to RMS for the Engineer's approval to establish inspection limits of allowable coating coverage and color shade range. All stainless steel fasteners shall be colored by a thermal conversion process to match the dark bronze color of the aluminum extrusions. The finish shall be such that it does not peel, chip or crack. Samples of all fasteners shall be submitted along with material certificates to the Engineer for approval. III.124 202 4 Edition SECTION M8 : METALS AND RELATED MATERIALS M8.00.0 : General All structural steel and miscellaneous steel products shall be welded in accordance with the requirements of the AASHTO/AWS Bridge Welding Code (ANSI/AASHTO/AWS D1.5). All aluminum material shall be welded in accordance with the AWS Structural Welding Code - Aluminum (ANSI/AWS D1.2). All stainless steel material shall be welded in accordance with the AWS Structural Welding Code – Stainless Steel (ANSI/AWS D1.6). All steel tubular material shall be welded in accordance with the AWS Structural Welding Code - Steel (ANSI/AWS D1.1). All steel reinforcing shall be welded in accordance with the AWS Structural Welding Code – Reinforcing (ANSI/AWS D1.4). Aluminum castings shall be of uniform quality and condition, free from cracks, blow holes, porous places, hard spots or shrinkage defects which affect the suitability of the castings for their intended use. Sampling and Testing. Samples for testing shall be taken in accordance with the applicable ASTM and/or AASHTO specification for the material. Testing will be done in accordance with latest standard procedures of ASTM and/or AASHTO. M8.01.0 : Reinforcing Bars Reinforcing bars shall consist of deformed bars rolled from new billet steel conforming to the requirements of AASHTO M 31 M/M 31, Grade 60. Spiral reinforcement for columns shall be plain steel meeting the requirements of AASHTO M 31 M/M 31 , Grade 60. Steel for reinforcing shall be free from imperfections, dirt, loose scale, paint, oil, or other foreign substance that might tend to prevent bonding with concrete. Rust that occurs in scales or that pits the steel will be considered an imperfection. Surfac e rust will not be considered an imperfection, but the surface shall be brushed to remove loose material. M8.01.1 : Cold Drawn Steel Wire This material shall conform to AASHTO M 336 M/M 3 36. M8.01.2 : Welded Steel Wire Fabric This material shall conform to AASHTO M 336M/M 336 . M8.01.3 : Steel Bar Mats This material shall conform to AASHTO M 54M/M 54 . M8.01.4 : Tie Bars and Bolts Tie bars f or longitudinal joints shall be either deformed bars of new billet steel (AASHTO M 31M/M 31, Grade 60) or approved tie bolts as shown on the plans which shall conform in all respects to the standard require -ments specified for strength and design. III.125 202 4 Edition M8.01.5 : Anchor Bolts, Nuts and Washers All bolts, nuts and washers, with the exception of those with weathering characteristics, shall be galvanized in accordance with AASHTO M 232M/M 232. Used For Anchoring Bridge Railing Base Plates to Concrete Bolts, nuts, and washers shall conform to the requirements of ASTM F1554 Grade 105. Used For Anchoring Bridge Bearings to Concrete Bolts, nuts, and washers shall conform to the requirements of ASTM F1554 Grade 105. Used For Anchoring Signal Lighting and Sign Structures Bolts, nuts, and washers shall conform to the applicable requirements of one of the following: • AASHTO M 31 Type W Grade 60 • AASHTO M 314 Grade 36 • AASHTO M 314 Grade 55 • AASHTO M 314 Grade 105 • ASTM F1554 Grade 55 • ASTM F1554 Grade 105 Notes:
High Strength Bolts High strength bolts, where specified, shall conform to M8.04.3: High Strength Bolts . A galvanized hexagon nut, leveling nut and flat washer shall be furnished with each bolt. M8.01.7: Epoxy Coated Reinforcing Bars Epoxy coated reinforcing bars shall be bars conforming to M8.01.0: Reinforcing Bars shall be epoxy coated in accordance with ASTM A775/A775M and tested in accordance to AASHTO T 285 . M8.01.8: Galvanized Reinforcing Bars Galvanized Reinforcing Bars shall be bars conforming to M8.01.0: Reinforcing Bars and shall be galvanized in accordance with ASTM A767. M8.01.9: Mechanical Reinforcing Bar Splicer Mechanical reinforcing bar splicers are devices to join two steel reinforcing bars subject to tension and compression. All mechanical reinforcing bar splicers shall meet the following requirements: III.126 202 4 Edition Table M8.01.9- 1: Requirements for Mechanical Reinforcing Bar Splicers Description Test Method Requirement Ultimate Tensile Strength of Mechanical Splicer System ASTM A1034 (Monotonic Tension Test) 100% of ultimate tensile strength of reinforcement bars per AASHTO M31 Allowable Slip California Test No. 670 – Slip Test 0.01 in., maximum for #14 and smaller bars, 0.03 in. maximum for #18 bars The mechanical splicer coating shall be consistent with the reinforcement to be spliced; therefore, uncoated splicers shall be used for uncoated rebar, epoxy coated splicers for epoxy coated rebar, and galvanized splicers for galvanized rebar. The mechanical splicer coating shall be in conformance with the applicable requirements of M8.01.7: Epoxy Coated Reinforcing Bars or M8.01.8: Galvanized Reinforcing Bars . The mechanical reinforcing bar splicer system shall be evaluated with the applicable coating. Mechanical reinforcing bar splicers shall be tested for conformance with the above requirements. Reinforcing bar splicers that meet these requirements (coated or uncoated) shall be placed on the QCML. Only products listed on the QCML are acceptable for use . Damage to the mechanical reinforcing bar splicer coating shall be repaired in accordance with 901.62: Reinforcement. For mechanical splicer systems that cannot be effectively sealed with an epoxy or galvanizing repair coating they shall be protected with an approved corrosion protection wrap system listed on the QCML. M8.02.0: Drilled Steel Rods This material shall conform to the requirements of AISI – W1. M8.03.0: Iron Castings Gray Iron Castings shall conform to the requirements of AASHTO M 105, Class 35B. Test bars shall conform to the requirements of tension test specimen B with a minimum of 1 in thread on each end. The thread size shall be 1 ⅛ in. – 7 UNC. Ductile Iron Casting for double grates shall conform to the requirements of ASTM A536 Grade 80 -55-06. Test bars shall conform to the requirements of standard round tension specimen (2 in gage length) with a minimum of 1 in. thread on each end. The thread size shall be ⅞ in. – 9 UNC. All iron castings shall conform to the requirements of AASHTO M 306 and shall be manufactured true to pattern in form and dimensions, free from pouring faults, cracks, blow holes and other defects affecting their strength and value for the service intended. The casting shall be boldly filleted at angles and the arises shall be sharp and perfect. The surfaces shall have a workmanlike finish. M8.03.2: Steel Castings Type A- 3 grates shall be cast to the dimensions shown on the plans and composed of cast steel conforming to the requirements of AASHTO M 103 M/M 103, Grade 65 -35, full anneal. III.127 202 4 Edition Steel castings shall be true to pattern in form and dimensions, without sharp unfilleted angles or corners and shall be free from pouring faults, sponginess, cracks, blow holes and other defects in positions affecting their strength and value for the service intended. Castings shall be shot blasted prior to painting. Painting shall consist of a coating system approved by RMS . M8.04.1: Stud Shear Connectors
girders with automatically timed stud welding equipment. Ferrules shall be kept clean and dry and stored at a temperature of 60°F.
with each stud. The material shall not be detrimental to the welds or cause excessive slag and shall have sufficient strength so as not to crumble or break due to thermal or structural shock before the weld is completed.
with their function as shear connectors.
Shear connector studs shall conform to the requirements of the Specification for Cold Finished Carbon Steel Bars and Shafting, AASHTO M 169 , cold -drawn bar, Grades 1015, or 1020, either semi - skilled or s killed. If flux -retaining caps are used, the steel for the caps shall be of a low carbon grade suitable for welding and shall comply with ASTM A109. Tensile properties as determined by tests of the bar stock after drawing or of finished studs shall conform to the following requirements: Tensile Strength ................................................................................................... 60,000 psi (400 MPa) (min .) Yield Strength (as determined by a 0.2% offset method) ................... 50,000 psi (345 MPa) ( min. ) Elongation ............................................................................................................... 20% in 2 in. (50 mm) ( min. ) Reduction of area ................................................................................................. 50% ( min. ) Tensile properties shall be determined in accordance with the applicable sections of ASTM A370, Mechanical Testing of Steel Products. Tensile tests of finished studs shall be made on studs welded III.128 202 4 Edition to test plates. If fractures occur outside of the middle half of the gage length, the test shall be repeated. Finished studs shall be of uniform quality and condition, free from injurious laps, fins, seams, cracks, twists, bends or other injurious defects. Finish shall be as produced by cold drawing, cold rolling, or machining. The manufacturer shall certify that the studs as delivered are in accordance with the material requirements of this Section. Certified copies of in -plant QC test reports shall be furnished to the Engineer. M8.04.2: Steel Pins Pins more than 9 in. in diameter shall be manufactured from carbon steel conforming to AASHTO M 102 M/M 102, Classes B, C and D. Pins 9 in. or less in diameter shall conform to AASHTO M 102M/M 102 , Classes B, C and D, or AASHTO M 169, Grades 1016 thru 1030 inclusive. M8.04.3: High Strength Bolts Bolts, nuts and washers shall conform to the appropriate material specification ASTM F3125/F3125M, ASTM A563 , AASHTO M 292M/M 292 and ASTM F436/F436M as amended herein. Material. Hardness for bolts with diameter ½ in. to 1 in. inclusive shall be Brinell HB -minimum of 248; HB - maximum of 311 or Rockwell HRC -minimum of 24; HRC -maximum of 33. Plain (ungalvanized) nuts shall be grades 2, C, D or C3 with a minimum Rockwell hardness of 89 HRB (or Brinell hardness 180 HB) or heat treated grades 2H, DH or DH3. Galvanized nuts shall be heat treated grades 2H or DH. For galvanized fasteners, the nuts shall be tapped oversize, the minimum amount required for the fastener assembly. The amount of overtap in the nut shall be such that the nut will assemble freely on the bolt in the coated condition and shall meet the mechanical requirements of ASTM A563 , and the rotational -capacity tests herein. Galvanized nuts shall be lubricated with a lubricant containing a dye of any color that contrasts with the color of the galvanizing. Black fasteners must be “oily” to the touch whe n installed. Weathered or rusted fasteners shall be cleaned and re- lubricated prior to installation. Testing. The tests need not be witnessed by a representative of the Department; however, the manufacturer or distributor that performs the tests shall certify that the results recorded are accurate. Documentation shall be in accordance with 960.61: Design, Fabrication and Erection . Bolts. Proof load tests in accordance with ASTM F606 Method 1 are required. The minimum frequency of the tests shall be as specified in ASTM F436/F436M . Wedge tests on full size bolts (ASTM F606) are required. If the bolts are to be galvanized, the tests shall be performed after galvanizing. Minimum frequency of the tests shall be as specified in ASTM F436/F436M . III.129 202 4 Edition If galvanized bolts are supplied, the thickness of the zinc coating shall be measured. Measurements shall be taken on the wrench flats or the top of the bolt head. Nuts. Proof load tests (ASTM F606) are required. Minimum frequency of tests shall be as specified in ASTM A563 or AASHTO M 292 M/M 292. If nuts are to be galvanized, the tests shall be performed after galvanizing, overtapping and lubricating. If galvanized nuts are supplied, the thickness of the zinc coating shall be measured. Measurements shall be taken on the wrench flats. Washers. If galvanized washers are supplied, hardness testing shall be performed after galvanizing. (Coating shall be removed prior to taking hardness measurements.) The thickness of the zinc coating shall be measured. Assemblies. Rotational -capacity tests are required and shall be performed on all black or galvanized (after galvanizing) bolt, nut and washer assemblies by the manufacturer or distributor prior to shipping. Washers are required as part of the test even though they may not be required as part of the installation. The rotational capacity test is intended to evaluate the presence of a lubricant, the efficiency of the lubricant and the compatibility of assemblies as represented by the components selected for testing. This test shall be performed in accordance with the requirements of ASTM F3125/F3125M except as modified herein:
assembly.
an acceptable equivalent device. For bolts that are too short to be assembled in a Skidmore, a steel joint shall be used.
engage the nut. Test Methods : Normal Length and Long Bolts
bolt are located between the bearing face of the nut and the underside of the bolt head. Spacers and/or washers with holes not exceeding ¹⁄₁₆ in. greater than the bolt diameter may be used to achieve the 3 to 5 thread requirement. Tighten the bolt to the snug tight condition. The snug tight tensions are listed in Tables M8.04.3 -1 (-0 kN, +9 kN) and M8.04.3-2 (- 0 kips, +2 kips).
III.130 202 4 Edition Table M8.04.3- 1: Snug Tight Tensions (SI Units) Bolt Diameter ( mm) 13 16 19 22 25 29 32 35 38 Snug Tension ( kN) 5 9 14 18 23 27 31 40 45 Table M8.04.3- 2: Snug Tight Tensions (US Customary Units) Bolt Diameter ( in.) ½ ⅝ ¾ ⅞ 1 1 ⅛ 1 ¼ ⅜ 1 ½ Snug Tension (kips) 1 2 3 4 5 6 7 9 10
rotation: • 240° ( ⅔ turn) for bolt lengths ≤4 diameters • 360° (1 turn) for bolt lengths >4 diameters and ≤8 diameters • 480° (1 ⅓ turn) for bolt lengths >8 diameters
tension shown below. Table M8.04.3- 3: Turn Test Tensions (SI Units) Bolt Diameter ( mm) 13 16 19 22 25 29 32 35 38 Turn Test Tension (k N) 62 98 142 200 262 285 365 436 525 Table M8.04.3- 4: Turn Test Tensions (US Customary Units) Bolt Diameter ( in.) ½ ⅝ ¾ ⅞ 1 1 ⅛ 1 ¼ ⅜ 1 ½ Turn Test Tension (kips) 14 22 32 45 59 64 82 98 118
shall be taken and recorded. Using a calibrated manual torque wrench, record the torque. For proper torque readings, the nut must be in motion. The measured bolt tension can be read off the Skidmore. The torque value shall conform to the following: 𝐴𝐴𝑓𝑓𝑓𝑓𝑞𝑞𝑎𝑎𝑎𝑎 ≤0.25 𝑃𝑃𝑃𝑃 Where: 𝐴𝐴𝑓𝑓𝑓𝑓𝑞𝑞𝑎𝑎𝑎𝑎 =𝑎𝑎𝑎𝑎𝑝𝑝𝑎𝑎𝑎𝑎𝑓𝑓𝑎𝑎𝑎𝑎 𝑎𝑎𝑓𝑓𝑓𝑓𝑞𝑞𝑎𝑎𝑎𝑎 (𝑓𝑓𝑎𝑎–𝑐𝑐𝑠𝑠) 𝑃𝑃=𝑎𝑎𝑎𝑎𝑝𝑝𝑎𝑎𝑎𝑎𝑓𝑓𝑎𝑎𝑎𝑎 𝑠𝑠𝑓𝑓𝑐𝑐𝑎𝑎 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑠𝑠𝑓𝑓𝑎𝑎 (𝑐𝑐𝑠𝑠) 𝑃𝑃=𝑠𝑠𝑓𝑓𝑐𝑐𝑎𝑎 𝑎𝑎𝑠𝑠𝑝𝑝𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑓𝑓 (𝑓𝑓𝑎𝑎)
Test Methods: Short Bolts Procedure for performing rotational capacity test on bolts too short to fit in a tension calibrator is as follows: Equipment Required
III.131 202 4 Edition 2. Spacers and/or washers with hole size no larger than ¹⁄₁₆ in. greater than bolt to be tested.
a plate thickness that will provide the number of threads under the nut required in step 1 below. Mark off a vertical line and lines ⅓ of turn, 120 °; ½ of a turn, 180° ; and ⅔ of a turn 240°, from vertical in a clockwise direction on the plate. Procedure
second wrench must be used to prevent rotation of the bolt head during tightening. Record the torque required to reach this rotation. Torque must be measured with t he nut in motion. Bolt Length , as measured in step 1 4 bolt diameters or less Greater than 4, but not more than 8 bolt diameters Greater than 8 bolt diameters Required Rotation ⅓ of a Revolution ½ of a Revolution ⅔ of a Revolution The measured torque should not exceed the values listed below. Assemblies which exceed the listed torque have failed the test. Bolt Diameter (in .) ½ ⅝ ¾ ⅞ 1 1 ⅛ 1 ¼ ⅜ 1 ½ Torque (ft-lb) 150 290 500 820 1,230 1,500 2,140 2,810 3,690
Bolt Length , as measured in step 1 4 bolt diameters or less Greater than 4, but not more than 8 bolt diameters Greater than 8 bolt diameters Required Rotation ⅔ of a Revolution 1 Revolution 1 ⅓ Revolutions
shear failure, stripping, or torsional failure of the bolt should be evident. Assemblies which have evidence of stripping have failed the test. M8.05.0: Structural Steel All structural steel shall conform to the requirements of AASHTO M 270 Grades 36, 50, or 50W or 70HPS. III.132 202 4 Edition Orientation of the test bars for the Charpy V -Notch (CVN) test specimens shall be longitudinal to the direction of final rolling. The “H” frequency of testing shall be used. CVN impact testing temperatures shall be in accordance with those specified for Zo ne 2. CVN tests are required for main members only. Secondary members typically including stiffeners and diaphragms do not require CVN tests. All welding shall comply with the provisions of the AASHTO/AWS Bridge Welding Code (ANSI/AASHTO/AWS D1.5). M8.05.1: Steel Piles Steel piles shall consist of structural steel shapes of the section shown on the plans. The steel shall conform to the requirements of AASHTO M 270 Grade 36 (Grade 250 MPa). Copper bearing steel will not be required. M8.05.3: Steel Baffles and Drainage Troughs Steel used for the manufacture of baffles and drainage troughs shall conform to the requirements of AASHTO M 270 M/M 270 Grade 50W (Grade 345W) with the additional requirement that the steel shall exhibit a corrosion resistance at least 4 times that of AASHTO M 270 M/M 270 Grade 36 (Grade 250) Steel. M8.05.4: Steel Sheeting Steel sheeting shall be an approved standard section either new or used, weighing not less than 22 psf of wall. Steel sheeting which is to be left in place shall conform to the requirements of AASHTO M 202M/M 202 (ASTM A328). M8.05.5: Steel Pipe Piles This specification covers cylindrical steel pipe of uniform cross section and diameter throughout its length and in which the cylindrical pipe acts as a permanent load -carrying member. The steel pipe shall be new and shall conform to the requirements of ASTM A252, Grade 2 except where it is in conflict with other parts of the specifications. In such cases those Specifications shall govern. Pipe having seams of spiral -lap welded construction will not be permitted under this specification. Pipes having spiral welded butt joint construction will not be permitted except where the pipe is concrete filled. The outside diameter and wall thickness of the pipe shall be as shown on the plans. All piles shall be driven as a closed end pipe and filled with concrete conforming to M4.02.00: Cement Concrete for 4,000 psi, ¾-inch, 610 cement concrete. A steel plate having the same outside diameter as the pipe and a thickness as shown on the plans shall be welded to the bottom of the pipe with a full penetration weld using an approved backing ring, which shall develop the full strength of the pipe in compression and tension. The bottom end of the pipe shall be beveled in accordance with ASTM A252 and the top end of the pipe shall not be beveled. III.133 202 4 Edition Steel reinforcement shall conform to the requirements of M8.01.0: Reinforcing Bars and shall be as detailed on the plans. M8.05.6 : Steel Casing This specification covers cylindrical steel casings of uniform cross section and diameter throughout its length in which the cylindrical casing acts as either a temporary or permanent load -carrying member. Permanent steel casings shall conform to the requirements of ASTM A252. Temporary casings shall be of a grade selected by the Contractor. Temporary casings that are used and are in good condition without strength impairing defects are acceptable for use as temporary casings. Permanent casings shall not have been previously used. Temporary casings that are left in place and connected to permanent casings shall meet the requirements of permanent casings. Casings having seams of spiral -lap welded construction will not be permitted for use as permanent steel casings. The outside diameter and wall thickness of the permanent steel casings shall be as shown on the plans. When permanent casings are used to carry part of the design load, all joints shall have full- penetration welds. All welds shall be inspected using ultrasonic testing. Any attachment between permanent and temporary casings shall be welded with full penetration welds using an approved backing ring, which shall develop the full strength of the casings in compression and tension. Temporary casings shall be the responsibility of the Contractor and shall be of sufficient strength to resist the handling, transportation, installation, and external stresses of the subsurface materials. M8.05.7 : Steel Extrusions Material utilized to produce steel extrusions suitable to mechanically lock elastomeric strip seals shall conform to properties of AASHTO M 270M/M 270 Grade 36 or Grade 50 (ASTM A709 Grade 36 or Grade 50) and shall be hot dipped galvanized after attachment of anchorage devices. Steel extrusions shall have a minimum thickness of ¼ in. as measured from the internal locking mechanism cavity to the top surface of the steel extrusion shape and shall be capable of resisting HS-25 wheel loading. Steel shapes shall be monolithic with the extrusion cavity. M8.07.0: Guardrail The materials for this work shall conform to AASHTO M 180 and the suppliers/manufacturers of guardrail and guardrail components shall be listed on the QCML. All steel components and hardware shall be galvanized. All metal fabrication work shall be done in the shop. No punching, cutting or welding shall be done in the field. Fabrication shall include all operations such as shearing, cutting, punching, forming, drilling, milling, bending, welding and riveting. Components of bolted assemblies shall be galvanized separately before assembly. When it is necessary to straighten any sections after galvanizing, such work shall be performed without damage to the zinc coating. Galvanized surfaces that are abraded or damaged at any time after application of the zinc coating shall be repaired by thoroughly wire brushing the damaged areas and removing all loose and III.134 202 4 Edition cracked coating after which the cleaned areas shall be painted with two coats of paint, high zinc dust content, conforming to the requirements of M7.04.11.
