110 psi for 70 durometer compounds at 25 percent strain of the total effective elastomer thickness after an extended 4-day ambient temperature of -20 F. 1038.3.4 The manufacturer shall proof load each laminated neoprene bearing with a compressive load of 1,500 psi on the bearing area. The bulging pattern shall not indicate improper laminate placement or poor laminate bond. No more than two separate surface cracks with a width of 0.08 inches and a depth of 0.08 inches will be permitted. 1038.4 Type “N” Polytetrafluoroethylene (PTFE) Bearings. 1038.4.1 Type “N” PTFE bearings shall be either fixed units or expansion units having sliding surfaces of mirror stainless steel against PTFE material. Shop drawings for type “N” PTFE bearings shall be prepared and submitted to Bridge for approval in accordance with Sec 1080.3.2 The PTFE sliding bearings shall consist of a steel sole plate with a welded upper element of stainless steel bearing on a lower element consisting of a layer of PTFE material bonded to a stainless steel plate that shall be bonded to the neoprene elastomeric pad. The surface of the stainless steel plate shall be protected from weld splatter during the welding procedure. 1038.4.2 The stainless steel sheet for the top and bottom elements of sliding bearings shall be Type 304 in accordance with ASTM A 240. The finished stainless surface of the top element shall be a plane within a tolerance of 1/32 inch, polished sufficiently to meet the friction requirement in Sec 1038.4.6.1, and shall be comparable to a No. 8 mirror finish as established by the American Iron and Steel Institute Committee of Stainless Steel Producers “Finishes for Stainless Steel” at the completion of fabrication. 1038.4.3 Neoprene elastomeric pads shall be in accordance with Sec 1038.3. 1038.4.4 The PTFE material shall be 100 percent virgin PTFE fluorocarbon resin, unfilled or filled with fiberglass reinforcement to minimize the cold flow tendencies while maintaining the friction properties of the PTFE fluorocarbon resin. The amount of filler by weight of filled PTFE sheet shall be no more than 15 percent. The finished material shall exhibit the following physical properties: RequirementTest MethodFilled ValueUnfilled Value Tensile Strength, psiASTM D 6382000, min - ASTM D 2256 - 2800, min Elongation, PercentASTM D 638150, min - ASTM D 2256 - 200, min Melting Point ASTM D 4895621 ± 18 F623 ± 2 F Specific Gravity ASTM D 48952.20 ± 0.032.16 ± 0.03 1038.4.5 The PTFE sheet shall be bonded to the stainless steel with epoxy bonding material designated by the manufacture as compatible with the PTFE sheet and stainless steel and be able to withstand the temperatures of vulcanization. The stainless steel shall then be bonded by vulcanization to the neoprene elastomer to provide a homogenous bond free of air and moisture pockets. 1038.4.6 One load specimen from the sliding bearing, consisting of a bottom element and a compatible top element no less than the smaller of the bearing area or 7 x 7 inches shall be tested by the manufacturer. 1038.4.6.1 The specimen shall be loaded to 800 psi compression at 68 F ± 2 F and subjected to 100 cycles of one inch of horizontal movement each way from center at a rate of 2.5 inches per minute. The breakaway friction coefficient shall be computed for each direction of each cycle, and the breakaway friction coefficient mean and standard deviation shall be computed for the sixth through twelfth cycles. The initial static breakaway coefficient of friction for the first cycle shall not exceed twice the design coefficient of friction. The maximum coefficient of friction for all subsequent cycles shall not exceed the design coefficient of friction. Failure of a single sample shall result in rejection of the entire lot. Following the test, the breakaway coefficient of friction shall be determined again and shall not exceed the initial value. The bearing shall show no signs of bond failure or other defect. 6181038.4.6.2 A minimum of one test for sliding bearings shall be performed for each lot of bearings. 1038.5 Rubber and Fabric Pads. 1038.5.1 Rubber and fabric bearings pads shall be manufactured of new material and be composed of multiple layers of prestressed cotton duck material weighing no less than 8.1 ounces per square yard. The duck warp count shall be 50 threads plus or minus one thread per inch and filing count 40 threads plus or minus two threads per inch, each with two yarns per thread. The finished pads shall have 64 plies per inch of thickness. The duck material shall be impregnated and bound with a high quality rubber compound containing rot and mildew inhibitors and anti-oxidants, compounded into resilient pads of uniform thickness. 