535.02Materials Materials for precast/prestressed concrete pro ducts shall meet the

535.01 Description This work shall consist of casting and erec ting precast/prestressed

concrete products and related material. Materials, work, inspe ction and documentation not specifically addressed by this Specification shall be done in a ccordance with the applicable sections of the Precast/Prestressed Concrete Institute (PCI) , Manual for Quality Control for Plants and Production of Structural Precast Concrete Products (MNL 116), including Commentary. ALL REQUIREMENTS IN THIS SPECIFICATION ARE THE RESPONSIBILITY O F THE CONTRACTOR, UNLESS NOTED OTHERWISE.

535.02 Materials Materials for precast/prestressed concrete pro ducts shall meet the

requirements of the following Subsections of the Standard Speci fications: Portland Cement and Portland Pozzolan Cement 701.01 W a t e r 701.02 Air-Entraining Admixtures 701.03 Water Reducing Admixtures 701.04 High Range, Water Reducing, Admixture (HRWR) 701.0401 Set-Retarding Admixtures 701.05 F l y A s h 701.10 C a l c i u m N i t r i t e S o l u t i o n 701.11 S i l i c a F u m e 701.12 Ground Granulated Blast Furnace Slag 701.13 F i n e A g g r e g a t e f o r C o n c r e t e 703.01 C o a r s e A g g r e g a t e f o r C o n c r e t e ( C l a s s A , A A o r L a t e x ) 703.02 Reinforcing Steel 709.01 W e l d e d S t e e l W i r e F a b r i c 709.02 S t e e l S t r a n d 709.03 Portland cement shall conform to AASHTO M85 (ASTM C150), Type I , Type II, or Type III or AASHTO M 240. Supply the Department with copies of Certified Mill Test Reports for the cement. Provide a Materials Certification from the manufacturer of the prestressing strand. The certification shall include a representative load elongation cu rve for each coil. The manufacturer shall identify each coil of strand. Do not remove the identification from the coil. Partial coils may be used with the approval of the Fabri cation Engineer. Failure to maintain traceability of a coil will be cause for rejection. P rovide Certified Mill Test Reports for the reinforcing st eel, welded wire fabric and fusio n bonded epoxy coating. 5-167

535.03 Working Drawings Prepare shop detail, erection and othe r necessary Working

Drawings in accordance with Section 105.7, Working Drawings. T he Department will review the drawings in accordance with the applicable requireme nts of Section 105.7, Working Drawings. Changes and revisions to the reviewed Workin g Drawings will require further review by the Fabrication Engineer. Concrete mix designs shall be pa rt of the Working Drawing submi ttal. Include aggregate specific gravity, absorption, percent fracture, finen ess modulus and gradation as part of the mix design. Provide the mix design calculations de monstrating how the batch weights, water-cement ratio and admixture dosage rate were dete rmined.

535.04 Plant The plant shall be a PCI Certified facility.

535.05 Facilities for Inspection Provide a private office at t he fabrication plant for the

Department’s inspection personnel, or Quality Assurance Inspect ors (QAI’s). The office shall be in close proximity to t he Work. The office shall be c limate controlled to maintain the temperature between 68° F and 75° F and have the exit(s) cl osed by a door(s) equipped with a lock and 2 keys which shall be furnished to the QAI’s. The QAI’s office shall meet the following minimum requirements: Description Q u a n tity Office area (minimum ft2) 100 Drafting table surface (ft2) 3 5 Drafting stools-each 1 O f f i c e d e s k 1 Ergonomic swivel chairs 1 Folding chairs 2 High-speed internet connection (ports) o r w i r e l e s s 1 Fluorescent lighting of 100 ft-candles minimum for all work are as 2 110 Volt 60 cycle electric wall outlets 3 W a l l c l o s e t 1 Waste basket with trash bags 1 B r o o m 1 D u s t p a n 1 Water cooler 1 Cleaning materials-floor, surf aces, windows, for duration of th e project The Contractor will be responsib le for disposing of trash and s upplying commercially bottled water for the water cooler. The QAI will have the option to reject any furniture or supplie s provided to the QAI’s office, based on general poor condition. 5-168 Provide parking space for the QAI(s) in close proximity to the entrance to the QAI’s office. Maintain the pathway betw een the parking area and the QAI’s office so that it is free of obstacles, debris, snow and ice. The facilities and all furnishings shall remain the property of the Contractor upon completion of the Work. Payment for the facilities, heating, l ighting, internet connection and monthly internet charges and all furnishings shall be incid ental to the Contract. Failure to comply with the above requirements will be considere d denial of access to the Work for the purpose of inspection. The Department will reject all Work done when access for inspection is denied.