Steel Posts. Steel posts and channel members for anchor posts shall be fabricated from new structural steel sections conforming to the dimensions and design shown on the plans. Posts shall conform to the requirements of ASTM A36. Galvanizing shall meet the requirements of M7.10.0: Galvanized Coatings . Wood Posts. The posts shall be rough sawn (unplaned) with nominal dimensions as indicated on the plans and with tolerances of 1 in. in length and ¼ in. in width and thickness. All holes in the posts shall be drilled prior to pressure application of the preservative at a wood preserving facility. The stress grade shall be 1,000 psi or more in extreme fiber bending. Grading for stress -graded timber shall be in accordance with AASHTO M 168. Prior to treatment, all posts shall be seasoned, conditioned, and completely machined in accordance with AWPA M1. Posts shall be treated with chromated copper arsenate, type C (CCA -C) conforming to AWPA P23, to a minimum retention of 0.60 pcf. Treatment shall be full length under pressure by the empty -cell or full-cell process in accordance with AWPA U1. Manufacturers shall adhere to the processing and treatment limitations in AWPA T1. No unnecessary cutting of treated posts will be allowed after treatment. All posts with surfaces damaged by cutting, drilling or any other cause shall be field treated with a preservative solution in accordance with AWPA M4. Certificates of compliance and certificates of inspection bearing the independent inspection agency’s verification for each lot of wood must be presented before installation and contain the species of wood, the type of preservative, the retention rate and penetration of the preservative. The certificates of inspection and compliance do not signify mandatory acceptance of the entire lot. The Department still has the option of rejecting posts (included in any particular lot) that the Engineer considers sub -standard because of unsound knots a nd shakes, excessive checking or other defects that may be detrimental to the structural integrity of the posts. The fabricator shall retain an independent inspection agency to inspect and certify the treated posts in accordance with these specifications and AWPA M2, Part A. All treated posts shall be marked in accordance with AWPA U1 (and M6 as required). (The mark is to include the identifying lot and/or charge number). The post shall also be stamped with the Inspector’s identification. The mark is to be placed on the upper side head of the post and located so that it is not obstructed by the offset blocks, rails, or any other appurtenances. The Inspector’s stamp shall be legibly hammer -stamped on the head of the post, in accordance with AWPA M2 and the above. III.135 202 4 Edition B. Offset Blocks. The blocks shall be of the same type throughout the project. Requirements for specific material types are as follows: • Wood Offset Blocks: Wood offset blocks shall meet the requirements of A . Posts, Wood Posts , above. When wood offset blocks are used on wood posts, they shall be the same species as the posts. • Plastic Offset Blocks: Plastic offset blocks shall meet all applicable performance requirements of MASH and be listed on the QTCE . Each block shall be stamped at the factory with the manufacturer’s identification and lot number and conform to the dimensions shown on the plans. Prior to approval and use of the plastic guardrail offset blocks, the manufacturer shall submit to the Engineer, the manufacturers name, the product brand name and/or model number, a copy of the MASH test results, a Material Safety Data Sheet, and a sample block. Acceptance of the material will be based on the manufacturer’s certification.
The steel rail element, transition panels, terminal sections and connecting hardware shall conform to AASHTO M 180, Type II, Class A with the following additions: The length of the rail shall be according to the plans. Each end of the steel rail for every stretch of guard shall be fitted with a terminal section as shown on the plans. The projecting heads of all connection and splice bolts shall be button head type so no appreciable projection will obstruct a vehicle sliding along the rail. Steel rail elements with a radius of 150 ft or less shall be shop bent. The manufacturers are required to submit a Brand Registration and Guarantee document annually to RMS showing compliance of the Guardrail Components with AASHTO M 180 Specification. M8.07.1: Guardrail End Treatment The same type of tangent end or flared end treatment shall be used throughout the project. All steel components and hardware shall conform to M8.07.0: Guardrail. All metal work shall be done in the shop. The approach end shall have Type 3 Object Marker sheeting that conforms to the requirements of the MUTCD. The sheeting material shall meet the requirements of M9.30.0: Retroreflective Sheeting . M8.09.0: Chain Link Fences and Gates Materials for this work shall conform to the following requirements: III.136 202 4 Edition A. General. All material used shall conform to AASHTO M 181 except as noted herein. The fence fabric shall be Type II - Aluminum Coated Steel or Type IV -- Polyvinyl Chloride (PVC) - Coated Steel. All tubular posts and rails, and roll -formed “C” section posts and rails shall be zinc coated steel. All wire shall have a diameter tolerance of ±0.005 in. diameter. For chain link fabric used on bridge protective screens Type I and II see M8.13.3: Aluminum Handrail and Protective Screen Type I and Type II . Spring tension wire shall be aluminum coated steel. Aluminum coated fence fabric and spring tension wire shall be tested in accordance with AASHTO T 213 M/T 213. All zinc coated posts, hardware, and fittings shall be in conformance with AASHTO M 232 M/M 232. Polyvinyl Chloride
Vinyl Coated Chain Link Fences, Posts, Rails, Fabric, Gates and Accessories. Post caps, rail end and other fittings and appurtenances shall be pressed steel or malleable iron. All materials shall be new and undamaged when installed. Imperfectly coated materials will be rejected.
Steel round pipe posts and “C” sections shall have a tolerance of ±10% from specified weight and ±5% from specified dimensions. Type B round pipe shall conform to ASTM A 1011. Roll- formed “C” section shall conform to ASTM F1043. Galvanized steel Line, End, Corner and Intermediate Posts shall conform to the sizes in Table M8.09.0-1: Table M8.09.0- 1: Post Sizes for Chain Link Fence Post Type Under 5 Ft in Height 5 Ft and Over in Height Line Post 1) Round Pipe - 1.90- in. O.D. Type B @ 2.29 lb per ft; or 2) “C” section - 1 ⅞ x 1 ⅝ in. @ 2.28 lb per ft 1) Round Pipe - 2 ⅜-in. O.D. Type B @ 3.117 lb per ft; or 2) “C” section -2 ¼ x 1.70 in . @ 2.64 lb per ft End Post and Corner Post 1) Round Pipe - 2 ⅜-in. O.D. Type B @ 3.117 lb per ft 1) Round Pipe - 2 ⅞ -in. O.D. Type B @ 4.64 lb per ft Intermediate Brace Posts 1) Round Pipe - 2 ⅜-in. O.D. Type B @ 3.117 lb per ft; or 2) “C” section - 2 ¼ x 1.70 in . @ 2.64 lb per f t 1) Round Pipe - 2 ⅞-in. O.D. Type B @ 4.64 lb per ft Gate posts shall be 4 in . O.D. pipe, Type B with a weight of 6.56 lb per ft. The galvanizing for “C” sections shall not be less than 2.0 oz per ft² of metal surface as per AASHTO M 232M/M 232. For Type B round pipe the external coating shall be 0.9 oz of galvanizing per ft ² minimum, 15 µg of chromate per in. ² minimum, plus 0.3 mils minimum of clear cross -linked polyurethane acrylic coating. The internal surface shall be coated with zinc -rich based organic coating containing not less than 87% zinc powder and capable of providing galvanic protection. All round p osts shall be fitted with an approved top, so designed as to fit securely over the post and carry the top rail or cable. The base of the top fitting shall carry an apron around the outside of the post. III.137 202 4 Edition C. Top Rail and Spring Tension Wire. 1) Rail shall have a tolerance of ±10% from specified weight and ±5% from specified dimensions. Steel top rails shall be Type B 1.66 in . O.D. tubular pipe with a weight of 1.83 lb per ft, or 1.625 x 1.25 in . roll-formed “C” section with a weight of 1.40 lb per ft. The protective coating for top rails shall meet the requirements of paragraph B above. Couplings or expansion sleeves shall be outside sleeve type and at least 6 in. long. 2) Spring tension wire shall be coil spring steel 7 gage (0.177 in .). The base metal shall have a minimum breaking strength of 1,950 lb coated with aluminum applied at a rate of not less than 0.40 oz per ft² of surface area.
Compression braces shall be the same type and size as top rail. Tension truss rods shall be ⁵⁄₁₆ -in. minimum round rods with drop forged turnbuckles, or other approved type of adjustments.
The fabric shall consist of 9 gage (0.148 in .) wire having a minimum breaking strength of 1,290 lb coated with aluminum applied at the rate of not less than 0.40 oz per ft² of uncoated wire surface. It shall be woven into approximately 2 in. diamond mesh. The width of the fabric shall be specified or shown on current standard drawings. Fabric for chain link fence less than 6 ft in height shall be finished at top and bottom with a “ knuckled ” selvage. All other fence sizes shall have a knuckled selvage at the bottom and twisted selvage at the top. Barbing shall be done by cutting the wire on the bias.
All bands shall be a minimum of 12 gage (0.106 in .) and at least ¾ in. in width. Tension or stretcher bars shall be no less than ³⁄₁₆ in. x ¾ in. stock. Galvanizing shall conform to the requirements of AASHTO M 232 M/M 232.
Aluminum tie wire shall be a minimum of 6 gage (0.192 in .) round wire Alloy 1350 -H19 or equal. Aluminum hog rings shall be a minimum of 11 gage (0.120 in .) round wire Alloy 1350- H19 or equal.
Barbed wire shall consist of two strands of 0.0985 in . diameter wire with 0.08 in . diameter 4 point barbs approximately 5 in . apart, shall be aluminum coated and conform to the requirements of AASHTO M 280 . Barbed wire Extension Arms shall be at an angle of approximately 45° and shall be fitted with clips or other means for attaching three lines of barbed wire, and with top outside wire approximately 12 in . horizontally from the fence line and the other wires spaced uniformly between the top of the fence fabric and the outside barbed wire. III.138 202 4 Edition I. Gates. Gate frames shall be constructed of galvanized steel of sizes and weights shown below. The corners of the gate frame shall be fastened together and reinforced with suitable fittings designed for the purpose or they may be welded. Single gate frames 6 ft or less in width shall be 1.66 in . O.D. pipe galvanized steel conforming to Section C of this specification. Single gate frames over 6 ft wide shall be 1.90 in . O.D. galvanized steel pipe conforming to Section B of this specification. Cross trussing shall be ⁵⁄₁₆ -in. galvanized iron adjustable rods. Chain link fence fabric for filling the gage frame shall conform to Section E of this specification. Each gate shall be furnished complete with necessary hinges, latch and drop bar locking device designed for the type of gate post and gate used. Gate sizes shall be as specified with the height conforming to the height of the fence.
Drive anchors shall be galvanized steel angle iron or extruded aluminum alloy 6061 -T6. Minimum dimensions shall be 1 ¼ in. x 1 ¼ in. x ⅛ in. The weight of zinc for galvanized components shall be 1.5 o z per ft² of metal surface. Shoes for drive anchors shall be galvanized cast or malleable steel, or extruded aluminum alloy 6061 -T6. The weight of zinc for galvanized components shall be 2.0 o z per ft² of metal surface. M8.09.1: Bonded Vinyl Coated Chain Link Fences, Posts, Rails, Fabric, Gates and Accessories The fence shall have a bonded polyvinyl chloride (PVC) coating over aluminum coated or galvanized steel. All material used shall conform to AASHTO M 181. Polyvinyl chloride coated by dipping, thermal fusion or any other method that meets the requirements o f this specification. The fence fabric shall be PVC coated wire that is woven into a 2 in. diamond mesh. The coating shall not crack, craze, or peel. The color of the PVC coated fabric and accessories shall be medium green as defined in AASHTO M 181. All materials shall have dimensions and weights as specified in M8.09.0: Chain Link Fences and Gates except as follow: Spring Tension Wire ............................ 9 gage. Ties ............................................................. Aluminum 10 gage Hog Rings ................................................. Aluminum 11 gage The bonded PVC coating shall be a minimum of 0.007 in. as determined by measuring the diameter of the coated wire, stripping off the coating, measuring the diameter of the stripped wire and dividing the difference by two. M8.10.0: Steel Pipe Rail or Fence Materials for this work shall conform to the following requirements: III.139 202 4 Edition A. Rails and Posts. Steel pipe for rails and posts shall conform to requirements of ASTM A53, Grade B. Galvanized pipe ordered under this specification shall be coated with zinc inside and outside by the hot -dip process. The weight of zinc coating shall be not less than 2.0 o z per ft² of surface area. For rails and posts, a tolerance of ±10% from the specified weight and ±5% from the specified dimension is allowed.
All fittings shall be steel conforming to ASTM A307. They shall be galvanized in accordance with AASHTO M 232M/M 232.
Lead wool for caulking shall be of standard manufacture and shall be approved for such use by the Engineer.
Bitumen for use with pipe sleeves shall be approved for that use by the Engineer. M8.10.1 : Aluminum Pipe Ra il or Fence Materials for this work shall conform to ASTM F1183 with 2 in . diamond mesh and the following requirements:
materials. All castings shall be sound, free from blow -holes or other imperfections and have smooth surfaces.
Washers .
M8.11.0: Bronze Self -Lubricating Bearing Plates The self -lubricating bronze plates shall conform to one of the following materials as called for on the design drawings:
extent that 1.5 to 2.5 % lead will be required.
III.140 202 4 Edition Finishes and Tolerances The surfaces of the bronze and steel plates which bear upon each other shal l have a surface roughness not exceeding 125 micro inches when measured in accordance with American Standards Association B46.1 for surface roughness, waviness and lay. The lay of the tool marks shall be in the direction of expansion or contraction of the bridge. The flat surfaces of the bronze and steel plates which bear upon each other shall be flat within 0.5 mil per inc h (0.0005 mm per mm) of length and width. Bronze Bearing plates having radial convex surfaces shall have a negative tolerance of 10 mils (250 µm) maximum and a positive tolerance of 0.000 in . (10 µm) on the specified radius. Concave radial surfaces of steel bearing plates shall have a positive tolerance of 10 mils (250 µm) maximum and a negative tolerance of 0.000 in . (10 µm) on the specified radius. Lubricated Recesses. The recesses for the containment of the solid lubricant in the bronze bearing plates shall consist of annular rings or drilled holes with a minimum vertical wall depth of ³⁄₁₆ in. The recesses shall be arranged in a geometric pattern in such a manner that each successive row shall overlap in the direction of motion. The entire area of all bearing surfaces which have provision for motion shall be lubricated by means of these lubricant filled recesses. The total area of these recesses shall comprise not less than 25% nor more than 35% of the total bearing area of the plate. Lubricant. The lubricant for filling the recesses shall be of the solid type and shall consist of graphite and metallic lubricants with a lubricating binder. The lubricant shall be compressed into the lubrication recesses by hydraulic pressure of at least five times the design unit loading as shown on the contract drawings to form a dense nonplastic insert which shall project not less than 0.010 in. above the surface of the bronze bearing plate. Testing. A self -lubricating bronze test plate measuring not less than 5 in. long by 5 in. wide shall be prepared and shall conform to one of the above materials and all other requirements of the specifications. An assembly consisting of the fixed self -lubricating test plate and a movable steel plate shall be subjected to the design vertical unit loading specified in the contract drawing. The steel plate shall then be subjected to not less than 100 cycles of horizontal movement at a speed not to exceed 30 cycles per minute. Each cycle shall consist of a forward and return movement of not more than ½ in. in each direction. The recorded horizontal force divided by the recorded vertical force shall be established as t he co -efficient of friction between the sliding surfaces. The coefficient of friction determined by the foregoing method shall not exceed 0.010. If the tests indicat e a coefficient of friction greater than 0.10, the entire lot of solid lubricant shall be rejected. Where no inspection of materials is arranged for by the Party of the First Part and before such materials are incorporated into the work , the manufacturer of the bronze bearings will be required to certify that the bronze bearing material with lubricant, when tested as hereinbefore described, shall not have a coefficient of friction greater than 0.10. Batches of solid lubricant that successfully III.141 202 4 Edition meet the friction coefficient requirements shall be properly identified by the manufacturer with a lot number and date marked “ Approved for use on Commonwealth of Massachusetts projects .” Preparation of Mating Steel Plates. The sliding surfaces of the mating steel plates shall be coated, just prior to installation, with a liquid lubricant recommended and furnished in sealed containers by the manufacturer of the bronze bearing plates. Material Certifications. Certified copies of the chemical analysis and physical properties of the bronze used in manufacturing of the bearing plates shall be supplied for each project. Certifications shall be identified with the hea t numbers of the bronze, solid lubricant lot numbers , and a statement that the solid lubricant used in the manufacture of the bronze bearing plates has successfully passed the test requirements of this specification. M8.13.0: Bridge Railings, Aluminum, TypesAL -1 & AL -3 Materials used in the fabrication of aluminum bridge railings shall conform to the following requirements:
sound, free from blowholes or other imperfections and have smooth surfaces.
Washers .