1038.5.2 The pads shall withstand compressive loads perpendicular to the plane of laminations of no less than 10,000 psi without separation of bond or detrimental deformation. Load deflection properties, determined in accordance with procedures of Military Specifications MIL-C-882B, shall not exceed 10 percent of total pad thickness at 1,000 psi and 15 percent of total pad thickness at 2,000 psi. When loaded to 1,500 psi, permanent set as load shall be removed in accordance with procedures of MIL-C-882B and shall be no more than 2.5 percent of the original "zero point" thickness. Type A Durometer hardness shall be 87 to 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 temperature range of -65 F to 150 F. The thickness shall vary no more than five percent from that shown on the plans. There shall be no visible evidence of damage or deterioration resulting from environmental effects of sunshine, humidity, salt spray, fungus or dust in accordance with MIL-E-5272. 1038.6 Rubber and Fiber Pads. 1038.6.1 Rubber and fiber bearing pads shall consist of a rubber body and fabric fibers for insulation under aluminum rail posts. The bearing pads shall be made from new unvulcanized rubber and unused fabric fibers. Fibers and rubber shall be in proper proportion to maintain specified strength and stability. 1038.6.2 Type A durometer surface hardness of the pads shall be 70 to 90. Pads of the specified thickness shall be capable of withstanding compressive loads of no less than 7,000 psi without excessive extrusion or detrimental reduction in thickness. 1038.7 Tolerances. For both plain and laminated bearings, the permissible variation from the dimensions and configuration shown on the plans shall be as follows: Inch Overall Vertical Dimensions Average total thickness 1 1/4 inches or less Average total thickness over 1 1/4 inches-0, +1/8 -0, +1/4 Overall Horizontal Dimensions 36 inches and less Over 36 inches-0, +1/4-0, +1/2 Thickness of Individual Layers of Elastomer (Laminated bearings only)± 1/8 Variation from a Plane Parallel to the Theoretical Surface (as determined by measurements at the edges of bearings) Top Sides Individual non-elastic laminates1/8, 1/4 1/8 Position of Exposed Connection Members 1/8 Edge Cover of Embedded Laminates or Connection Members-0, +1/8 Size of Holes, Slots or Inserts -0, +1/8 Position of Holes, Slots or Inserts ± 1/8 1038.8 Certification. The manufacturer shall furnish certification of all material. The certification shall indicate that the components are in accordance with this specification and shall include typical test results representative 619of the material, except for bearings meeting 1038.3 and 1038.4 which will require test results for the material actually used in the bearing. The certification shall indicate the results of the proof loading, when required. 620SECTION 1039 POLYMER PRODUCTS SECTION 1039.10 TYPE II EPOXY.
1039.10.1 Scope. This specification covers epoxy resin to be used to bond plastic concrete or mortar to
hardened concrete or mortar.
1039.10.2 General Requirements. The epoxy shall be furnished as a system in accordance with the
requirements of ASTM C 881, Type II, Grade 2, Class B or C.
1039.10.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the
manufacturer shall submit to Construction and Materials a certified test report showing specific test results from an independent laboratory in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one-quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and an MSDS. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of concrete bonding compounds. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.
1039.10.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to
the engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material is the same system and is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.20 TYPE III EPOXY.
1039.20.1 Scope. This specification covers epoxy to be used in the grouting of dry cracks, in epoxy mortar for
patching concrete and in epoxy mortar surface leveling.
1039.20.2 General Requirements. The epoxy shall be furnished as a system in accordance with the
requirements of ASTM C 881, Type III, Grade 1, Class B or C.
1039.20.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the
manufacturer shall submit to Construction and Materials a certified test report showing specific test results from an independent laboratory in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one-quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and an MSDS. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of concrete bonding compounds. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.
1039.20.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish a certification
to the engineer at destination certifying that the material supplied is in accordance with all requirements specified and stating that the material is the same system and is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.30 EPOXY OR POLYESTER BONDING AGENTS FOR DOWELS.
1039.30.1 Scope. This specification covers a multi-component epoxy or polyester bonding agent to be used in
anchoring epoxy coated dowel bars in concrete for pavement repair.
1039.30.2 General Requirements. Epoxy or polyester bonding agents for anchoring epoxy coated dowel bars
shall be furnished as a multi-component system. The system shall include automatic mixing, whether in 621cartridge or bulk form. The component ratios shall be shown on the label of each cartridge or bulk container.