535.06 Notice of Beginning Work Give the Department a minimum of two weeks notice

for in-Maine work and three weeks notice for out-of-Maine work, prior to beginning production. If the production schedule changes, notify the Fab rication Engineer no less than 3 working days prior to the initial start-up date. Any Work do ne without the QAI present will be rejected. Advise the F abrication Engineer of the produ ction schedule and any changes to it. If Work is suspended on a project, the Fabricat ion Engineer will require 72 hours notice prior to the resumption of Work.

535.07 Quality Control Quality Control (QC) is the responsibil ity of the Contractor.

Provide a copy of the Quality System Manual (QSM) to the Fabric ation Engineer, if requested. Calibrate all production equipment in accordance with MNL 116, except that stressing jacks shall be calibrated every 6 months. Provide calibration certifications to the QAI prior to beginning fabrication. Calibrate scales, admixture dispense rs and water gauges at the frequency specified in MNL 116. U se proving rings, load cells and solid standard weights, as applicable. The calibration shall be performed by a testing laboratory acceptable to the Department using calibration equipment the accuracy of which is traceable to a National Institute of Standards and Technology (NIST) standard. Quality Control Inspectors (QCI’s) shall have a valid PCI Quali ty Control Certification Level I, Level II or Level III. Personnel performing concrete testing shall hold a current ACI Field Testing Technician Grade I Certification, or equivale nt. Inspect all aspects of the Work in accordance with the Contract or’s QSM. Reject materials and workmanship that do not meet Contract requirement s. Record measurements and test results on the appropriate forms f rom APPENDIX E of MNL 116, or an equivalent form pr epared by the user. Provide c opies of measurements and test results to the QAI as follows: Type of Report When Provided to QAI* Aggregate gradations-fine aggregate and coarse Prior to beginni ng work and at least once a 5-169 aggregate week thereafter Material certifications / stressing calculations / calibration certifications Prior to beginning work (anticipate adequate time for review by QAI) Tensioning report The same work day Pre-placement inspection report Prior to the concrete placement Concrete batch slips The morning of the next work day Results of concrete testing The morning of the next work day Results of compressive strength testing (for release) The same work day Concrete temperature records Provide with compressive strength testing (for release) Nonconformance reports/repair procedures Within 24 hours of dis covery Results of compressive strength testing (for design strength) Prior to stopping curing Post-placement inspection report Within 48 hours of achieving d esign strength * The Contractor and QAI may, by mutual agreement, modify any p art of the schedule; however, failure to provide the documentation when required by the Fabrication Engineer will result in the product being deemed unacceptable. The Contracto r may perform testing in addition to the minimum required. The results of all testing s hall be made available to the Department.

535.08 Quality Assurance Quality Assurance (QA) is the preroga tive of the Department.

The QAI will perform acceptance sampling and testing and will w itness or review documentation, workmanship and testing to assure the Work is be ing performed in accordance with the Contract Documents. The QAI has the authority to reject materials and products that do not meet the Contract requirements, including Work rejected due to denial of access o r the lack of adequate notice of the beginning of production. The acceptance of material or workmanship by the QAI will not preclude subsequent rejection, if found unacceptable by the Department, at a later date.

535.09 Nonconforming Work Correct or replace nonconforming mat erial and/or

workmanship. Generate a nonconformance report (NCR) describing the nonconformance and the proposed corrective action; provide a copy to the QAI a nd forward a copy to the Fabrication Engineer for review. In the event that an item does not meet the Contract requiremen ts but is deemed suitable for use by the Department, said item may be accepted in accorda nce with Section 106.8, Non-Conforming Work, of the Standard Specifications.