M8.13.1: Bridge Railing, Steel, Type S3 -TL4 All steel shall be new and fabrication shall conform to 960.61: Design, Fabrication and Erection. The fabricator shall be approved by the Department in compliance with the requirements of 960.61: Design, Fabrication and Erection, Paragraph A. Posts and base plates shall conform to the requirements of AASHTO M 270 M/M 270 Grade 50. CVN tests are required. Rails shall be made from hollow structural tubing and shall conform to the requirements of ASTM A500 Grade B or C with a minimum yield (F
Anchor plates and splice tube plates shall conform to AASHTO M 270M/M 270 Grade 36. CVN tests are not required. Picket tubes shall conform to the requirements of ASTM A513 with a certified yield (F y) of 36 ksi or ASTM A500 Grade B. CVN tests are not required. III.142 202 4 Edition Carrier angles shall conform to the requirements of AASHTO M 270 M/M 270 Grade 36. CVN tests are not required. Round headed bolts shall conform to the chemical and physical requirements of ASTM F3125/F3125M . Rotational capacity tests are not required. High strength bolts shall conform to M8.04.3: High Strength Bolts . Anchor bolts shall conform to M8.01.5: Anchor Bolts, Nuts and Washers . Molded fabric bearing pad shall conform to M9.16.2: Molded Fabric Bearing Pad . Screws shall be hardened countersunk machine screws. M8.13.2 : Metal Bin -Type Retaining Wall Metal sheets used in fabricating the retaining wall shall be of U.S. Standard Gauge thickness as specified on the plans, but no unit shall be formed from sheets thinner than 0.062 in. The base metal and coating shall conform to the requirements of AASHTO M 218. All bolts and nuts used in the erection of the wall shall be galvanized. Bolts shall have a diameter of ⅝ in. and a minimum length of 1 ¼ in., measured from the underside of the bolt head. M8.13.3: Aluminum Handrail, Protective Screen Type I and Type II, and Snow Fence Material used in the fabrication of Handrail, Protective Screen Type I and Type II, and Snow Fence shall conform to the following requirements (see Subsection 975: Metal Bridge Railings, Protective Screens and Snow Fences for anodizing and powder coating requirements):
T94). Prior to bending and coating, the wire shall meet the minimum tensile strength of 54 ksi as specified in AASHTO M 181. After fabrication and coating, the minimum ten sile strength of the wire shall be 43 ksi.
stainless steel with a hardness of 32 to 35 HRC.
testing shall be required. The bolts and washers shall be galvanized in accordance with AASHTO M 232 M/M 232. The anchor cage shall be galvanized in accordance with AASHTO M 111M/M 111 or shall be electroplated with zinc in accordance with ASTM B633, Service Condition 1, Type III.
A307 Tee Bolts.
Alloy 6061 -T6. III.143 202 4 Edition M8.14.0 : Load Transfer Assembly
so designed as to hold the slip -bars exactly and firmly in their correct positions during concreting operations. The complete assembly shall conform to the requirements and dimensions as shown on the plans or as approved by the Engineer.
plain rail steel. They shall be free from burring or other deformations restricting slippage in the concrete.
with a coat of either a graphite lubricant or a wax base grease.
drying characteristics. The graphite paste shall be thoroughly mixed and have the following composition (Percentage by weight). Table M8.14.0- 1: Graphite Paste Composition Minimum Maximum Pigment: (Flake Graphite) 55% 65% Graphite Carbon 85% Passing No. 100 Sieve 84% 92% Passing No. 325 Sieve 46% 50% Vehicle 35% 45% Vehicle shall consist of 52% fixed oils; remainder to be volatile thinners and driers. To prepare lubricant for application, approximately 3 to 4 lb of the graphite paste shall be placed in a suitable container and 40% by weight of 60/40 mixture of carbon tetrachloride and naphtha shall be added thereto. The resulting lubricant shall be thoroughly mixed.
conform to the following requirements:
at 77°F ....................................................... 120 -160
M8.15.0: Strand Chuck The chuck shall be of a design suitable for securely gripping high tensile strand steel without deformation or slippage. It shall be manufactured from a corrosion resistant steel alloy capable of III.144 202 4 Edition withstanding repeated use and overload conditions in excess of the ultimate tensile strength of the strand without fatigue or failure. The surface body of the chuck shall be treated to increase corrosion resistance. M8.16.0: Electrical Wire & Cable This specification covers all electrical wire and cable for traffic control devices, traffic signals, ITS systems, highway lighting, signs and supports. All wire and cable herein are for copper conductors rated for 600V. All traffic signal cable conductors shall not be less than #14 AWG, with an exception for individual conductor drops between a span wire hub and the signal head, which shall be not less than #16 AWG. All traffic signal conductors shall be stranded. M8.16.1: Type 1 Traffic Signal Cable (Installed above ground or in Duct) Traffic signal cable shall be thermoplastic and conform to requirements of IMSA Specification 19 -1. M8.16.2: Type 2 Traffic Signal Cable (Installed above ground or in Duct) Traffic signal cable shall be thermoplastic and conform to requirements of IMSA Specification 20 -1. M8.16.3: Type 3 Traffic Signal Cable (Installed above ground) Traffic signal cable shall be thermoplastic and conform to requirements of IMSA Specification 19 -3 or 20- 3. M8.16.4: Type 4 Traffic Signal Cable (Installed above ground) Traffic signal cable shall be thermoplastic and conform to requirements of IMSA Specification 19 -4 or 20- 4. M8.16.5: Type 5 Traffic Signal Cable (Direct Burial) Traffic signal cable shall be thermoplastic and conform to requirements of IMSA Specification 19 -5 or 20- 5. M8.16.7: Type 7 General Purpose Wire (XH HW- 2 with XLP Jacket ) General Purpose Wire shall conform to requirements of UL Standard UL -44 “Rubber -Insulated Wires and Cable.” Type 7 Wire installed in a tunnel shall have a VW -1 Rating. M8.16.8: Type 8 Direct Burial Wire (USE) Direct burial wire shall be insulated as specified for Type 8 and conform to requirements of UL Standard UL -854 “Service -Entrance Cables” for USE listed cable. M8.16.9: Type 9 Special Purpose Wire (TW -THW -UF) Special purpose wire shall be TW or THW conforming to requirements of UL Standard UL -83 “Thermoplastic -Insulated Wires ” or UF conforming to the requirements of UL Standard UL -719 “Nonmetallic- Sheathed and Underground Feeder Cables ” as specified. III.145 202 4 Edition M8.16.10: Type 1 0 Grounding and Bonding Conductors (Solid or Standard, Insulated or Bare) Grounding and bonding conductors shall not be less than #14 AWG. Ground and bonding conductors shall be copper conforming to requirements of ASTM -B3 for soft or annealed copper wire, ASTM -B8 for stranded copper wire. Where wire is provided with an individual covering, the covering shall be finished a continuous green color or a continuous green color with one or more yellow stripes. M8.16.11: Shielded Loop Detector Lead-In cable Two -conductor #14 AWG, tinned copper stranded (19 x 27) conductors, polyethylene insulated (0.032 in. thick), conductors cabled, aluminum -polyester shield (100% shielding), #16 AWG stranded tinned copper drain wire. Chrome vinyl outer jacket (0.035 in. thi ck), nominal cable outside diameter 0.340 in. and conform to the requirements of IMSA specification 50 -2. M8.16.12: Type 12 Multi -conductor heavy duty portable power cord This material shall conform to the requirements of Underwriters Laboratories Standard UL -62, Flexible Cord and Fixture wire for Type 50, 600V flexible cord. M8.16.13: Type 13 Loop Detector Wire THHN with Tube Loop detector wire shall be PVC insulated, nylon jacketed, loose encased in a PVC or PE tube and conform to requirements of IMSA specification 51 -5. M8.16.14: Type 14 Coaxial Cable Coaxial Cable shall be a 75 -ohm, precision video cable with 20 -gauge solid bare copper conductor (9.9 ohms/M), solid polyethylene insulating dielectric, 98% (minimum) tinned copper double - braided shield and black polyethylene outer covering. The signal attenuation shall not exceed 0.78 dB per 100 ft. at 10 MHz. The nominal outside diameter shall be 0.304 in. Coaxial Cable shall be suitable for installation in conduit or overhead with appropriate span wire. M8.16.15: Type 15 Cat5e Ethernet Cable Cat5e Ethernet Cable shall consist of a 4 -pair, #24 AWG solid, color- coded conductors contained within an insulated jacket. The insulation material of the inner conductors shall be Polyolefin (PO), the insulation material of the outer jacket shall be Polyethylene (PE). The outer shield shall be aluminum foil/polyester tape and cover 100% of the inner conductors. The outer shield drain wire shall be tinned copper. Cat5e Ethernet Cable shall have an operating temperature range of -30℃ to +75℃, a maximum pulli ng tension of 110 N, and a minimum bending radius of 50.4 mm. Cat5e Ethernet Cable shall meet TIA/EIA 568 -c.2 Category 5e, NEMA WC -63.1 Category 5e, and IEC 11801 Category 5e. M8.16.16: Type 16 Twisted Pair Copper Cable Twisted Pair Copper Cable shall be a flexible power cable consisting of three #16 AWG, stranded, insulated conductors contained within an insulated jacket. The operating voltage of the cable shall be rated at 300V RMS, maximum. The insulation material shal l be thermoplastic elastomer (TPE) with an insulation thickness of 0.031 in. (nominal) and an insulated conductor diameter of 0.120 in. III.146 202 4 Edition (nominal). The cable filler type shall be polypropylene and the separator wrap shall be paper tissue. The cable shall have a temperature rating of - 50℃ to +105℃. Twisted Pair Copper Cable shall meet UL Standard 62, CSA 22.2 No. 49, and NEC article 400. M8.16.17: Type 17 Twisted Pair Copper/Fiberoptic Hybrid Cable Twisted Pair Copper/Fiberoptic Hybrid Cable shall be a fiberoptic/power hybrid cable capable of supporting single point camera system which utilizes fiber optic- based communications for video transmission. The cable shall be of rugged, outdoor rated hybrid design consisting of four tight buffered breakout fibers and two copper conductors encased in a flame -retardant outer jacket. The cable shall also consist of aramid yarns encapsulating the tight buffered fibers under a sub -unit jacket. The cable shall contain a ripcord to facilitate outer jacket removal. The fiber strands shall be OM3 multimode 50/125 BIF, 10 GIG. The copper conductors shall be stranded copper #16 AWG. The outer jacket shall be UV -resistant black flame -retardant PVC with a diameter of 0.40 -0.42 in. The cable sub -jacket shall consist of thermoplastic elastomeric (TPE) with a diameter of 0.095 in. The central strength member shall be epoxy glass rod. The cable shall be temperature rated for a range of -40℃ to +70℃. The cable shall be RoHS compliant and meet IEC 60793 -2-10 and TIA -492AAAD Optical Fiber specifications. M8.17.0 : Ground Rod Ground Rods shall be nominal ⅝ in. diameter (measured diameter shall not be less than 0.558 in.) by a minimum of 8 ft long copper bonded to steel rod, with bolt type clamps, conforming to the requirements of UL-467. M8.18.0: Traffic Signal, Highway Lighting and Sign Supports This section covers the poles, posts, masts, arms and bases for traffic signals, highway lighting and sign supports. M8.18.1: Traffic Signal Supports Posts Steel signal posts shall be 4 in. diameter Schedule 40 seamless pipe conforming to ASTM A53, Grade A or B. Interiors shall be coated as specified in Underwriters Laboratories UL -6 for enameled conduit, or aluminum conduit conforming to M5.07.1: Electrical Conduit -Rigid Metallic (Type RM), Paragraph C. Aluminum signal posts shall be 4 in. diameter Schedule 40 pipe conforming to aluminum alloy 6063 -T6 (ASTM B221, B429 or B241). Poles and Mast Arms Structures shall be made of steel. Structural steel material over ½ in. thick that is part of main load carrying tension members shall meet the Charpy V Notch impact requirements of 15 ft -lb at 40°F. Tapered shafts shall conform to ASTM A595, Grade A, or AASHTO M 270 M/M 270 Grade 50. III.147 202 4 Edition The arms shall conform to ASTM A595, Grade A; or ASTM A1011/A1011M, or ASTM A500 Grade B. Steel shall have a minimum yield of 50 ksi. The shaft cap shall conform to ASTM A126, Class A. All hardware shall be stainless steel or ASTM F3125/F3125M , fully galvanized. Baseplates and all other standard structural shapes shall conform to AASHTO M 270M/M 270 Grades 36 or 50. Anchor bolt covers shall meet the requirements of ASTM A181/A181M or ASTM A126, Class A or AASHTO M 103M/M 103, Grade 450 -240 (Grade 65 -35) or ASTM A36/A36M. Galvanizing shall be in accordance with Section M7: Paints, Protective Coatings and Pavement Markings. Bases Bases shall be the same materials as the poles. Octagonal bases are for use with posts and shall be cast iron conforming to AASHTO M 105 or cast aluminum alloy conforming to Aluminum Association No. 356.0 T -6 (ASTM B26, B108). Pedestal bases are for use with posts and poles and shall be made of not less than No. 10 gage steel and galvanized in accordance with Section M7: Paints, Protective Coatings and Pavement Markings or cast aluminum alloy conforming to Aluminum Association No. 356.0 T -6 (ASTM B26, B108). M8.18.2 : Highway Lighting Poles and Arms Aluminum Tapered aluminum poles shall conform to ASTM B221, alloy 6063 -T6 or 6061 -T6. Structural aluminum shapes shall conform to ASTM B308, alloy 6061 -T6. Bases shall conform to ASTM B108, alloy 356.0- T6. Steel Structural steel material over ½ in. thick that is part of main load carrying tension members shall meet the Charpy V Notch impact requirements of 15 ft -lb at 40°F . Tapered components shall be fabricated from steel conforming to ASTM A595, Grade A; or ASTM A1011M, Grade 55; or AASHTO M 270 M/M 270, Grade 50. Gussets, flanges, baseplates, wing plates, connecting end plates, and all other standard structural shapes shall conform to AASHTO M 270 M/M 270 Grades 36 or 50. Anchor Bolts Anchor bolts shall conform to M8.01.5: Anchor Bolts, Nuts and Washers and be fully galvanized in accordance Section M7: Paints, Protective Coatings and Pavement Markings . M8.18.3: Sign Supports Structural steel material over ½ in. thick that is part of main load carrying tension members shall meet the Charpy V Notch impact requirements of 15 ft -lb at 40°F . III.148 202 4 Edition Supports shall be fabricated from steel conforming to ASTM A595, Grade A; ASTM A1011M, Grade 55; AASHTO M 270 M/M 270, Grade 50; ASTM A500, Grade B; or API -5LX -52. Gussets, flanges, baseplates, wing plates, connecting end plates, and all other standard structural shapes shall conform to AASHTO M 270 M/M 270 Grades 36 or 50. Truss and cantilever beam connections shall be furnished with the necessary beam support clamps. The ends of beams shall have a mounting clevis and closure plate fabricated from steel plate as an assembly. All structural steel and steel hardware shall be galvanized in accordance with Section M7: Paints, Protective Coatings and Pavement Markings . Anchor bolts, nuts, and washers shall conform to M8.01.5: Anchor Bolts, Nuts and Washers and be fully galvanized in accordance with Section M7: Paints, Protective Coatings and Pavement Markings . Sign Posts – P5.
Square tube posts shall be square tube fabricated from 12 gage hot -rolled carbon steel conforming to the requirements of ASTM A1011, Grade 50. Galvanizing shall be in accordance with ASTM A653, Coating Designation G140 with a minimum coating of 1.4 oz per ft² total of zinc on both sides under triple spot tests; or a minimum coating of 1.15 oz per ft² total of zinc on both sides under triple spot tests and after all fabrication and re - galvanizing the posts shall be coated with a chromate conversion coating and sealed with an air - dried clear organic polymer topcoat. Posts shall be welded directly in the corner by high frequency resistance welding or equal and externally scarfed to agree with standard corner radius of 0.15625 in. ±0.015625 in. The corner weld and holes shall be zinc coated after scarfing operations. Holes shall be 0.4375 in. in diameter and shall be placed 1 in. on center.
U-channel posts shall be fabricated from re -rolled rail steel or an equivalent steel and shall conform to the mechanical requirements of ASTM A499, Grade 60 and the mechanical requirements of ASTM A1. All steel U -channel posts shall weigh at least 4 lb per ft and be entirely galvanized in accordance with Section M7: Paints, Protective Coatings and Pavement Markings . Holes shall be 0.4375 in. in diameter spaced at 1 in. on center and be punched prior to the galvanizing of the posts. All bolts, nuts and washers shall conform to the requirements of ASTM A307, Grade A. Bolts, nuts and washers shal l be galvanized in accordance with the requirements of Section M7: Paints, Protective Coatings and Pavement Markings . Steel posts, sign post anchors, anchor sleeves, slipbases, lap splices, and any related hardware shall all be from the same manufacturer. No mixing of brands shall be allowed. M8.19.1: Aluminum Sign Panels Aluminum sign panels shall be fabricated from ASTM -B209, Alloy 6061 -T6, (0.080 in. thick) with 3 in. minimum diameter amber reflectors affixed thereto. III.149 202 4 Edition M8.20.4: Anti -Glare Systems Anti -Glare Systems shall consist of modular sections consistent in length with standard length of concrete median barrier. Glare blocking shall be accomplished by vertical blades or panels attached to a horizontal base to create the modular units. The anti -glare system shall be of a type listed on the QTCE. M8.21.0 : Stay -in-Place Bridge Deck Forms Stay -in-Place Bridge Deck Forms and supports shall be fabricated from steel conforming to ASTM A653 (Grades 33, 37, 40, 50 Class 1 and 2, and 80 English and Grades 230, 255, 275, 340 Class 1 and 2, and 550 Metric) having a coating class of G165 according to ASTM A924. M8.22.0: Cross Hole Sonic Testing Access Pipes Steel pipe for cross hole sonic testing access pipes shall be Schedule 40 and shall conform to ASTM A53, Grade B. III.150 202 4 Edition SECTION M9 : MISCELLANEOUS MATERIALS M9.00.0 : General All materials in this category shall be sampled and tested in accordance with the standard methods applicable to that particular material. M9.01.0 : Calcium Chloride Calcium Chloride shall conform to the requirements of AASHTO M 144, Type I or Type II. M9.01.1 : Sodium Chloride Sodium Chloride to be used for road purposes shall conform to the requirements of AASHTO M 143, except that the grading shall conform to the following: Table M9.01.1- 1: Gradation Requirements for Sodium Chloride Sieve Percent Passing ⅜ in. 100 No. 4 82 (maximum) No. 8 50 (maximum) No. 30 7 (maximum) M9.02.0 : Herbicides These specifications cover chemicals used to destroy and/ or control the growth of plants both indiscriminately (non -selective herbicides) and selectively (selective herbicides). Only those herbicides currently approved by the State Pesticide Board and the Department may be used. M9.03.0 : Insecticides These specifications cover chemicals to be used in the control of insects which are harmful to trees and desirable growth. Only those insecticides currently approved by the State Pesticide Board and the Department may be used. M9.04.0 : Curb and Edging All granite curb and edging shall be basically light gray in color, free from seams and other structural imperfections or flaws which would impair its structural integrity, and of a smooth splitting appearance. Natural color variation characteristic of the deposit from which the curbing is obtained will be permitted. Whenever curbing is sawed, all surfaces that are to be exposed shall be thoroughly cleaned and any iron rust or iron particles removed by sand blasting or other approved methods satisfactory to the Engineer and any saw mark in excess of ⅛ in. shall be removed. M9.04.1 : Granite Curb The stones for the several types of granite curb shall be cut to the dimensions and curvature hereinafter stated: III.151 202 4 Edition Table M9.04.1- 1: Standard Granite Curbstone Dimensions Type Minimum Length Width at Top Depth Minimum Width at Bottom VA1 6 ft 7 in 17 in. to 19 in. 4 in. (for ⅔ length) VA2 6 ft 7 in. 19 in. to 21 in. 4 in. (for ⅔ length) VA3 6 ft 6 in. 19 in. to 21 in. 4 in. (for ⅔ length) VA4 6 ft 6 in. 17 in. to 19 in. 4 in. (for ⅔ length) VA5 5 ft 6 in. See Plans 5 in. (for ⅔ length) VB 3 ft 5 in. 15 in. to 17 in. 3 ½ in. (for ⅔ length) Except for the 3 following conditions, 10% of the length of each type of VA curb installed on the project may consist of stones no more than 6 in. shorter than the length specified in either table.