1039.30.3 Properties. The epoxy or polyester bonding agent shall exhibit good bonding properties between the
epoxy coated dowel bar and the existing concrete and shall cure in accordance with the manufacturer’s recommendation. Bonding agents, when initially mixed, shall have a viscosity, which prevents flow from a horizontal hole. When tested in accordance with MoDOT Test Method TM 49, the minimum pull-out load shall be 8,100 pounds.
1039.30.4 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the
manufacturer shall submit to Construction and Materials a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture, ratio of components by volume and system tested. In addition, the manufacturer shall submit to Construction and Materials a sample representing the system for laboratory testing accompanied by a technical data sheet, an MSDS and any special installation instructions relative to the system being submitted, including recommended curing time. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of bonding agents for dowels. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.
1039.30.5 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to
the engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material supplied is the same system and is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.40 EPOXY BONDING AGENTS FOR RESIN ANCHOR SYSTEMS.
1039.40.1 Scope. This specification covers a multi-component epoxy bonding agents to be used in anchoring
steel components in concrete for structures.
1039.40.2 General Requirements. The epoxy shall be furnished as a system in accordance with the
requirements of ASTM C 881, Type IV, and Grade 3 and as described herein. When a cartridge dispensing system is used the epoxy shall have a gel time as stated in ASTM C 881 paragraph 5.2. Epoxy bonding agents are not approved for sustained tension loads.
1039.40.3 Pull Test. The epoxy bonding agent shall exhibit good bonding properties between the anchored
product and the existing concrete and shall cure in less than 24 hours or manufacturer’s recommendation. For acceptance on the qualified list, Resin Anchor Systems shall be tested in accordance with ASTM E 488. The ultimate minimum pull-out load shall be in accordance with the following table when installed per manufacturer’s recommendation. Resin Anchor Systems shall also have a minimum strength of 9,000 lbs when tested in accordance with MoDOT Test Method TM-74. TM-74 testing will not be required if the Resin Anchor System has a current International Code Council Evaluation Service (ICC-ES) evaluation indicating the material complies with the latest edition of the International Building Code. Pull-Out Specification Requirements Diameter of Threaded Rod or Reinforcing BarMinimum Ultimate Pullout Strength 1/2” 9,800 lbs 5/8” 15,500 lbs 3/4” 20,400 lbs 7/8” 27,500 lbs 1” 33,600 lbs
1039.40.4 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the
manufacturer shall submit to Construction and Materials a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture, bar or rod size 622tested, embedment depth and ratio of components. In addition, the manufacturer shall submit a one- quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and a material safety data sheet. A copy of the current ICC-ES evaluation for the material shall be submitted to waive TM-74 testing. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of Epoxy Bonding Agents for Resin Anchor Systems. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.
1039.40.5 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to
the engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material is the same system and is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.50 SAND FOR EPOXY MORTAR.
1039.50.1 Scope. This specification covers sand for use in epoxy mortar for the repairing of concrete surfaces.
The epoxy material used in epoxy mortar shall be Type III epoxy in accordance with Sec 1039.20.
1039.50.2 Properties. Sand for mortar shall be a quartzite sand, Ottawa sand or equal. The sand shall be clean
and dust free. The maximum moisture content shall be 2 percent. The gradation shall be in accordance with the following requirements: Gradation Requirements Sieve SizePercent Passing by Weight No. 16 100 No. 30 97-100 No. 50 5-35 No. 1000-2 No. 2000-0.4
1039.50.3 Acceptance. The manufacturer shall furnish certification to the engineer at the destination that the
material supplied is in accordance with all requirements of this specification. Acceptance will be based on certification and testing. SECTION 1039.60 EPOXY POLYMER WEARING SURFACE.
1039.60.1 Scope. This specification covers epoxy polymer and aggregate to be used for an epoxy polymer
wearing surface.