table, except that for VA5 the closure piece shall have a minimum length of 4 ft.
the run of curbing.
not more than 6 ft in length. Type VA stones to be set on a radius of 100 ft or less shall be cut to the required curvature and except for making closures shall be of minimum lengths as follows: Table M9.04.1- 2: Minimum Lengths of Curved Granite Curbstone Radius Minimum Length 50 ft to 100 ft 6 ft 25 ft to less than 50 ft 4.5 ft Less than 25 ft 3 ft Type VB stones to be set on a radius of 100 ft or less shall be cut to the required curvature . All VB stones shall have a minimum length of 3 ft regardless of curvature. The ends of all curved stones shall be cut on radial lines. Finish The finish and surface dimensions for the several types of curb shall conform to the following requirements:
This type of curbstone shall have a top surface free from wind, shall be peen hammered or sawed to an approximately true plane, and shall have no projections or depressions greater than ⅛ in. The front and back arris lines shall be pitched straight and true and there shall be no projection on the III.152 202 4 Edition back surface for 3 in. down from the top which would exceed a batter of 4 in . in 1 ft, except on V A5 the back surface shall have no projection or depression greater than 1.5 in. The front face shall be at right angles to the planes of the top and ends and shall be smooth quarry split. free from drill holes and with no projection of more than 1 in. and no depression of more than ½ in. measured from the ve rtical plane of the face through the arris or pitch line for a distance down from the top of 8 in . for types VA 1 and VA4, 10 in. for VA2 and VA3, and the full depth of VA5. For the remaining distance there shall be no projection or depression greater than 1 in. measured in the same manner. The ends of all stones shall be square with the planes of the top and face so that when the stones are placed end to end as closely as possible no space shall show in the joint at the top and face of more than ½ in. for the full width of the top and for 8 in . down on the face for Type VA 1 and VA4, 10 in. for VA2 and VA3, and the full depth of VA5, after which the end may break back not over 8 in. from the plane of the joint. The arris formed by the intersection of the plane of the joint with the planes of the top and exposed faces shall have no variation from the plane of the top and exposed faces greater than ⅛ in.
This type of curbstone shall have a top surface free from wind, shall be pointed, peen hammered or sawed to an approximately true plane and shall have no projections or depressions greater than 0.25 in. The front and back arris lines shall be pitched straight and true. The front face shall be at right angles to the plane of the top, and shall be smooth quarry split, free from drill holes and with no projection of more than 1.5 in. and no depression greater than 1 in . measured from the ve rtical plane of the face through the arris or pitch l ines for the full depth of the face. The ends of all stones shall be square with the planes of the top and face so that when stones are placed end to end as closely as possible no space shall show in the joint in the top and face of more than ½ in. for the full width of the top and 8 in. down on the face after which the ends may break back not more than 1 ft from the plane of the joint. On pieces less than 4 ft in length , the ends shall not break back more than 9 in. The arris formed by the intersection of the plane of the joint with the planes of the top and exposed faces shall have no variation from the plane of the top and exposed faces greater than ⅛ in. M9.04.2: Granite Edgestone The stones for the several types of edging shall be cut to the dimensions given in Table M9.04.2 -1. Table M9.04.2- 1: Granite Edgestone Dimensions Type SA Type SB Type SC Minimum Length 3 ft 2 ft 1 ft Maximum Length 6 ft 6 ft 6 ft Thickness 5 in. to 8 in. 3 in. to 6 in. 3 in. to 6 in. Width of Face 12 in . 11 in. to 13 in. 11 in. to 13 in. III.153 202 4 Edition When the edging is used on a curve of 160 f t radius or less the length shall be as directed by the Engineer except that where the edging is to be set on a radius of 10 ft the maximum length shall be 1 ft. Finish. Type SA Edging. The exposed face shall be smooth quarry split to an approximately true plane having no projections or depressions which will cause over 1 in . to show between a 2 -ft straight- edge and the face when the straightedge is placed as closely as possible on any part of the face. If projections on the face are more than that specified they shall be dressed off. The top and bottom lines of the face shall be pitched off to a straight line and shall not show over 0.5 in . between stone and straightedge when straight -edge is placed along the entire length of the top and bottom lines and when viewed from a direction at right angles to the plane of the face, and for the top line only not over ½ in. when viewed from a direction in the plane of the face. The ends shall be square to the lengt h at the face and so cut that when placed end to end as closely as possible no space shall show in the joint at the face of over ¾ in., except that where the edging is to be used on a curve having a radius of 10 ft or less the ends of the stones shall be so cut as to provide a finished joint at the face of not more than ½ in. The arris formed by the intersection of the plane of the face with the plane of the end joint shall not vary from the plane of the face or the plane of the joint more than ¼ in. Drill holes may show on the exposed face but only along the bottom edge. The sides shall not be broken under the square more than 4 in . and the side adjacent to the grass shall not project over 1 in. Type SB Edging. The exposed face shall be smooth quarry split to an approximately true plane having no projections or depressions which will cause over 1 in . to show between a 2 ft straight -edge and the face when the straight -edge is placed as closely as possible on any part of the face. If projections on the face are more than that specified they shall be dressed off. The top and bottom lines of the face shall be pitched off to a straight line and shall not show over 1 in. between stone and straight -edge when straight -edge is placed along the entire length of the top and bottom lines and when viewed from a direction at right angles to the plane of the face, and for the top line only not over 1 in. when viewed from a direction in the plane of the face. The ends shall be square to the length at the face and so cut that when placed end to end as closely as possible, no space shall show in the joint at the face of over 1.5 in. , except that where the edging is to be used on a curve having a radius of 10 ft or less the ends of the stones shall be so cut as to provide a finished joint at the face section of not more than ½ in. The arris formed by the intersection of the plane of the face with the plane of the end joint shall not vary from the plane of the face more than ¼ in. Drill holes not more than 3.5 in. in length and ½ in. in depth will be permitted. The sides shall not be broken under the square more than 4 in. and the side adjacent to the grass shall not project over 1 in . Type SC Edging. The exposed face shall be smooth quarry split to an approximately true plane having no projections or depressions which will cause over ½ in. to show between a 2 ft straight -edge and the face when the straightedge is placed as closely as possible on any part of the face. If projections on the face are more than that specified they shall be dressed off. The top and bottom lines of the face shall be III.154 202 4 Edition pitched off to a straight line and shall not show over 1 in. between stone and straight -edge when straight -edge is placed along the entire length of top and bottom lines and when viewed from a direction at right angles to the plane of the face, and for the top line only, not over 1 in . when viewed from a direction in the plane of the face. The ends shall be square to the length at the face and so cut that when placed end to end as closely as possible no space shall show in the joint at the face of over 1.5 in. , except that where the edging is to be used on a curve having a radius of 10 ft or less the ends of the stones shall be so cut as to provide a finished joint at the face of not more than ½ in. The arris formed by the intersection of the plane of the face with the plane of the end joint shall not vary from the plane of the face more than ¼ in. Drill holes not more than 3.5 in . in length and ½ in. in depth will be permitted. The sides shall not be broken under the square more than 4 in . and the side adjacent to the grass shall not project over 1 in. M9.04.4: Stone for Stone Masonry Walls Stone for stone masonry walls shall consist of sound durable blasted or field stone free from seams, cracks and other structural defects and of an approved and satisfactory quality and shape. The stone shall consist of angular blasted or field stones having straight edges without re -entrant angles. The faces shall be flat but not necessarily rectangular in shape. Individual stone shall have, when set in the wall, no face dimension less than 8 in. Stretchers shall have a depth in the wall at least 1.5 times the rise, and a length on the face at least twice the rise. Headers shall have a length on the face at least equal to the rise. Headers shall hold in the heart of the wall the same size as shown on the face and shall extend at least 12 in. more than the stretchers into the backing. M9.04.5: Granite Curb Inlets The granite for curb inlet shall conform to M9.04.0: Curb and Edging . It shall have a horizontal bed and the top shall be free from wind. The stone shall be sawn or peen hammered on top and the front and back edges shall be pitched true to line. The back face for a distance of 3 in. down from the top shall have no projection greater than 1 in. The front face shall be straight split, free from drill holes, and it shall have no projection greater than 1 in or depression greater than 0.5 in . for a distance of 10 in . down from the top, and for the remaining distance there shall be no depression or projection greater than 1 in. The ends shall be squared with the top for the depth of the face finish and so cut that the curb inlet can be set with joints of not more than ½ in. The granite curb inlet shall be 6 ft in length ± ½ in., from 17 to 19 in. in depth, 6 in . wide at the top and at least 6 in . wide at the bottom. Curb inlets to be set on a radius of 160 ft or less shall be cut to the curve required. The joints of all curved curb inlets shall be cut on radial lines. A gutter mouth at least 3 in . in depth and at least 2 ft in length shall be cut in the front face of the stone as shown on the plans. Granite curb inlets shall match the adjacent curbing in color. III.155 202 4 Edition M9.04.6 : Granite Curb Co rners The granite for curb co rners shall conform to M9.04.0: Curb and Edging and shall have horizontal beds. They shall match the adjacent curbing in size, color and quality. The front arris lines shall extend through one-quarter of a circle having a radius of 2 ft or 3 ft respectively for Type A or Type B Curb Comer. The back arris line shall be straight. The plane of back shall be normal to top. M9.04.8 : Granite Bounds Granite bounds shall be of sound granite, the top and bottom faces parallel and the front and back shall be straight split. The bounds shall be cut to the dimensions shown on the plans and shall be plain or lettered as indicated on the plans or as directed. The stone shall be pointed on the top and on three sides and hammer dressed on the face for a distance of not less than 12 in . below the top. The top shall be 6 in . square and shall have a drill hole in the center 1.5 in. in depth and ½ in. in diameter, with the bottom somewhat flared. M9.04.9 : Dry Stone Masonry Stone for dry stone masonry shall be hard and durable and free from seams or other imperfections and of an approved quality and shape. No stone shall be less than 6 in . in its least dimension. The stone shall be roughly square on joint beds and faces. M9.05.0 : Lumber and Wood Sheeting Lumber and Wood Sheeting shall be sound Spruce, Douglas fir, white or yellow Lodgepole or Ponderosa pine, or western hemlock plank, planed on one side and either tongue and grooved or splined. Lumber sheeting shall not be less than nominal 4 in . thick. Wood sheeting shall not be less than nominal 2 in. thick. M9.05.1: Wood Products Timber shall conform to the requirements of AASHTO M 168, Wood Products, Structural Timber, Lumber, and Piling. Preservative treatment shall meet the requirements of M9.05.5: Wood Preservatives . M9.05.5: Wood Preservatives Preservative treatment shall meet the requirements of AASHTO M 133 and AWPA U1, except that only preservative materials meeting current EPA or DEP regulations will be allowed. Certificates of compliance and certificates of inspection bearing the independent inspection agencies verification for each lot of wood must be presented before installation and contain the species of wood, the type of preservative, the retention rate and penetration of the preservative. M9.0 5.6: Timber Piles
Timber piles shall conform to the requirements of ASTM D25 and shall be cut from sound and live trees, preferable during the winter season. Piles shall be free from any defects which will impair their strength or usefulness for the purpose intended or that will prevent proper driving. III.156 202 4 Edition Untreated timber piles shall have the bark unpeeled. Treated timber piles shall be clean -peeled so that all of the outer bark and at least 95% of the inner bark well distributed over the outer surface of the pile shall be removed. All piles shall be cut above the ground swell, shall have a uniform taper from bun to tip end, and shall be free from short kinks. Knots or blemishes shall be trimmed off close and even with the body of the pile. A line from the center of the bun to the center of the tip must lie wholly within the body of the pile.
All piles will be subject to inspection before or after shipment to the site, or both, at the option of the Engineer. Any pile that does not conform to all the requirements will be rejected.
All treated piles shall have not less than 1 in . of sapwood at any point on the butt end for Douglas -fir and not less than 2 in . of sapwood at any point on the butt end for Southern Pine. Treated timber piles shall be Douglas -fir treated with ACZA or Southern Yellow Pine treated with CCA -C in accordance AWPA U1 Treated timber piles used in a marine environment shall be Southern Yellow Pine or Douglas -fir treated with creosote in accordance with AWPA U1 Certificates of compliance and certificates of inspection bearing the independent inspection agencies verification for each lot of wood must be presented before installation and contain the species of wood, the type of preservative, the retention rate and penetration of the preservative. Butt and tip dimension for various lengths of piles shall be as set forth in the following table: Table M9.05.6- 1: Timber Pile Butt and Tip Dimensions Length Minimum Dimension 3 ft from Butt Minimum Tip Dimension Up to 40 ft 12 in . 8 in. 40 ft and up to 50 ft 12 in . 7 in. 50 ft and over 13 in . 6 in. For all piles the maximum dimension 3 ft from the butt shall be 20 in. Measurements are under the bark in all cases. Where the piles are to support a concrete cap, the maximum butt dimensions shall be 6 in. less than the designated width of the concrete cap. Where piles are to be in line in a bent, all piles in the bent shall be of uniform size to permit the proper fastening of the bracing. Cutting of piles to accommodate the bracing will not be permitted. M9.06.0: Waterproof Paper Covers Waterproof paper covers shall conform to the requirements of ASTM C 171. The name of the manufacturer shall be marked or imprinted clearly on the paper for proper identification. III.157 202 4 Edition M9.06.1: Polyethylene Covers
Black polyethylene sheeting suitable for use in covering storage piles of bulk or bag salt, or sand piles which have been blended with salt shall meet the requirements of NBS Product Standard PS - 17. The covers shall be 8 mils in thickness, black in color and contain suitable inhibitors to prevent deterioration due to sunlight and heat. The sheeting shall be 40 ft in width and 100 ft in length. It shall be folded when packaged into rolls, so that the shipping width is not greater than 10 ft.
This material shall conform to the requirements of ASTM C171 .
Reinforced Polyethylene Covers for stockpiles of salt and treated sand shall be reinforced with non - woven nylon or rayon cord, shall have a minimum tear strength of 110 lb in all directions, and shall weigh no less than 20 lb per 1,000 ft ². They shall be black in color. The material shall be free from any additive which would reduce its resistance to water penetration or adversely affect the durability of the film. The covers shall contain suitable inhibitors to prevent deterioration due to sunlight and hea t. They shall be 40 ft in width and 100 ft in length. They shall be folded when packaged into rolls, so that the shipping width is not greater than 10 ft. M9.06.2: Tar Paper Tar impregnated felted paper shall conform to the requirements of ASTM D227. M9.06.3: Burlap Burlap shall conform to the requirements of AASHTO M 182, Class 3. It shall not have been used as a container for sugar or other substances deleterious to concrete and shall be in good condition, free from holes, tears, or other defects that would render it unsuitable for curing concrete. It shall be furnished in strips not less than 3 ft nor more than 6 ft in width and not more than 2 .5 ft longer than the width of the pavement slab. M9.06.4: Polyethylene Coated Burlap The material shall conform to the requirements of ASTM C171 . M9.06.5: Impervious Liquid Membrane This material shall consist of an impervious liquid conforming to the requirements of ASTM C 1315, Type 1 or 2. When tested in accordance with AASHTO T 155, the liquid membrane forming compound shall restrict the loss of water present in the test specimen at the time of application of the curing compound to not more than 0.055 g per cm ² of surface after 3 days. When Type I is specified, it shall contain a fugitive dye. III.158 202 4 Edition M9.07.0: Plastic Waterstops Waterstops shall be fabricated from a plastic compound, the basic resin of which shall be polyvinyl chloride. The compound shall contain any additional resins, plasticizers, inhibitors or other materials such that when compounded it shall meet the performance requirements hereinafter specified. No reclaimed polyvinyl chloride shall be used. Waterstops shall be extruded in such a manner that any cross section shall be dense, homogenous and free from porosity or other imperfections. The cross section of waterstops shall be as shown on Department Standard Sketches. Physical Requirements. The waterstops shall meet the following requirements:
Increase in weight after 7 days .......................................................... Maximum 0.25% Increase in weight after 30 days ........................................................ Maximum 0.40% Decrease in weight after 7 days ......................................................... Maximum 0.10% Decrease in weight after 30 days ...................................................... Maximum 0.30% Change in dimensions after 30 days ................................................ Maximum 1.00%
General Requirements. The waterstops shall be spliced only at jointing made necessary by construction design. Where joints are required, they shall be made in accordance with the manufacturer ’s instructions, without appreciable loss in strength, elasticity or permeability of the material. The waterstop material shall be practically impervious to water and unaffected by most common acids, alkalis, sea water and mineral oils. The material shall be such that it will not engage in electrolytic action with steel, and will not discolor concrete. The approved waterstop when properly installed, as in a concrete construction or expansion joint, shall be capable of maintaining a head of 75 ft of water without leakage. Qualification Samples. A manufacturer requesting approval of a waterstop shall furnish to RMS a 3-ft length of each type of waterstop they intend to supply and a COA shall be furnished with the samples. The certificate shall state that the material furnished conforms without exception to all the requirements specified herein; and shall also include all qualitative and quantitative test results. III.159 202 4 Edition M9.08.0 : Waterproofing Membranes M9.08.1: Spray -Applied Waterproofing Membrane
Only products listed on the QCML will be accepted for use. The membrane waterproofing system shall consist of: • Primer • One or two coat rapid curing cold liquid spray applied seamless methyl methacrylate, polyurea, or polyurethane methyl methacrylate membrane • Aggregate keycoat • Polymer modified tack coat
The total minimum base thickness for the membrane shall be 80 mils measured over peaks. The membrane shall easily accommodate the need for day joints and patch repairs. The membrane shall be able to bridge live cracks up to ⅛ in. in width and meet the criteria specified in Table M9.08.1 -2. The membrane waterproofing system shall be asbestos- free. The chemical composition of the primer, membrane, aggregate keycoat and tack coat that make up the membrane waterproofing system shall conform to the manufacturer’s specifications for the material. All components shall be approved by the manufacturer as being compatible for use with the specified membrane. Cleaning solvents shall also be approved by the manufacturer for use with the membrane. Primer for Spray -Applied Membrane. The primer shall promote adhesion of the membrane to the concrete surface. Table M9.08.1- 1: Primer Material Properties Property Test Requirements Gel Time > 5 minutes Tack Free Time < 2.5 hours, max at 77 ℉ Adhesion to Concrete ASTM D7234 ≥ 100 psi minimum and failure in concrete Membrane The membrane shall be meet the requirements in Table M9.08.1 -2. III.160 202 4 Edition Table M9.08.1- 2: Spray Applied Waterproofing Membrane Material Properties Property Test Requirements Solids Content 100% Stability ASTM C836 ≥ 6 months Crack Bridging (Neat Material + Aggregated Keycoat) ASTM C1305 ( see Note 1) Pass, no cracking Extensibility after Heat Aging ASTM C1522 For information only Percent Elongation at Break ASTM D638 ≥ 130% Tensile Strength ASTM D638 ≥ 1,100 psi Shore Hardness ASTM D2240 ( see Note 2) ≥ 50 Type 00 Minimum Thickness (Membrane only) ASTM D6132 or other approved method ≥ 80 mils minimum measured over peaks ; or ≥ thickness used to pass ASTM C1305 (Whichever thickness is greater) Membrane Waterproofing System Adhesion to Concrete ASTM D7234 ≥ 100 psi minimum and failure in concrete Permeance ASTM E96 ≤ 1.0 perms Note 1: ASTM C1305 shall be modified to 25 cycles at - 15℉ no failure at ⅛ in. per hour. Note 2: ASTM D2240 shall be modified per ASTM C836 section 6.5. Aggregate for Keycoat The broadcast aggregate shall be durable and provide shear resistant to prevent the HMA from shoving. Aggregate shall have a minimum Mohs hardness rating of 7 and be approved by the manufacturer. Polymer Modified Tack Coat The tack coat shall consist of either a polymer modified asphalt emulsion, or a polymer modified asphalt binder approved for use by the membrane waterproofing manufacturer and the Engineer. The tack coat shall be either supplied by the membrane waterproofing manufacturer or by a MassDOT approved asphalt emulsion Supplier.