1039.60.2 Epoxy Polymer. The infrared spectrum for each component of the epoxy polymer shall essentially
match that of the standard infrared spectrum for the particular component as specified in AASHTO T 237, Sections 4 and 5. The epoxide equivalent for Component A shall not exceed 270. The mixed epoxy polymer shall meet the following requirements: Property Requirement Pot life (at75 F), minutes 10 to 55 Tensile Strength (at 75 F, 7 days), psi, min. 1500 Tensile elongation (at 75 F), percent, min. 20 Water Absorption, percent, max. 0.8 Compressive Strength (at 4 hr), psi, min. 1000 Compressive Strength (at 48 hr, wet), psi, min. 4000 Ash Content, percent, max 0.5 Rotational Viscosity, (at 75 F, spindle 3, 60 rpm), poise 7 to 25 Volatile Content, percent, max. 3.0 623Thermal Shear (shearing, shrinkage, expansion or scaling)None
1039.60.2 1 Classes. Epoxy resin shall be formulated for use at specific temperatures as specified in ASTM C
881. The controlling temperature shall be that of the hardened concrete surface to which the polymer is applied. Where unusual curing rates are desired and upon the approval from the engineer, a class of epoxy resin may be used at a temperature other than that for which the epoxy resin is normally intended.
1039.60.2 2 Packaging. Containers shall be identified as "Component A--Contains Epoxy Resin" and
"Component B--Contains Hardener" and shall show the type, class and mixing directions. Each container shall be marked with the name of the manufacturer, class, batch, or lot number, date of packaging, date of shelf life expiration, pigmentation, if any, manufacturer, and the quantity contained in pounds and gallons.
1039.60.3 Aggregate. Aggregate shall be bauxite, crushed porphyry, aluminum oxide, flint chat or other
similarly hard, durable, dry aggregates with less than 0.2 percent moisture. Aggregate shall be in accordance with the following gradation: Sieve Size% Passing By Weight No. 4 100 No. 20 0-5 No. 2000-1.0
1039.60.3 1 Lead Content. Aggregate produced as a by-product from lead or zinc mining operations shall not
have a total lead content greater than 4,500 ppm, as determined by EPA Method 3050A, “Acid Digestion of Sediments, Sludges and Soils. Suppliers of this aggregate shall provide certification to the engineer for each shipment that the total lead content of the aggregate does not exceed this value, and attach a typical test report from the same source no older than 12 months prior to the shipment.
1039.60.3 2 Aggregate Recommendation. For each contract, the epoxy polymer supplier shall supply a letter to
the engineer specifically recommending the use of a designated aggregate and source, which has been previously approved by Construction and Materials.
1039.60.4 Epoxy Polymer Performance. The epoxy polymer system shall not exhibit shearing, shrinkage,
expansion or scaling.
1039.60.5 Test Methods. Tests will be performed in accordance with the following methods:
Test Methods Rotational ViscosityASTM C881 Epoxy Equivalent ASTM C881 and AASHTO T237 Volatile Content a ASTM D 1259, Method B, for mixed system Filler Content ASTM C881 Ash Content ASTM D 482 Pot Life AASHTO T 237 Tensile Strength ASTM D 638 Compressive StrengthASTM C 881 Water Absorption ASTM D 570 Thermal Shear ASTM C881 a Sample cured 4 days at room temperature and weighed on a previously weighed metal foil.
1039.60.6 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the
manufacturer shall submit to Construction and Materials a certified test report showing specific test results in accordance with all requirements of this specification. The certified test report shall include the manufacturer's name, brand name of material, lot tested, date of manufacture, ratio of components by volume and system tested. In addition, the manufacturer shall submit to Construction and Materials a sample representing the system for laboratory testing accompanied by a technical data sheet, an MSDS and any special installation 624instructions relative to the system being submitted. Upon approval of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of epoxy resin material for epoxy polymer concrete wearing surface. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates non-conformity with any of the requirements herein specified.
1039.60.7 Product History. The epoxy polymer shall have a proven record of a minimum of two years on
similar bridge decks within the United States. A list including the location, the name of the agency involved with the project, and a name and phone number of a contact person with that agency, shall be provided for each location used as evidence of satisfactory use.
1039.60.8 Acceptance. The manufacturer shall furnish certification to the engineer at the destination that the
material supplied is in accordance with all requirements specified and stating that the material supplied is the same system and is identically formulated to the material tested for manufacturer and brand name approval. Acceptance will be based on certification and testing. SECTION 1039.70 POLYMER CONCRETE.
1039.70.1 Scope. This specification covers polymer concrete consisting of a fast setting epoxy based solid that
may contain aggregate for use at bridge expansion joints.