A manufacturer requesting approval of a spray applied membrane system shall furnish to the Research and Materials Section the following:
Accreditation (NACLA) in Construction Materials Engineering and Testing (CMET) or an equal program approved by Research and Materials.
III.161 202 4 Edition c. Samples for all required testing shall be fabricated at the same time. Test reports shall denote the lot of material as well as the sample fabrication and testing dates.
surfaces (no primer or aggregate in the keycoat). The samples shall be a minimum of 80 mils thick or the thickness used to pass the crack bridging requirement found in Table M9.08 -4. All submittals shall be certified to be in conformance with the manufacturer’s instructions. Systems qualified by MassDOT per the performance criteria shall be considered for placement on the QCML. Membrane waterproofing systems shall remain on the QCML fo r a period of 5 years at which time the manufacturer will be required to submit certified test reports demonstrating conformance to this specification. M9.08.2: Sheet Membrane
Only products listed on the QCML will be accepted for use. Chemical composition, physical properties and dimensional requirements of the sheet membrane shall conform to the manufacturer’s specifications for the material. Also, all accessory materials such as, flashing, primer, etc., used in the application of the sheet membrane will be considered a part of this specification and shall conform to the manufacturer’s requirements. The membrane waterproofing system shall consi st of: • Primer • Sheet Membrane • Mastic
The primer shall meet the requirements of M9.09.1: Primer . The membrane sheet shall meet the requirements in ASTM D6153 and Table M9.08.2 -1. The mastic for use with rubberized sheets shall be a rubberized asphalt cold -applied joint sealant. The mastic for use with modified bitumen sheet shall be a blend of bituminous and synthetic resins. The mastic shall be approved for use by the manufacturer. Table M9.08.2- 1: Sheet Membrane Material Properties Property Test Requirements Thickness ASTM D3767 ≥60 mils Permeance ASTM E96 Water Method, Procedure B ≤0.1 perms Pliability ASTM D146 (see Note 1) No breaks Note 1: The test temperature of the specimen shall be 0℉ after 24 hours and 180 ° bend over a ¼ in. mandrel. III.162 202 4 Edition C. Material Qualification. A manufacturer requesting approval of a preformed sheet membrane shall furnish to the Research and Materials Section the following:
after the membrane is applied.
M9.08.2- 1, and the submitted product performance data.
and any other additional information requested by the Department. All submittals shall be certified to be in conformance with the manufacturer’s instructions. The Research & Materials Section shall review the manufacturer’s submitted documentation. A demonstration of the product’s installation and performance may be requ ired to be qualified by MassDOT. Systems qualified by MassDOT shall be considered for placement on the QCML. Preformed sheet membrane systems shall remain on the QCML for a period of 5 years at which time the manufacturer will be required to submit certified test reports demonstrating conformance to this specification. M9.08.3: Hot Applied Rubberized Asphalt Membrane
Only products listed on the QCML will be accepted for use. Chemical composition, physical properties and dimensional requirements of the sheet membrane shall conform to the manufacturer’s specifications for the material. The membrane waterproofing systems hall consist of: • Primer • Hot poured rubberized asphalt membrane consisting of a single component hot applied asphalt • Protective covering
The primer shall meet the requirements of M9.09.1: Primer . III.163 202 4 Edition The membrane shall be able to bridge live cracks up to ⅛ in. in width and meet the criteria specified in Table M9.08.3 -1. The protective covering shall be rolled asphalt sheets conforming to ASTM D6380, Type II. Table M9.08.3- 1: Hot Applied Rubberized Asphalt Membrane Material Properties Property Test Requirements Solids Content 100% Flash Point AASHTO T 48 ≥ 500 ℉ Flexibility ASTM D5329 No delamination or cracking Penetration ASTM D5329 at 77 ℉ ≤ 110 ; at 122℉ ≤ 200 Permeance ASTM E96 Water Method, Procedure B ≤ 0.1 perms Softening Point ASTM D36 ≥ 176 ℉
A manufacturer requesting approval of a hot applied rubberized asphalt membrane shall furnish to the Research and Materials Section the following:
Accreditation (NACLA) in Construction Materials Engineering and Testing (CMET) or an equal program approved by Research & Materials. All testing shall be performed by one independent lab.
and any other additional information requested by the Department. All submittals shall be certified to be in conformance with the manufacturer’s instructions. The Research & Materials Section shall review the manufacturer’s submitted documentation. A demonstration of the product’s installation and performance may be requ ired to be qualified by MassDOT. Systems qualified by MassDOT shall be considered for placement on the QCML. Hot applied asphalt membrane systems shall remain on the QCML for a period of 5 years at which time the manufacturer will be required to submit cer tified test reports demonstrating conformance to this specification. III.164 202 4 Edition M9.09.0: Primer and Damp -Proofing M9.09.1: Primer This material shall be suitable for priming concrete and masonry surfaces prior to the application of waterproofing or damp- proofing and shall meet the requirements of ASTM D41. M9.09.2: Damp -Proofing This material shall meet one of the following requirements: • ASTM D449, Type II. • ASTM D1227, Type II – Class 1 or Type III – Class 1 M9.11.0 : Insulation and Waterproof Jackets Where water pipe is installed or hung on structures, it shall be covered with insulation conforming to the following requirements: The insulating material shall be fiberglass, cellular glass, expanded polystyrene, or urethane, and shall be covered with a waterproof jacket as specified. Section lengths and thickness shall depend on the pipe size and the recommendations of the insulation manufacturers. Under no conditions shall the minimum total thickness be less than 3 in. , except when urethane is the insulating material and then the total thickness shall be no less than 2 in. Only one type of insulating material shall be used throughout an installation. M9.11.1 : Cellular Glass Cellular glass insulation shall conform to the requirements of Federal Specification, HH -1-551, Insulation Block and Pipe Covering, Thermal Cellular Glass or revisions thereof. The following installation accessories shall be part of this specification:
M9.11.2 : Fiberglass Fiberglass insulation shall conform to the requirements of Federal Specification, HH -1-562, Insulation, Thermal, Mineral Wool, Block or Board and Pipe Insulation (Molded Type) Type II , Class 2 and 3, or revisions thereof. The following installation accessories shall be part of this specification:
M9.11.3 : Polystyrene Expanded polystyrene insulation shall conform to the requirements of Federal Specification, HH -1- 524, Insulation Board, Thermal, Type I, Class 2 or revision thereof. The following installation accessories shall be part of this specification:
III.165 202 4 Edition b) Corrugated aluminum jacket, 0.02 in. thick with integral vapor barrier.
M9.11.4 : Urethane Urethane insulation shall conform to the requirements of Federal Specification, HH-1- 00530, Insulation Board, Thermal (Urethane), Type II, Class 2 or revisions thereof. The following installation accessories shall be part of this specification:
M9.11.5: Waterproof Jackets Waterproof jackets for covering insulation on water pipes shall be assembled as specified from any of the following materials or combinations thereof.
M9.12.0 : Reflectors for Barriers An oversized yellow reflectorized cluster, diamond shape 24 in. x 24 in., and a 28 -in. x 22 -in. x ¾-in. thick plywood panel shall be bolted onto barrier as directed. The yellow reflectorized cluster (Type H1 -2) shall conform to the requirements of Section 2D of the MUTCD and the approved standard detail sheets. The 28-in. x 22 -in. panel shall be ¾- in. exterior type (Grade A -A, Commercial Standard PS -1). M9.13.0 : Hydrated Lime Hydrated Lime shall consist of a minimum of 95% calcium and magnesium oxides, pulverized so that at least 99.5% will pass a No. 30 sieve and at least 85% pass a No. 200 sieve. M9.14.0 : Preformed Expansion Joint Filler This specification covers non -extruding and resilient non- bituminous types of preformed expansion joint fillers and shall conform to AASHTO M 153. M9.14.1 : Preformed Compression Joint Seals (Bridges) This specification covers the materials requirements for preformed polychloroprene elastomeric joint seals for bridges. The seal consists of a multiple -web design composed of polychloroprene and III.166 202 4 Edition functions only by compression of the seal between the faces of the joint with the seal folding inward at the top to facilitate compression. The seal is installed with a lubricant adhesive and is designed to seal the joint and reject incompressibles. The compression seal and the lubricant- adhesive shall conform to AASHTO M 297. M9.14.2: Closed Cell Foam Joint Filler This specification covers the requirements for closed cell foam used as a joint filler between different components of bridges and walls. Closed Cell Foam Joint Filler shall have a compact closed cell structure composed of synthetic isomeric polymers and s hall be gray in color. It shall offer sufficient heat resistance so that it is compatible with hot applied sealing compounds. Closed Cell Foam Joint Filler shall meet the requirements of Section 5.1 through 5.4 of ASTM D1752, with the compression requirement modified to 10 psi minimum to 25 psi maximum. Typical physical properties, as determined using test method ASTM D545, shall be as follows: Compression, 50% ............................................................... 13 psi Extrusion .................................................................................. 0.1 in . Recovery ................................................................................... 99.21% Water Absorption, Volume ............................................... 0.246% The Contractor shall provide certified test data which documents compliance with the required physical properties. The certified test data shall be submitted to the Engineer for approval. M9.14.3 : Polyurethane Joint Sealer This specification covers the requirements for a cold applied, two component, elastomeric joint sealing compound suitable for use as a joint sealer and/or caulking compound on joints in Portland cement concrete or steel surfaces. This material shall meet ASTM C920 . M9.14.4 : Polyurethane Joint Sealer, Non -Sag This specification covers the requirements for a cold applied, single component elastomeric joint sealing compound for sealing, caulking vertical joints on bridges and other structures. This material shall meet ASTM C920 . M9.14.5 : Elastomeric Bridge Bearing Pads Elastomeric bearing pads shall consist of plain pads (consisting of elastomer only) and laminated bearings (consisting of layers of elastomers restrained at their interfaces by bonded metal laminates). The elastomeric compound shall be composed of 100% low temperature Grade 3 virgin crystallization resistant polychloroprene (neoprene) meeting the requirements of AASHTO M 251 and Division II, Section 18 of the AASHTO Standard Specifications for Highway Bridges. The type of bearing (plain or laminated), hardn ess, dimensions, design compressive load, design compressive stress, and whether the bearings are subject to shear deformation shall be as specified on the Plans. All bearings shall be tested by a nationally recognized testing laboratory approved by the Engineer to ensure compliance with all applicable requirements of AASHTO M 251. The Contractor shall provide the Department with written notification 30 days prior to the start of bearing production. The notification shall include the contract number, quantity, type, and size of bearing being produced, manufacturer’s name, and the representative who will coordinate production, inspection, sampling, and testing with the Department. At least 30 days prior to the III.167 202 4 Edition scheduled date of beam erection, the Contractor shall deliver to the job site all bearings called for on the plans plus one additional elastomeric bearing pad of each size and type identified on the Plans. Certified test result data that demonstrates compl iance with all applicable requirements of AASHTO M 251 shall also be provided to the Engineer at least 30 days prior to the scheduled date of beam erection. One elastomeric bearing pad of each size and type identified on the Plans shall be randomly sampled from the job site by the Engineer for additional destructive testing at least 30 days prior to the scheduled date of beam erection. No beams shall be erected until the bearings have been accepted by the Engineer. All components of the elastomeric bearing pad shall be molded together as an integral unit and all surfaces of the steel laminations shall be covered with a minimum of ³⁄₁₆ in. of elastomer. The finished pads shall be free of cuts, blemishes, and molding defects. All bearings that are delivered to the job site with exposed steel laminations are rejected. All imperfections or exposed laminations that result in either less than ³⁄₁₆ in. of elastomer cover over any surface of the steel laminations shall be repaired by the manufacturer at the point of manufacture. The repair shall consist of sealing the imperfections flush on the finished pad with a bonded vulcanized patch material compatible with the elastomeric bearing pad. Repairs employing caulking type mate rials or repairing the bearings in the field shall not be permitted. M9.14.6: Bonded Closed Cell Joint System The joint seal shall be composed of either closed cell cross linked ethylene vinyl acetate polyethylene copolymer or of closed cell polychloroprene (neoprene). The joint seal shall feature grooves or ribs which run the full length of the joint. The joints eal shall be bonded to the concrete surfaces on each side of the joint using a two -component epoxy based adhesive. The joint seal shall have the following typical physical properties: Tensile Strength, (ASTM D412) ...................................... 115 psi, Minimum Elongation @ Break (ASTM D3575 ) ............................. 200%, Minimum Water Absorption, Volume % .......................................... 5%, Maximum The two -component epoxy based adhesive shall conform to ASTM C881, Type I & II, Grade 2, Class B & C, and shall have the following physical properties: Tensile Strength, (ASTM D638) ...................................... 3,500 psi, Minimum Compressive Strength ......................................................... 7,000 psi, Minimum Bond Strength ........................................................................ 430 psi, Minimum The Contractor shall provide certified test data which documents compliance with the required physical properties. The certified test data shall be submitted to the Engineer for approval. M9.15.0 : Liquid Penetrant/Sealant Liquid penetrant/sealant for Portland cement concrete surfaces used to protect concrete surfaces from chloride intrusion shall be a material previously approved by the Department for the purpose intended and listed on the QCML . III.168 202 4 Edition M9.16.1: Rubber -Cotton Duck Bearing Pad The bearing pads shall be manufactured of all new (unused) materials and composed of multiple layers of prestressed duck, 8.1 oz per net square yard, duck warp count 50 ±2 threads per inch and filling count 40 ± threads per inch, 64 plies per inch of finished pad thickness, impregnated and bound with a high quality rubber compound, containing rot and mildew inhibitors and anti - oxidants, compounded into resilient pads of uniform thickness. The pads shall withstand compressive loads perpendicular to the plane of laminations of not less than 10,000 psi before breakdown. Load deflection properties in accordance with procedures of MIL-C- 882 shall be the following maximum percentages of total pad thickness: 10% at 1 ,000 psi, 15% at 2,000 psi. When loaded to 1,500 psi, permanent set as load is removed in accordance with procedures of MIL -C-882 shall be a maximum of 2.5% of the original “ zero point ” thickness. Shore Durometer shall not be less than 85 nor more than 95. The ratio of lateral expansion to vertical deflection shall not exceed 0.25 when loaded to 1 ,500 psi. The material shall not lose effectiveness throughout a te mperature range of - 65°F to +200°F. No visual evidence of damage or deterioration by environmental effects of sunshine, humidity, salt spray, fungus, and dust in accordance with MIL - E-5272. Thickness shall be as shown on drawings within tolerances of ±5%. M9.16.2: Molded Fabric Bearing Pad The preformed pads shall consist of a fabric and rubber body. The pad shall be made with new unvulcanized rubber and unused fabric fibers in proper proportion to maintain strength and stability. The surface hardness expressed in standard rubber hardness figures shall be 80 Shore A Durometer ±10 durometer average, the ultimate breakdown limit of the pad under compression loading shall be no less than 7,000 psi for the specified thickness without extrusion or detrimental reduction in thickness. The pads shall be furnished to specified dimensions with all bolt holes accurately located. M9.17.0: Asphaltic Binder for Asphaltic Bridge Joint System The thermoplastic polymeric modified asphalt binder shall conform to physical properties based on the designated ASTM testing methods found in Table M9.17.0 -1. III.169 202 4 Edition Table M9.17.0- 1: Physical Properties of Asphaltic Binder for Asphaltic Bridge Joint Systems Test ASTM Test Method Required Properties Softening Point D36 180°F minimum Tensile Adhesion D5329 700% minimum Ductility at 77°F D113 400 mm minimum Penetration at 77°F, 150 g, 5 sec. D3407 7.0 mm maximum Flow, 5 hours at 140°F D3407 3.0 mm maximum Resiliency at 77°F D3407 70% maximum Asphalt Compatibility D3407 Pass Low Temperature Penetration at 0°F, 200g, 60 sec. D5 with cone* 1.0 mm minimum Flexibility at - 10°F D5329 Pass Bond 3 Cycles at - 20°F, 50% Elongation D3405 Pass Bond 3 Cycles at 0°F, 100% Elongation D3405 Pass Recommend Installation Range 360°F to 390°F Safe Heating Temperature Range 390°F to 420°F * Use Method D5; however replace the standard penetration needle with a penetration cone conforming to the requirements given in Test Method D217, except the interior construction may be modified as desired. The total moving weight of the cone and attachments shall be 150.0 g ± 0.10. M9.17.1: Aggregate for Asphaltic Bridge Joint System The aggregate shall be granite, basalt or gabbro. The aggregate shall be selected, crushed, processed, double -washed and dried at the source. It shall be delivered to job site in prepackaged waterproof containers. The supplier shall certify the above requi rements are met. The aggregate shall be made available in ¾- in., ½-in. and ⅜-in. sizes and shall meet gradation requirements specified by the manufacturer for the joint system. M9.17.2: Backer Rod The backer rod shall be closed cell foam expansion joint filler, compatible with polymeric binder and the elevated temperatures of the polymeric binder application. The size of the backer rod shall be in accordance with the manufacturer’s recommendations f or the gap width. The backer rod shall meet ASTM D1752 and have the following typical physical properties using a ½ in. specimen and the test method ASTM D545: Compression, 50 % ............................................................... 13.3 psi Extrusion .................................................................................. 0.1 in . Recovery ................................................................................... 99.21% Water Absorption, Volume ............................................... 0.246% III.170 202 4 Edition M9.17.3 Bridge Plate for Asphaltic Bridge Joint System The bridge plate shall be AASHTO M 270 M/M 270 Grade 36 steel, minimum width and thickness of 8 in. x 0.25 in . and shall be galvanized in accordance with AASHTO M 111 M/M 111. Holes for the locating pins shall be 12 in . on center. Locating pins shall be 16d common nails or larger, hot dipped galvanized. M9.17.4: Neoprene Seals Neoprene seals shall be composed of flexible, non -reinforced, extruded neoprene compound exhibiting the physical properties listed in Table M9.17.4 -1. All neoprene seals shall incorporate a matching locking lug that mechanically snaps into the corresponding extrusion shape cavity to ensure watertightness and proper joint performance. All mitering and/or splicing of the neoprene seal shall be performed under controlled conditions at the place of manufacturer. The neoprene seal shall be supplied and installed in one continuous length without field splices. Table M9.17.4- 1: Physical Properties of Neoprene Seals Property Test Method Requirement Tensile Strength ASTM D412 2,000 psi Tensile Strength, Elongation at Break ASTM D412 250%, minimum Hardness, Durometer Type A ASTM D2240 Modified 50 to 60 Oven Aging , 70 hours at 212°F : Loss of Tensile Strength ASTM D573 20% loss maximum Loss of Elongation ASTM D573 20% loss maximum Maximum Change in Hardness ASTM D573 -0 to +10 points Oil Swell, ASTM Oil #3, 70 hours at 212°F ASTM D471 45% maximum weight increase Low Temperature ASTM D746 Not Brittle Ozone Resistance, 70 hours at 104°F, 20% elongation, 300 pphm, in air, Wipe Surfaces to Remove Contamination ASTM D1149 No Cracks Low Temperature Stiffening, 7 days at 14°F, Hardness, Durometer Type A ASTM D2240 0 to +15 points change Compression Set, 70 hours at 212°F ASTM D395 Method B 40% maximum M9.18.0: Impact Attenuators All Impact Attenuators shall be tested to MASH crash testing standards. M9.18.1: Redirective Impact Attenuators To be classified as a Redirective Impact Attenuator, the results of the following crash test designations must fall within the acceptable impact tolerances and evaluation criteria show in Table 2 -3 of MASH (n = Test Level): n -30, n -31, n -32, n -33, n -34, n -35, n -36, n -37 (2270P Pickup Truck, only), and n- 38. Redirective Impact Attenuators will be designated as such on the QTCE. III.171 202 4 Edition M9.18.2: Non -Redirective Impact Attenuators To be classified as a Non -Redirective Impact Attenuator, the results of the following crash test designations must fall within the acceptable impact tolerances and evaluation criteria show in Table 2 -3 of MASH (n = Test Level): n -40, n -41, n -42, n -43, n -44, and n -45. Non -Redirective Impact Attenuators will be designated as such on the QTCE. M9.18.3: Low -Maintenance Impact Attenuators To be classified as a Low -Maintenance Impact Attenuator, the device must: • Meet the criteria of M9.18.1: Redirective Impact Attenuators . • Meet the Department’s minimum requirements for the evaluation of Low -Maintenance Impact Attenuators. Low -Maintenance Impact Attenuators will be designated as such on the QTCE. A single product may be listed as both a Redirective Impact Attenuator and a Low -Maintenance Impact Attenuator. M9.30.0: Re trore flective Sheeting This specification covers retroreflective sheeting designed to reflectorize traffic control signs, delineators, barricades, and other devices. All re trore flective sheeting shall meet the requirements of ASTM D4956 and AASHTO M 268, and as listed below: Table M9.30.0- 1: Retroreflective Sheeting Requirements Retroreflective Sheeting Application Allowable Retroreflective Sheeting Classification(s) per ASTM D4956 Type A Permanent Sign Panels (per Subsection
828.42: Panels) Type IV
Temporary Rigid Sign Panels (flat panel aluminum or plywood substrate) Type IV, Type VIII, Type IX Temporary Roll -Up Signs Type VI Type B Sign Panels (per Subsection 828.42: Panels) Type VII, Type IX, Type XI Traffic Cones Type VI Reflectorized Drums Type IV, Type VIII, Type IX Portable Breakaway Barricades Type III Type IV, Type VIII, Type IX Flexible Delineator Posts Type IV, Type V, Type VIII, Type IX Guardrail End Treatments Type VIII, Type IX Guardrail Terminal Delineators Type IV, Type VIII, Type IX Demountable Reflectorized Delineator, Guard Rail Type VIII, Type IX Impact Attenuator Delineators Type IV, Type VIII, Type IX Sheeting shall only be applied to a substrate that is recommended by the sheeting manufacturer. III.172 202 4 Edition M9.30.4 : Acrylic Plastic 3 .25 Inch Diameter Center -Mount Reflectors Acrylic plastic 3.25 in . diameter center -mount reflectors shall be a material previously approved by the Department for the purpose intended and listed on the QTCE. M9.30. 6: Temporary Raised Pavement Markers Temporary raised pavement markers shall consist of a durable plastic or another type of durable material and have the following characteristics. • Color: (ASTM D1535) White or Yellow. • Dimensions are to be at least 4 in. wide and a minimum reflective area of 1.5 in. ² of retrore flective sheeting meeting M9.30.0, Type C. • Markers shall contain one way or two way retro reflective faces as required by the Engineer. Markers shall provide daytime delineation and shall adhere to HMA or PCC surfaces using adhesives and/or methods recommended by the manufacturer. Markers shall be removable from HMA and PCC pavements without the use of heat, solvents, grinding or blasting. After removal, permanent marks, scars or damage to the pavement surface shall be minimal, free from dirt or any other contaminants. M9.30. 7: Guardrail Delineator Guardrail delineators shall be fabricated from galvanized steel having a minimum coating thickness of 0.9 o z per square foot, polycarbonate plastic or thermoplastic and shall allow a minimum of 8 in.² of retroreflective sheeting per face, conforming to M9.30.0: Retroreflective Sheeting . Guardrail delineators shall be shaped to fit in the valley of the W shape. Circular holes shall be used for the bolt connecting the delineator to the W beam. Adhesive connections shall not be allowed. M9.30.8: Reflectorized Flexible Delineator Post Reflectorized Flexible Delineator Posts shall be used as directed for delineation of roadways and ramps. Only those products previously approved for the purpose intended and listed on the QTCE may be used. M9.30.9: Reflectorized Drum Reflectorized drums shall be plastic and shall meet the requirements of the MUTCD. Retrore flective sheeting for drums shall meet the requirements of M9.30.0: Retroreflective Sheeting and be 6 in. wide. Reflectorized drums are listed on the QT CE. M9.30.10: Guardrail Termini Delineator Guardrail termini delineators shall be fabricated in accordance with the Plans. The panel shall consist of Type A aluminum sign panel. Re trore flectorized sheeting shall conform to M9.30.0: Retroreflective Sheeting . III.173 202 4 Edition M9.30.11: Traffic Cones Traffic cones shall be orange in color, 36 in. tall and with re trore flective sheeting collars that conform to M9.30.0: Retroreflective Sheeting . Traffic cones are listed on the QTCE. M9.31.0: Non -motorized Traffic Counting Stations (NTCS) NTCS shall have a count accuracy of 85% or greater, by direction of travel. When located on a facility that has both pedestrian and bicycle traffic, such as a multi- use path, the minimum count accuracy shall apply to both user types. When located on a faci lity that is limited to pedestrians, such as a sidewalk, the minimum count accuracy shall only apply to pedestrian counts. When located on a facility that is limited to bicyclists, such as a bike lane, the minimum count accuracy shall only apply to bicycli st counts. NTCS shall have the capability to collect counts by direction and log the data for pedestrians and bicyclists separately. The data collected shall be in predefined time interval bins. These bins shall, at a minimum, include options for 1 -minute, 5 -minute, 15 -minute, 1 -hour, and 24- hour intervals. 24 -hour counts shall be formatted with intervals that start at midnight (0:00 a.m.). Data shall be exportable in a Department -defined .csv, .xlsx, and/or .xml format. NTCS shall have an independent, battery -operated power source and shall not require a hard -wired service connection, with exceptions to Permanent NTCS for Intersections as described below. Batteries shall be sized to allow uninterrupted operation of the NTCS for a minimum of 1 year. Solar panels, if required, may be used to keep the batteries at a sufficient charge. All batteries shall carry a minimum 1 -year warranty. Replacement batteries shall be industry standard, commercially available, and not proprietary to device. As an exception to the independent power source requirement, a traffic signal cabinet may be used to leverage the installation of a Permanent NTCS for Intersections by providing Power over Ethernet (PoE) from the cabinet to the proposed device. All NTCS shall offer free, manufacturer support available during typical business hours, Monday through Friday. Permanent devices shall be furnished with a manufacturer’s warranty for all materials for at least one year following acceptance. Firmware, software, and security updates shall be included at no cost for the life of the product. M9.31.1: NTCS for Intersections Items classified for use at Intersections shall have the capability of uniquely identifying, classifying, and discretely counting pedestrians and/or bicyclists passing through one or more user -defined zones, traveling in both directions along multiple axes . The accuracy of Intersection Devices shall not be influenced by the presence of motor vehicles adjacent to the user -defined detection zones, if separate, or within the detection zone if the space is shared between motorized and non -motorized traffic, such as a shared lane or crosswalk. III.174 202 4 Edition M9.31.2: NTCS for Trails Items classified for use on Trails shall have the capability of uniquely identifying, classifying, and discretely counting pedestrians and/or bicyclists passing a user -defined point or zone in both directions on a single axis. The accuracy of Trail Devices shall not be influenced by the presence of motor vehicles that are offset a minimum of 6 ft from the edge of the detection point or zone. M9.40.0: Drilling Slurry Drilling slurry shall conform to one of the following specifications. Reports of all required tests shall be furnished to the Engineer upon completion of each drilled shaft. Mineral Slurry. Mineral slurry shall be premixed thoroughly with water and adequate time, as prescribed by the manufacturer, shall be allotted for hydration prior to introduction into the shaft hole. Slurry tanks of adequate capacity are required for slurry circulation, s torage, and treatment. Control tests shall be performed on the mineral slurry by the Contractor to determine density, viscosity, sand content and pH. Properties of mineral slurry (Bentonite or Attapulgite) in water shall meet the range of values found in T able M9.40.0-1. Table M9.40.0- 1: Physical Properties of Mineral Slurry Property Value Required Test Method Density* 64 to 75 pcf Mud Density API 13B -1 Section 1 Viscosity 26 to 50 s per qt Marsh Funnel and Cup API 13B -1 Section 2.2 pH 8 to 11 Glass Electrode, pH Meter, or pH Paper Sand Content 4.0% by volume maximum Sand Content API 13B -1 Section 5 * To be increased by 2 pcf in salt water or brackish water. Tests to determine density, viscosity and pH shall be performed during shaft excavation to establish a consistent working pattern. Four sets of tests shall be made during the first 8 hr of slurry use. When the results show consistent behavior, one set of testing shall be made every 4 hr of slurry use thereafter. Water Slurry. The use of water slurry without full length steel casings will only be allowed if approved in writing by the Engineer. In that case, all of the properties of mineral slurry shall be met, except that the maximum density shall not exceed 70 pcf . Mixtures of water and on -site soils shall not be allowed for use as a drilling slurry, since particulate matter falls out of suspension easily and can contaminate the concrete. Polymer slurry. Natural or synthetic slurry shall have specific properties at the time of mixing and of concreting that are in conformance with the written recommendations of the manufacturer and the Contractor’s Drilled Shaft Installation Plan. The Contractor shall perfo rm the required tests at the III.175 202 4 Edition specified frequency and shall provide slurry that complies with the maximum and/or minimum property requirements for the subsurface conditions at the site and with the construction methods that are used. Whatever product is used, the sand content at the base of the shaft excavation shall not exceed 1% when measured by the API sand content test, immediately prior to concreting. M9.40.1: Well casing Pipe Well casing pipe shall conform to the requirements for welded and seamless steel pipe, ASTM A53. M9.40.2: Water Pumps Water pumps (jet, submersible or shallow well) shall be of a standard commercial quality. The capacity of the pump shall be such that it will be capable of discharging water at the rate and pressure for the pumping depth specified for the installation. The motor voltage of the pump shall be compatible with the voltage available at the electrical source. The Contractor shall submit for approval to the Engineer five days before placing any purchase orders for the water pump, accessories and electrical equipment, the name of the manufacturer, the specifications for the pump, accessories and electrical equipment that they propose to furnish. M9.40.3: Chlorine Solution Chlorine solution used for disinfecting springs, wells and other water systems, shall consist of a solution of water and liquid chlorine, sodium hypochlorite, calcium hypochlorite or chloride of lime. Liquid forms of chlorine or sodium hypochlorite and powder forms of calcium hypochlorite or chloride of lime shall be used according to the instructions supplied by the manufacturer and as recommended by the DEP. If sodium hypochlorite is already in solution as a laundry bleach containing 5.25% sodium hypochlorite, it shall be used at the rate of 1 qt per 3,000 gallons of water to be disinfected. The dosage should be sufficient to produce a chlorine taste in the water. M9.40.4 : Plastic Water Pipe, Flexible Flexible plastic pipe shall be polyethylene plastic pipe schedule 40 or 80 suitable for the transportation of potable water and conform with the requirements of AASHTO M 258. The material grade selected shall be capable of withstanding a minimum sustained water pressure of 160 psi at 73.4°F. T he pipe shall be inside diameter controlled. Fittings may be either nylon, copper or bronze. Clamps shall be stainless steel. M9.40.5 : Plastic Water Pipe, Rigid (PVC) Rigid polyvinyl chloride (PVC) plastic pipe shall be suitable for transportation of potable water and conform. with the requirements of AASHTO M 258. The material grade and standard pipe dimension ratio (SDR) shall be capable of withstanding a minimum sustained water pressure of 160 psi at 73.4°F. Fittings shall be PVC plastic conforming with AASHTO M 258. The burst strength of the fittings shall be not less than that of the pipe being furnished. III.176 202 4 Edition M9.40.6 : Plastic Water Pipe, Rigid (ABS) Rigid A crylontrile- Butadiene- Styrene (ABS) plastic pipe shall be suitable for the transportation of potable water and conform with the requirements of AASHTO M 258. The material grade and SDR shall be capable of withstanding a minimum sustained water pressure of 160 psi at 73.4°F. Fittings shall be ABS plastic conforming with AASHTO M 258. The burst strength of the fittings shall be not less than that of the pipe being furnished. M9.40.7 : Copper Water Tube, Seamless Seamless copper water tube suitable for general plumbing shall conform to the requirements of AASHTO M 258. Tube material shall conform to ANSI/ASTM 888, Type k. M9.40.8 : Steel Water Pipe, Galvanized Galvanized steel water pipe shall be the standard weight class conforming to the requirements of AASHTO M 258. Pipe material shall conform with the ASTM A120 option. M9.50.0: Geotextile Fabrics Geotextile fabric used for subsurface drainage, separation, stabilization, permanent erosion control, temporary silt fences, or paving fabric shall conform to requirements of AASHTO M 288 for the intended application and be listed on the QCML. III.177 202 4 Edition SECTION M 10: TRAFFIC CONTROL DEVICES M10.00.0: General All Traffic Control Devices shall be designed, manufactured and tested in accordance with the applicable standards of the ANSI, IMSA, ITE, NEMA, UL and these Specifications. Inclusion on the Qualified Traffic Control Equipment (QTCE) List is contingent upon meeting these Specifications. M10.01.0: Advanced Transportation Controller Cabinets (General) Definitions All Advanced Transportation Controller (ATC) Cabinets shall conform to the requirements defined in the Advanced Transportation Controller Cabinet (ATCC) 5301 v02 Standard. ATC Cabinet types are classified in Table M10.01.0 -1: Table M10.01.0- 1: ATC Cabinet Types Type Description Doors Nominal Dimensions (Height x Width x Depth) Material Specification P4 Ground -mount NEMA “P” 4 (2 front, 2 rear) 67 in. x 44 in. x 26 in. M10.01.1 P1 Ground -mount NEMA “P” 1 67 in. x 44 in. x 26 in. M10.01.2 352 Ground -mount Caltrans 352 2 (1 front, 1 rear) 67 in. x 30 in. x 24 in. M10.01.3 336S Side -of-pole -mount Caltrans 336S 1 46 to 48 in. x 24 to 26 in. x 22 to 24 in. M10.01.4 Cabinet Fabrication All ATC Cabinets shall be fabricated from a minimum of ⅛ -in. thick 5052 -H32 sheet aluminum alloy and be of all- weather construction. All internal and external hardware shall be fabricated from non - corrosive material. Finish and surface preparation of the cabinet shall conform to Section 7.7 of the NEMA TS2 -2016 Standard. The door hinge shall be a continuous type with a stainless -steel hinge pin. The door handle and all external fasteners used in the cabinet construction shall be stainless steel. All unwelde d cabinet seams shall be sealed with clear RTV silicone sealant to prevent dust intrusion. Cabinet Rack Cage Standard rack cages shall be installed inside the cabinet. The EIA rack portion of the cage shall consist of four continuous, adjustable equipment mounting angles. The mounting angle nominal thickness shall be 11 -gauge plated steel. The mounting angles shall be tapped with 10 -32 threads with Electronic Industries Association (EIA) universal spacing. The mounting angle shall comply with EIA -310 -B and shall be supported at the top and bottom be either welded or bolted support angle to form the cage. The mounting angles shall provide holes to mount the side panels. Clearance between the rails for mounting assemblies shall be 17.75 in. The cage shall be bolted to the cabinet at four points via the housing cage supports and four points via associated spacer brackets and the top and bottom. The cage shall be centered within the cabinet door opening. III.178 202 4 Edition Cabinet Power The main cabinet circuit breaker shall be rated at 30 amps. Circuit breakers shall be approved and listed by the UL. All circuit breakers shall be quick -make, quick -break on either automatic or manual operation and shall conform to UL 489 . Contacts shall be silver alloy enclosed in an arc quenching chamber. Back of Door Documentation All ground -mount ATC Cabinets shall be supplied with a 6 -in. high riser aluminum base that elevates the cabinet above the cabinet foundation. The color and finish of the base shall match the color and finish of the cabinet it supports. ATC Cabinets shall be supplied with a laminated door sticker. This sticker shall be permanently affixed to the inside front control side of the cabinet door. At a minimum, the sticker shall contain the following information:
approaches, and cabinet termination points.
The back of the main front door shall contain a resealable, heavy -duty opaque plastic envelope with two grommets that provide mounting to two integrated hooks installed on the back side of the front cabinet door. The heavy -duty plastic envelope shall be used to store cabinet wiring diagrams and operatio ns manuals that cannot be accommodated in the pull- out drawer storage tray. Electric Meter Trim The cabinet shall be supplied and installed with an electric service meter socket trim and electrical service disconnect switch mounted on the exterior of the cabinet. The meter and disconnect switch shall be installed centered on the side of the cabinet w ithout doors such that it is not less than 48 in. nor more than 60 in. above final grade. The Contractor shall coordinate with the local electric utility company to determine the appropriate type of electric service meter socket trim and electrical conductors to be used. The line side cable shall be routed external to the cabinet from the ground to a 50A disconnect switch, then continuing to the bottom of the electric service meter socket trim, all through rigid steel conduit furnished and installed by the Contractor. The load side cable shall be routed through the cabinet and terminated on the line side of the main cabinet circuit breaker. The cable shall be routed through the interior of the cabinet such that it does not block or enter into available rack space preventing that space from being used either by equipment supplied as part of the project, or future equipment that would be installed in the rack system. The cable shall be routed between the edge of the rack system and the cabinet side wall, along the bottom of the cabinet and below the bottom opening of the doors. III.179 202 4 Edition Care shall be taken by the Contractor when installing the electric service meter socket trim and electrical service disconnect switch so that there is no damage inflicted on installed devices or the rack system during the installation. All metal shavings p roduced during the drilling of the access hole for the electric service shall be removed from the cabinet interior by the Contractor. The Contractor shall install appropriate bushings to all cabinet penetrations. All wiring shall comply with all applicable local electrical codes and the MEC. Detector Test Switch Panel The cabinet shall be supplied with a detector test switch panel. There shall be a total of 48 switches to allow for the manual placement of detector calls into the controller. Each switch shall be clearly labelled as to input channel. Each switch position shall correspond to the same controller input; switch 1 is for controller input channel 1, switch 2 is for controller input channel 2, etc. The detector switch panel shall be comprised of switches that are wired directly to the corresponding input channels on the rack assemblies. Each switch shall be supplied with a red LED indicator to be illuminated whenever a channel input is active via the three- position detector switch. The use of an SIU internal to the detector test switch panel to provide this capabi lity is not allowed. The switches shall be three position type and function as follows:
Standard Cabinet Devices A Cabinet Monitor Unit (CMU) and Auxiliary Display Unit (ADU) shall be supplied and installed in each cabinet. The CMU and ADU shall conform to requirements defined in the Advanced Transportation Controller Cabinet (ATCC) 5301 v02 standard. The CMU/ADU uni ts supplied and installed as part of this project shall support 32 channels. All configuration programming shall be resident in a non- volatile Datakey device. Each CMU shall be supplied with a Datakey programmer and associated software. The Datakey program ming software shall include a set -up wizard which shall assist the user with the initial set up of the device. The Contractor shall program the Datakey with data entries appropriate for each intersection. All programing resident on the Datakey shall be included in the hardcopy. A cabinet power supply shall be supplied with each cabinet. The cabinet power supply shall comply with ATCC 5301 v02. A full complement of switch packs shall be supplied with each cabinet, switch packs shall comply with ATCC 5301 v02. A full complement of flashers shall be supplied with each cabinet, flashers shall comply with ATCC 5301 v02. A full complement of SIUs shall be supplied with each cabinet, the Serial Interface Units (SIU) shall comply with ATCC 5301 v02. A full complement of flash transfer relays shall be supplied with each cabinet, flash transfer relays shall comply with ATCC 5301 v02. The Contractor shall reconfigure the default username and passwords on all communications/control equipment within the ATC Controller and Cabinet. This includes but is not III.180 202 4 Edition limited to the ATC traffic controller, ATC ancillary equipment, video detection equipment, Ethernet switches, and routers. The new username and passwords shall be created in accordance with the Department Information Technology (IT) standards; no manufactu re default level passwords shall be allowed. All SDLC cables used to interconnect devices within the cabinet shall be supplied with factory installed protective wire covers to protect the connector side of the cables. The use of Contractor supplied/installed cable protector covers shall not be allowe d. The Contractor shall utilize network communications encryption settings on all forms of wired Ethernet data paths. No “in the clear” communications shall be allowed. At a minimum all wired Ethernet connections shall meet 802.1AE standards. The Contractors hall supply and configure a Cyber Intrusion and Prevention Device (CIPD) in each ATC cabinet. The CIPD shall prevent any unauthorized access/connections to the traffic control system. Upon detection of unauthorized attempts, the CIPD shall notify the Department via SMS message and/or email and log the event. The CIPD shall be installed prior to any remote access device. The Contractor shall coordinate with the Engineer for final configuration of the CIPD. No direct access to the traffic system shall be allowed without the installation of a CIPD and/or Router/Firewall. Surge Suppression Electrical filtering/surge protection shall be supplied and installed in each cabinet in accordance with ATCC 5301 v02 requirements and the manufacturer’s recommendations. At a minimum, surge suppression shall be provided for incoming electric utility power conductors, all signal control circuits, vehicle detection, pedestrian detection, communications, and preemption system terminations. The use of a single fuse for surge suppression shall not be allowed. The cabinet shall be electrically bonded and grounded to comply with Section 643, the National Electrical Code (NEC) and the National Electrical Safety Code (NESC), latest versions of each document. Each in -cabinet current interrupting device (controller unit, flasher, and all other devices) shall be equipped with a suitable radio interference suppressor installed at the input power point. Interference suppressors shall be designed to minimize interference in both broadcast and aircraft frequencies. Suppressors shall be designed for 125 percent of the total connected load and shall meet standards of the UL and the EIA. External GFCI Outlet The cabinet shall be supplied with a GFCI outlet to be installed on the upper left, exterior of the control side wall of the ground -mount cabinet and the upper left side of the pole- mount cabinet. The electrical outlet will be GFCI protected, house in a locked access enclosure. The GFCI outlet shall be supplied via its own 15 -amp circuit breaker. The GFI outlet assembly shall be housed in a heavy -duty vandal resistant, weatherproof, dustproof enclosure designed for exterior applications. The GFCI enclosure door shall contain a weatherproof seal and supplied with a lock accessed with a skeleton style (#1) key. III.181 202 4 Edition Generator Transfer Switch The cabinet shall be supplied with a generator panel. The generator panel shall consist of a manual transfer switch and a twist -lock connector for generator hookup. The manual generator transfer switch shall be Reliance Controls model CSR302 or approved eq uivalent. The transfer switch and twist -lock connector shall be located inside a surface mounted generator access enclosure with a separate lockable door mounted on the lower left, exterior wall of the cabinet. The door shall be equipped with a tamper resistant hinge. The generator panel assembly shall be housed in a heavy -duty, vandal resistant, weatherproof, dustproof enclosure designed for exterior applications. The connection to an external generator shall be via a waterproof, secure connection. The connection shall allow authorized personnel to access, connect, and secure an external electrical source to the cabinet for power restoration. The generator panel door shall be constructed with a weatherproof seal and supplied with a lock accessed with a J201 key. Output Channel Assignments The cabinet shall be configured to provide output channel assignments per Table M10.01.0 -2: Table M10.01.0- 2: Output Channel Assignments Channels Outputs (16 Channel Cabinet) Outputs (32 Channel Cabinet)
1-8Phases 1 -8 Phases 1 -8
9-12Flashing Yellow Arrow, Overlaps, As Needed Flashing Yellow Arrow
13-16Pedestrians Pedestrians
17-20 n/a Overlaps 21+ n/a As Needed M10.01.1: P4 ATC Cabinet Cabinet Enclosure The cabinet size and functional requirements shall conform to the NEMA TS2 -2016 Standard, Section 7. The cabinet enclosure shall be a dust and moisture -proof aluminum housing with an auxiliary door in door feature. The cabinet shall be configured to eliminate arc flash. All electrical equipment shall be dead front, no open terminals, busbars, breakers, or exposed terminal strips. All cabinet switches and circuit breakers shall be permanently labeled as to function. The cabinet shall be designed, constructed, and installed with all necessary provisions to comply with the latest NFPA 70E requirements. All electrically live contact points over 50V shall be covered with Lexan or a suitable physical barrier to eliminate the possibility of arc flash. The lock for the police door switch compartment shall unlock with a skeleton style (#1) key. The lock for the main door(s) of the cabinet shall unlock with a Corbin #2 key. Two sets of two keys (main door/police door) shall be furnished with each cabinet. The cabinet shall be supplied with a permanent label mounted on the upper portion of the inside front main door that shall contain the name of the cabinet manufacturer, controller manufacturer, model/part number and year/month of assembly. III.182 202 4 Edition The cabinet shall be supplied with a GFCI duplex outlet and a rack mounted multi -outlet strip. The quantity, size and location of the equipment shall correspond to the contract drawings for the ATC Cabinet. All equipment shall be installed with the correct number of mounting screws/mounting support devices. All internal cabinet wiring shall be route d such that there is no conflict for access to cabinet devices or interference with door mechanisms. The cabinet shall be provided with two removable lifting eyes for placing the cabinet on its foundation. Each eye opening shall have a minimum diameter of ¾ in. Each lifting eye shall be able to support a weight limit of 1,000 lbs. The cabinet shall be equipped by the with an internal cable management system. The cable management system shall be comprised of nonconductive channels designed to facilitate wire and cable routing within an electrical enclosure. All shelving used on the Power and Auxiliary side of the cabinet shall be constructed of .125 -gauge aircraft grade aluminum or mold steel and designed to support a minimum of 250 lbs. The shelves shall be securely attached to the 19 -in. cage. Cabinet Configuration The cabinet shall be supplied with two side -by-side, 19- in. rack cages which shall extend from the bottom to the top of the cabinet. The cabinet front shall provide for user interface to the in -cabinet equipment including the front panel of the controller, the cabinet status displays and detection system control interfaces. The cabinet rear shall provide access for termination of field cables and shall only be accessed for installation and for cabinet troubleshooting. The left -side rack of the cabinet relative to facing the cabinet from the front, to be referred to as the “Control” side, shall house the control devices such as the Controller, Cabinet Monitor Unit (CMU) and Auxiliary Display Unit (ADU), switch packs, and the power distribution panel. As such, this rack shall be referred to as the “Control” side of the cabinet. The right -side rack of the cabinet relative to facing the cabinet from the front, to be referred to as the “Power and Auxiliary” side, shall house the spare card cage assembly, battery b ack-up devices (if required), communications elements and future ancillary devices. Cabinet Doors The cabinet shall be supplied with four main doors: two on the front face and two on the back face. Each door shall open independently with an independent center post latching for each of the four doors. The front control door shall be defined as the “primary” door; the remaining three main doors shall be defined as “secondary” doors. The cabinet main doors shall be provided with a stop to limit door opening to both 90° and 180° ±10°. The door stop bars shall be a captive- type mechanism that serves to keep the bars in contact with the cabinet at both stop bar ends and provided with a catch that can be operated when the doors reach these two positions and shall hold the doors open securely until released. The cabinet shall be supplied with a three- point draw roller latching system consisting of the following latching points: III.183 202 4 Edition a. Center of the cabinet (lock)
The latching points on the top and bottom of the cabinet doors shall remain in the locked position until the door locks are disengaged. The locking mechanism shall be equipped with nylon rollers to secure the top and bottom of the doors. The cabinet shall be supplied with a ¾ -in. diameter shank, stainless steel latching handle for each door. The latching handle shall have a provision for padlocking the door in a closed position. The cabinet shall have a pliable seal composed of caulking compound or mastic installed between the cabinet base and the concrete foundation and in between the riser base and the cabinet to prevent dust and dirt from entering the cabinet. Internal Cabinet Lighting The cabinet shall be supplied with white LED light panels which shall automatically illuminate via a door open switch whenever any one of the four main cabinet doors are opened. The LED panels shall produce a minimum of 1,000 lumens on the Control side of the cabinet and 1,000 lumens on the Power/Auxiliary side of the cabinet and be protected by a clear shatterproof shield. The cabinet shall contain four light panels: two at the top of each rack assembly and two at the bottom portion of each rack assembly. There shall be two switches on each of the four main doors. LED light panel mounting brackets shall be installed such that they do not interfere with the unused rack mounting holes which could potentially conflict with the installation of future rack mounted devices. The second door switch shall be used to monitor when the do or has been opened. The front control side door monitoring switch shall be connected to one of the door status inputs of the controller. The door monitoring switches for the remaining d oors shall be connected to the second door status input to the controller. The door status inputs shall log a report event that one of the doors was opened. Cabinet Fans The cabinet shall be provided with thermostatically controlled ventilating fans and throwaway glass fiber air filters. The electric fans shall have ball or roller bearings and shall have a capacity of 100 ft³ per minute. The fans shall be rated for continu ous duty with a minimum service life of 3 years. The fan blades shall be supplied with a safety screen to prevent accident contact with the blades. The ventilating system shall be designed to prevent the entrance of rain, snow, dust, and insects. The fans and vents shall be arranged in such a manner that the air intake is at the cabinet bottom and the exhaust is at the cabinet top. The air intake shall be rain tight and covered with a removable glass fiber air filter. The removable air filter shall be firmly held in place with aluminum louvered backing plate such that cracks, and openings are eliminated to ensure that all air is filtered. The cabinet shall contain two fans. The thermostat panel shall be mounted to the top, rear of the cabinet’s 19 -in. equipment rack and oriented to be clearly visible allowing user adjustable temperature settings from a minimum of 70℉ to 140℉ and capable of activating the fans within plus or minus five degrees of the set temperature; the thermostat shall be initially set to 10 0℉. Any exposed terminals shall be covered to protect a technician’s hand. There shall be two intake vents provided with the cabinet, one in each front door. III.184 202 4 Edition Cabinet Switches/Manual Control The cabinet shall be supplied with a police door panel located in the middle area of the front door on the Power and Auxiliary side. The switches shall be mounted in the police panel and labelled as to function. The three switches shall be supplied as foll ows:
The manual control cord shall be a coiled type, sealed weatherproof covered hand switch extending to 6 ft when fully stretched. The cord shall be fastened to the cabinet via a compression type connector to provide strain relief for the cord’s electrical co nnections. The police door panel shall be of sufficient size so as to store the manual control cord when panel door is closed. The cabinet shall be supplied with a technician’s panel mounted integral to the front of the input/output rack assemblies. This panel shall be supplied with the following switches:
Slide Out Tray The cabinet shall contain a pull- out drawer, 19 -in. wide with sufficient strength to hold a laptop computer. The top of the drawer shall be covered with a non- conductive, non- skid material and hinged such that a storage space is available to store cabinet documentation or small parts. The pull -out drawer shall be located in the Power and Auxiliary side below the first top unused empty shelf. Spare Devices The cabinet shall be supplied with a Spare Lateral Rack (SLR) assembly. This rack assembly shall not be wired to any cabinet device, but rather used to store spare rack mounted cabinet devices such as switch packs, isolators, serial interface units (SIUs), CMUs and phase selectors. This spare rack assembly shall be located at the top of the Power and Auxiliary rack. In addition to the full complement of switch packs, flashers, SIU’s and flash transfers relays, 2 additional SIU’s, 32 additional Phoenix connectors, and 1 additional CMU USB datakey programmer tool with software shall be supplied. All spare equipment required to be supplied with the cabinet shall be stored in the SLR and any additional spare equipment shall be placed on the Power and Auxiliary side shelves. No spare equipment shall be placed on the interior cabinet foundation. Input and Output Channels The cabinet shall be supplied with one of the following Input and Output Channel configurations, as called for in the Plans or Special Provisions:
III.185 202 4 Edition M10.01.2: P1 ATC Cabinet Cabinet Enclosure The cabinet size and functional requirements shall conform to the NEMA TS2 -2016 Standard, Section 7. The cabinet enclosure shall be a dust and moisture -proof aluminum housing with an auxiliary door in door feature. The cabinet shall be configured to eliminate arc flash. All electrical equipment shall be dead front, no open terminals, busbars, breakers, or exposed terminal strips. All cabinet switches and circuit breakers shall be permanently labeled as to function. The cabinet shall be designed, constructed, and installed with all necessary provisions to comply with the latest NFPA 70E requirements. All electrically live contact points over 50V shall be covered with Lexan or a suitable physical barrier to eliminate the possibility of arc flash. The lock for the police door switch compartment shall unlock with a skeleton style (#1) key. The lock for the main door(s) of the cabinet shall unlock with a Corbin #2 key. Two sets of two keys (main door/police door) shall be furnished with each cabinet. The cabinet shall be supplied with a permanent label mounted on the upper portion of the inside front main door that shall contain the name of the cabinet manufacturer, controller manufacturer, model/part number and year/month of assembly. The cabinet shall be supplied with a GFCI duplex outlet and a rack mounted multi -outlet strip. The quantity, size and location of the equipment shall correspond to the contract drawings for the ATC Cabinet. All equipment shall be installed with the correct number of mounting screws/mounting support devices. All internal cabinet wiring shall be routed such that there is no conflict for access to cabinet devices or interference with door mechanisms. The cabinet shall be provided with two removable lifting eyes for placing the cabinet on its foundation. Each eye opening shall have a minimum diameter of ¾ in. Each lifting eye shall be able to support a weight limit of 1,000 lbs. Cabinet Configuration The cabinet shall be supplied with three shelves. The top two shelves shall be supplied with two side by side 19” rack support systems. The cabinet front shall provide for user interface to the in - cabinet equipment including the front panel of the controller, the cabinet status displays and detection system control interfaces as well as provide access to the field cable terminations. Cabinet Doors The cabinet shall be supplied with one main door. The main door shall be defined as the “primary” door The cabinet main door shall be provided with a stop to limit door opening to both 90° and 180° ±10°. The door stop bars shall be a captive type mechanism that serves to keep the bars in contact with the cabinet at both stop bar ends and provided with a catch that can be operated when the doors reaches these 2 positions and shall hold the doors open securely until released. The cabinet shall be supplied wit h a three- point draw roller latching system consisting of the following latching points: III.186 202 4 Edition a. Center of the cabinet (lock)
The latching points on the top and bottom of the cabinet doors shall remain in the locked position until the door locks are disengaged. The locking mechanism shall be equipped with nylon rollers to secure the top and bottom of the doors. The cabinet shall be supplied with a ¾ -in. diameter shank, stainless steel latching handle for each door. The latching handle shall have a provision for padlocking the door in a closed position. The cabinet shall have a pliable seal composed of caulking compound or mastic installed between the cabinet base and the concrete foundation and in between the riser base and the cabinet to prevent dust and dirt from entering the cabinet. Internal Cabinet Lighting The cabinet shall be supplied with white LED light panels which shall automatically illuminate via a door open switch whenever the main cabinet door is opened. The LED panels shall produce a minimum of 1,000 lumens and be protected by a clear shatterproof shield. The cabinet shall contain two light panels: one at the top of the cabinet and one at the bottom portion of the cabinet. There shall be two switches on the main door. LED light panel mounting brackets shall be installed such that they do not interfe re with the installation of any in cabinet devices. A second door open status switch shall activate a controller input to log a report event that one of the doors was opened. Cabinet Fans The cabinet shall be provided with thermostatically controlled ventilating fans and throwaway glass fiber air filters. The electric fans shall have ball or roller bearings and shall have a capacity of 100 ft³ per minute. The fans shall be rated for continu ous duty with a minimum service life of 3 years. The fan blades shall be supplied with a safety screen to prevent accident contact with the blades. The ventilating system shall be designed to prevent the entrance of rain, snow, dust, and insects. The fans and vents shall be arranged in such a manner that the air intake is at the cabinet bottom and the exhaust is at the cabinet top. The air intake shall be rain tight and covered with a removable glass fiber air filter. The removable air filter shall be firmly held in place with aluminum louvered backing plate such that cracks, and openings are eliminated to ensure that all air is filtered. The cabinet shall contain two fans. The thermostat shall be mounted on the top interior of the cabinet and user adjustable to allow for temperature settings from a minimum of 70℉ to 140℉ and capable of activating the fans within plus or minus five degrees of the set temperature; the thermostat shall be initially set to 100℉. Any exposed terminals shall be covered to protect a technician’s hand. There shall be one intake vent provided with the cabinet in the front door. Cabinet Switches/Manual Control The cabinet shall be supplied with a police door panel located in the middle area of the front door. The switches shall be mounted in the police panel and labelled as to function. The three switches shall be supplied as follows:
III.187 202 4 Edition The manual control cord shall be a coiled type, sealed weatherproof covered hand switch extending to six ft when fully stretched. The cord shall be fastened to the cabinet via a compression type connector to provide strain relief for the cord’s electrical connections. The police door panel shall be of sufficient size so as to store the manual control cord when panel door is closed. The cabinet shall be supplied with a technician’s panel mounted integral to the front of the input/output rack assemblies. This panel shall be supplied with the following switches:
Slide Out Tray The cabinet shall contain a pull -out drawer, 19 -in. wide with sufficient strength to hold a laptop computer. The top of the drawer shall be covered with a non- conductive, non- skid material and hinged such that a storage space is available to store cabinet documentatio n or small parts. The pull -out drawer shall be located under the top shelf on the left -hand side. Spare Devices In addition to the full complement of switch packs, flashers, SIU’s and flash transfers relays; 2 additional SIU’s, 32 additional Phoenix connectors, and 1 additional CMU USB datakey programmer tool with software shall be supplied. All spare equipment required to be supplied with the cabinet shall be stored on the lower shelf. No spare equipment shall be placed on the interior cabinet foundation. Input and Output Channels The cabinet shall be supplied with one of the following Input and Output Channel configurations, as called for in the Plans or Special Provisions:
M10.01.3: 352 ATC Cabinet Cabinet Enclosure The cabinet size and functional requirements shall conform to the Caltrans Transportation Electrical Equipment Specifications (TEES), 2020 for cabinet size 352. The traffic signal control equipment shall be enclosed within a dust and moisture -proof aluminum housing with an auxiliary door in door feature. The cabinet shall be configured to eliminate arc flash. All electrical equipment shall be dead front, no open t erminals, busbars, breakers, or exposed terminal strips. All cabinet switches and circuit breakers shall be permanently labeled as to function. The cabinet shall be designed, constructed, and installed with all necessary provisions to comply with the latest NFPA 70E requirements. All electrically live contact points over 50V shall be covered with Lexan or a suitable physical barrier to eliminate the possibility of arc flash. III.188 202 4 Edition The lock for the police door switch compartment shall unlock with a skeleton style (#1) key. The lock for the main door(s) of the cabinet shall unlock with a Corbin #2 key. Two sets of two keys (main door/police door) shall be furnished with each cabinet. The cabinet shall be supplied with a permanent label mounted on the upper portion of the inside front main door that shall contain the name of the cabinet manufacturer, controller manufacturer, model/part number and year/month of assembly. The cabinet shall be supplied with a GFCI duplex outlet, as well as a cabinet mounted multi -outlet strip. The quantity, size and location of the equipment shall correspond to the contract drawings for the ATC cabinet. All equipment shall be installed with the correct number of mounting screws/mounting support devices. All internal cabinet wiring shall be route d such that there is no conflict for access to cabinet devices or interference with door mechanisms. The cabinet shall be provided with two lifting eyes for placing the cabinet on its foundation. Each eye opening shall have a minimum diameter of ¾ in. Each lifting eye shall be able to support a weight limit of 1,000 lb. Cabinet Configuration The cabinet shall be supplied with a single 19 -in. rack cage which shall extend from the bottom to the top of the cabinet. The cabinet front shall provide for user interface to the in -cabinet equipment including the front panel of the controller, the cabin et status displays and detection system control interfaces as well as provide access to the field cable terminations. Cabinet Doors The cabinet shall be supplied with two main doors: one on the front face and one on the back face. The front control door shall be defined as the “primary” door; the rear door shall be defined as “secondary” door. The cabinet main doors shall be provided with a stop to limit door opening to both 90° and 180° ±10°. The door stop bars shall be a captive- type mechanism that serves to keep the bars in contact with the cabinet at both stop bar ends and provided with a catch that can be operated when the doors reach these 2 positions and shall hold the doors open securely until released. The cabinet shall be supplied with a three- point draw roller latching system consisting of the following latching points:
The latching points on the top and bottom of the cabinet doors shall remain in the locked position until the door locks are disengaged. The locking mechanism shall be equipped with nylon rollers to secure the top and bottom of the doors. The cabinet shall be supplied with a ¾ -in. diameter shank, stainless steel latching handle for each door. The latching handle shall have a provision for padlocking the door in a closed position. The cabinet shall have a pliable seal composed of caulking compound or mastic installed between the III.189 202 4 Edition cabinet base and the concrete foundation and in between the riser base and the cabinet to prevent dust and dirt from entering the cabinet. Internal Cabinet Lighting The cabinet shall be supplied with white LED light panels which shall automatically illuminate via a door open switch whenever any one of the two main cabinet doors are opened. The LED panels shall produce a minimum of 1,000 lumens and be protected by a clear shatterproof shield. The cabinet shall contain two light panels: one at the top of the rack assembly and one at the bottom portion of the rack assembly. There shall be two switches on each of the two main doors. LED light panel mounting brackets shall be installed such that they do not interfere with the unused rack mounting holes which could potentially conflict with the installation of future rack mounted devices. A second door open status switch per door shall activate a controller input to log a rep ort event that one of the doors was opened. The door open status switches shall be connected to separate controller inputs. Cabinet Fans The cabinet shall be provided with a thermostatically controlled ventilating fan and throwaway glass fiber air filter. The electric fan shall have ball or roller bearings and shall have a capacity of 100 ft³ per minute. The fan shall be rated for continuous duty with a minimum service life of 3 years. The fan blades shall be supplied with a safety screen to prevent accident contact with the blades. The ventilating system shall be designed to prevent the entrance of rain, snow, dust, and insects. The fan and vent shall be arranged in such a manner that the air intake is at the cabinet bottom and the exhaust is at the cabinet top. The air intake shall be rain tight and covered with a removable glass fiber air filter. The removable air filter shall be firmly he ld in place with aluminum louvered backing plate such that cracks, and openings are eliminated to ensure that all air is filtered. The cabinet shall contain one fan. The thermostat panel shall be mounted to the top, rear of the cabinet’s 19 -in. equipment rack and oriented to be clearly visible allowing user adjustable temperature settings from a minimum of 70℉ to 140℉ and capable of activating the fans within plus or minus five degrees of the set temperature; the thermostat shall be initially set to 100℉. A ny exposed terminals shall be covered to protect a technician’s hand. There shall be one intake vent provided with the cabinet in the front door. Cabinet Switches/Manual Control The cabinet shall be supplied with a police door panel located in the middle area of the front door. The switches shall be mounted in the police panel and labelled as to function. The three switches shall be supplied as follows:
The manual control cord shall be a coiled type, sealed weatherproof covered hand switch extending to six ft when fully stretched. The cord shall be fastened to the cabinet via a compression type connector to provide strain relief for the cord’s electrical connections. The police door panel shall be of sufficient size so as to store the manual control cord when panel door is closed. III.190 202 4 Edition The cabinet shall be supplied with a technician’s panel mounted integral to the front of the input/output rack assemblies. This panel shall be supplied with the following switches:
Slide Out Tray The cabinet shall contain a pull- out drawer, 19 -in. wide with sufficient strength to hold a laptop computer. The top of the drawer shall be covered with a non- conductive, non- skid material and hinged such that a storage space is available to store cabinet documentation or small parts. The pull -out drawer shall be located in the rack directly under the 24 channel input assembly. Spare Devices In addition to the full complement of switch packs, flashers, SIU’s and flash transfers relays; 2 additional SIU’s, 32 additional Phoenix connectors, and 1 additional CMU USB datakey programmer tool with software shall be supplied. All spare equipment required to be supplied with the cabinet shall be delivered to the Department. Input and Output Channels The cabinet shall be supplied with 16 output channels and 24 input channels. M10.01.4: 336S ATC Cabinet Cabinet Enclosure The cabinet size and functional requirements shall conform to the Caltrans Transportation Electrical Equipment Specifications (TEES), 2020 for cabinet size 332. The traffic signal control equipment shall be enclosed within a dust and moisture -proof aluminum housing with an auxiliary door in door feature. All cabinets shall be configured to eliminate arc flash. All electrical equipment will be dead front, no open terminals, busbars, breakers, or exposed terminal strips. All cabinet switches and circuit breakers shall be permanently labeled as to function. The cabinet shall be designed, constructed, and installed with all necessary provisions to comply with the latest NFPA 70E requirements. All electrically live contact points over 50 volts shall be covered with Lexan or a suitable physical barrier to eliminate the possibility of an arc flash. The lock for the police door switch compartment shall unlock with a skeleton style (#1) key. The lock for the main door(s) of the cabinet shall unlock with a Corbin #2 key. Two sets of two keys (main door/police door) shall be furnished with each cabinet. The cabinet shall be supplied with a permanent label mounted on the upper portion of the inside front main door that shall contain the name of the cabinet manufacturer, controller manufacturer, model/part number and year/month of assembly. The cabinet shall be supplied with a GFCI duplex outlet, as well as a rack mounted multi -outlet strip. The quantity, size and location of the equipment shall correspond to the contract drawings for the ATC cabinet. All equipment shall be installed with the correct number of mounting III.191 202 4 Edition screws/mounting support devices. All internal cabinet wiring shall be routed such that there is no conflict for access to cabinet devices or interference with door mechanisms. The cabinet shall be provided with two lifting eyes for placing the cabinet on its mount. Each eye opening shall have a minimum diameter of ¾ in. Each lifting eye shall be able to support a weight limit of 1,000 lb. The cabinet shall be equipped by the with an internal cable management system. Comprised of nonconductive channels designed to facilitate wire and cable routing within an electrical enclosure. Cabinet Configuration The cabinet shall be supplied with a single 19 -in. rack cage which shall extend from the bottom to the top of the cabinet. The cabinet front shall provide for user interface to the in -cabinet equipment including the front panel of the controller, the cabin et status displays and detection system control interfaces. The cabinet rear shall provide access for field cable termination and shall only be accessed for installation and for cabinet troubleshooting. Cabinet Doors The cabinet shall be supplied with two doors: one on the front face and one on the back face. The front main door shall be defined as the “primary” door; the rear main door shall be defined as the “secondary” door. The cabinet main doors shall be provided with a stop to limit door opening to both 90° and 180° ±10°. The door stop bars shall be a captive type mechanism that serves to keep the bar in contact with the cabinet at both stop bar ends and provided with a catch that can be operated when the doors reaches these 2 positions and will hold the doors open securely until released. The cabinet shall be supplied with a three- point draw roller latching system consisting of the following latching points:
The latching points on the top and bottom of the cabinet doors shall remain in the locked position until the door locks are disengaged. The locking mechanism shall be equipped with nylon rollers to secure the top and bottom of the doors. The cabinet shall be supplied with a ¾ -in. diameter shank, stainless steel latching handle for each door. The latching handle shall have a provision for padlocking the door in a closed position. The cabinet shall have a pliable seal composed of caulking compound or mastic installed between the cabinet base and the concrete foundation and in between the riser base and the cabinet to prevent dust and dirt from entering the cabinet. Internal Cabinet Lighting The cabinet shall be supplied with white LED light panels which shall automatically illuminate via a door open switch whenever any one of the two main cabinet doors are opened. The LED panels shall produce a minimum of 1,000 lumens and be protected by a clear shatterproof shield. The cabinet shall contain two light panels: one at the top of the rack assembly and one at the bottom III.192 202 4 Edition portion of the rack assembly. There shall be two switches on each of the two main doors. LED light panel mounting brackets shall be installed such that they do not interfere with the unused rack mounting holes which could potentially conflict with the inst allation of future rack mounted devices. A second door open status switch per door shall activate a controller input to log a report event that one of the doors was opened. The door open status switches shall be connected to separate controller inputs. Cabinet Fans The cabinet shall be provided with a thermostatically controlled ventilating fan and throwaway glass fiber air filter. The electric fan shall have ball or roller bearings and shall have a capacity of 100 ft³ per minute. The fan shall be rated for continuous duty with a minimum service life of 3 years. The fan blades shall be supplied with a safety screen to prevent accident contact with the blades. The ventilating system shall be designed to prevent the entrance of rain, snow, dust, and insects. The fan and vent shall be arranged in such a manner that the air intake is at the cabinet bottom and the exhaust is at the cabinet top. The air intake shall be rain tight and covered with a removable glass fiber air filter. The removable air filter shall be firmly he ld in place with aluminum louvered backing plate such that cracks, and openings are eliminated to ensure that all air is filtered. The cabinet shall contain one fan. The thermostat panel shall be mounted to the top, rear of the cabinet’s 19 -in. equipment rack and oriented to be clearly visible allowing user adjustable temperature settings from a minimum of 70℉ to 140℉ and capable of activating the fans within plus or minus five degrees of the set temperature; the thermostat shall be initially set to 100℉. A ny exposed terminals shall be covered to protect a technician’s hand. There shall be one intake vent provided with the cabinet in the front door. Cabinet Switches/Manual Control The cabinet shall be supplied with a police door panel located in the middle area of the front door. The switches shall be mounted in the police panel and labelled as to function. The three switches shall be supplied as follows:
The manual control cord shall be a coiled type, sealed weatherproof covered hand switch extending to six ft when fully stretched. The cord shall be fastened to the cabinet via a compression type connector to provide strain relief for the cord’s electrical connections. The police door panel shall be of sufficient size so as to store the manual control cord when panel door is closed. The cabinet shall be supplied with a technician’s panel mounted integral to the front of the input/output rack assemblies. This panel shall be supplied with the following switches:
III.193 202 4 Edition Slide Out Tray The cabinet shall contain a pull- out drawer, 19 -in. wide with sufficient strength to hold a laptop computer. The top of the drawer shall be covered with a non- conductive, non- skid material and hinged such that a storage space is available to store cabinet documentation or small parts. The pull -out drawer shall be located in the rack directly under the controller. Spare Devices In addition to the full complement of switch packs, flashers, SIU’s and flash transfers relays; 2 additional SIU’s, 32 additional Phoenix connectors, and 1 additional CMU USB datakey programmer tool with software shall be supplied. All spare equipment required to be supplied with the cabinet shall be delivered to the Department. Input and Output Channels The cabinet shall be supplied with 16 output channels and 24 input channels. M10.02.0: Advanced Transportation Controller All Advanced Transportation Controllers (ATC) shall be solid state, menu driven, keyboard units. The Contractor shall supply a rack -mounted ATC unless otherwise indicated in the Plans or Special Provisions. The ATC shall be supplied with the latest firmware. The ATC firmware shall be upgradeable via a USB connection at the front of the controller. No additional software shall be required to perform this function. The ATC shall be supplied with a manufacture’s Software Development Kit (SDK) for the supplied firmware version to allow for future system modifications/expansions. The ATC shall be able to backup and restore programing data via a USB connection at the front of the controller. No additional software shall be required to perform this function. No additional hardware, software items, licenses, and/or subscription fees/costs shall be needed or allowed to satisfy the ATC requirements as defined in these specifications. The ATC shall be supplied with all necessary interfaces needed to support Advanced Transportation Controller Cabinet (ATCC) / Serial Interface Unit (SIU) communications. Compliance with Standards The ATC conform to or be compliant with the following standards: • ATC 5201 Standard v06.25 • NTCIP 1201 and 1202 • NEMA TS2 -2016, including all amendments The ATC shall contain Application Programming Interface (API) software conforming to ATC 5401 Standard v02. III.194 202 4 Edition Operating Environment The ATC shall be configured to operate in an ATCC 5301 v02 cabinet platform conforming to M10.01.0: Advanced Transportation Controller Cabinets (General) unless otherwise indicated in the Plans or Special Provisions. Operating System The ATC shall be supplied with the appropriate version of the Linux operating system, Board Support Package (BSP) and internal processing levels necessary to support connected vehicle (CV) as well as local and system operations. The ATC shall be supplied with programming documentation fully defining the coding (compiler and C libraries) used to create the ATC controller applications residing in the unit. The ATC shall be supplied with the source code used to produce and support the Linux kernel environment. Serial Interface Ports The ATC shall have a minimum of two SDLC ports. The ATC shall have a minimum of three Universal Serial Bus (USB) ports. The ports shall conform to USB v2.0 or later. The ATC shall have a minimum of three 10/100BaseT, RJ45 ethernet connector ports. All data communication connectors shall be supplied and installed with an outer boot molded cover designed specifically for the connector to ensure physical protection for the connector wire terminations. There shall be no exposed wires visible between the connector and the cable insulated jacket. User Interface The ATC shall contain the ability to alter the controller unit’s internal database using a built -in front panel keyboard, using a computer connected to the controller unit with a USB cable or an Ethernet cable, and remotely using a central management system application. In addition, a remote access system shall be provided using HTTPS. The ATC shall contain real -time context sensitive Help screens. The Real- Time Clock (RTC) shall be capable of daily, weekly, and yearly event time programming via a scheduler. A user shall have the ability to alter the controller unit’s internal database using a built -in front panel keyboard, using a computer connected to the controller unit with a USB cable or an Ethernet cable, and remotely using the central management system application. Functional Requirements The ATC shall support the following: III.195 202 4 Edition • A minimum of 8 vehicle/pedestrian phases and 8 overlaps. • The ability to provide 12 unique preemption/priority inputs. • Dedicated phase detection inputs, pedestrian detection inputs, and system detection inputs. • Flashing Yellow Arrow (FYA) and Flashing Red Arrow (FRA) operation with the ability to provide a minimum of 6 flashing pairs. • An internal database which stores all configurable parameters, including but not limited to phase timings, phase sequencing, overlaps, coordination parameters, preemption and priority parameters, time base parameters, communications parameters, detection parameters, flashing operation parameters, and security parameters. • The ability to generate user defined alarms and alerts. • Detector failure algorithms that initiate user defined actions when user defined criteria are met. The ATC shall not utilize internal logic processing or script programming to directly control conditional timing or operation of vehicle or pedestrian field signal circuits. Transit Signal Priority The ATC shall support Transit Signal Priority (TSP) without the need for additional software, hardware, data key device or any recurring licensing fees. TSP shall be available during both coordinated and free operation and shall include the following: • TSP shall support a minimum of six priority routines. • The TSP program shall be capable of extending the priority phase green time and truncating the non- priority phase(s) green when a priority call is received by the ATC unit. • TSP operation shall not cause the ATC unit to skip any phases that have active vehicle/pedestrian demand. • Emergency vehicle preemption (EVP) shall override TSP operation. • The TSP program shall have the ability to delay and/or extend priority calls. • The TSP program shall have the ability to support user defined time periods between servicing valid priority calls. • All TSP events shall be logged (time/date stamped) in the ATC unit. • The TSP algorithm shall allow for non -TSP phases to be conditionally truncated based on the absence of a concurrent pedestrian service of the non -TSP phase. • It shall be possible to user define in the traffic controller a minimum time between responses to priority calls. Under coordinated operation, the controller shall modify existing signal operation to accommodate a priority call. This may include modification to per phase termination points established under normal coordinated control. During a priority event, per phas e coordination modes shall remain in effect. Priority and non -priority phase duration shall be user programmable per coordination pattern. Under free operation, upon receipt of a valid priority call, the controller shall either extend the priority phase or reduce the non -priority(s). These settings for the adjusted green times shall be user defined, on a per phase basis, and adjustable on a t ime-of-day basis. III.196 202 4 Edition Reporting The ATC shall be supplied with all necessary hardware, software elements and instruction procedures needed to facilitate the extraction and processing of Automated Traffic Signal Performance Measures (ATSPM) data. The ATC shall collect and process all 255 high resolution enumerations as defined in the report “Indiana Traffic Signal Hi Resolution Data Logger Enumerations.” This data will be processed in the controller and available via download from the controller US B Ethernet port or, if available, via system communications. At a minimum, the ATC shall be configured to provide the following performance reports: • Approach delay • Preemption events • Transit Priority Events • Split Monitor • Approach Volumes • Purdue Coordination Diagrams • Arrivals on Red • Arrivals on Green • Phase Termination • Pedestrian Delay