1039.70.2 General Requirements. The polymer concrete shall be resilient, self-adhering, water tight and shall
withstand and remain bonded to the surrounding material under repeated impact and thermal cycling. The polymer concrete shall not flow or become tacky at temperatures up to 130 F, shall be resistant to ultraviolet radiation, petroleum products and abrasion, and shall be capable of curing at all temperatures above 50 F. Mixing and placement shall be in accordance with the manufacturer's recommendations.
1039.70.2 1 The combined liquid components with no aggregate added shall be in accordance with the
following requirements: Epoxy Requirements Property Specific Value Mixing Ratio, by Volume 1:1 Viscosity (ASTM D 2393), Poises, Spindle 2, 30 rpm, 25 C ± 2 C9-20 Color Black Gel Time (AASHTO M-200-73), minutes 25-50 Elongation (ASTM D 638a), percent 45-55 Tensile Strength (ASTM D 638a), psi , min.900 Shore D Hardness (ASTM D 2240), 77 F 45-75 a Test Method Type 1, Molded Specimens, 0.25 inches thickness
1039.70.2 2 The cured polymer concrete including aggregate, which shall be supplied by the manufacturer, shall
be in accordance with the following requirements: Polymer Concrete Requirements Property Specific Value Compression strength (ASTM C 579), psi min. at 24 hours2,500 Bond Shear Strength (ASTM C 882), psi 700 Abrasion Resistance (ASTM C 501), Wear Index (Taber H-22), max.1.0 Compressive Stress (OK/OHD L-6), psi 350 Resilience (OK/OHD L-6), percent 70 6251039.70.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the manufacturer shall submit to Construction and Materials a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one-quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and a material safety data sheet. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of polymer concretes. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.
1039.70.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to
the engineer at destination certifying that the material supplied is in accordance with all requirements specified and stating that the material is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.80 METHYL METHACRYLATE (MMA) POLYMER SLURRY WEARING SURFACE.
1039.80.1 Scope. This specification covers MMA primer, polymer slurry and top coat; and broadcast aggregate
to be used for a MMA polymer slurry wearing surface.
1039.80.2 Preapproved Product. The following material has been preapproved for use under this specification:
Transpo T-18 Thin Overlay and SterlingLloyd Bridgemaster.
1039.80.3 MMA Primer. The MMA primer shall be wax-free low odor and comply with the following
requirements: Property RequirementTest Method Viscosity, cps 50 to 70 ASTM D2393 Density, lb/gal 8 to 9 ASTM D2849 Pot Life (at 70 F), minutes 10 to 30 ASTM C881 Flash Point, F, min 43 ASTM D1310 Solids Content (w/catalyst), %, min. 100 ASTM D1644
1039.80.4 MMA Polymer Slurry. The MMA polymer slurry shall comply with the following requirements:
Property Requirement Test Method Elongation at Break, percent, min. 50 ASTM D 638 (Type 1) Tensile Strength (at 75 F), psi 500 to 900 ASTM D 638 Tensile Adhesion, psi, min. 250 ASTM C 1583 Water Absorption (at 24 hr), %, max. 0.8 ASTM D 570 Volatile Content, percent, max. 3.0 ASTM D 2369
1039.80.5 Broadcast Aggregate. Aggregate shall be in accordance with Sec 1039.60 unless otherwise
specified. Unless otherwise specified, aggregate shall be light-colored (i.e. flint rock or similar).
1039.80.5 1 All aggregates shall be furnished in appropriate packaging that is clearly labeled and protects the
aggregate from any contaminates on the jobsite and from exposure to rain or other moisture.
1039.80.6 MMA Top Coat. The MMA top coat shall comply with the following requirements:
Property RequirementTest Method Viscosity, cps 200 to 400ASTM D 2393 Flash Point, F, min. 50 ASTM D 1310 626SECTION 1039.90 POLYESTER POLYMER WEARING SURFACE.
1039.90.1 Scope. This specification covers MMA primer, polyester resin binder and aggregate to be used for a
polyester polymer wearing surface.
1039.90.2 Primer. The prepared surface shall receive a wax-free low odor, high molecular weight methacrylate
prime coat complying with the following requirements: Property RequirementTest Method Viscosity (Brookfield RVT w/UL adapter, 50 rpm at 77 F), Pa-s, max. 0.025 ASTM D 2196ª Specific Gravity (at 75 F), min. 0.90 ASTM D 1475ª Volatile Content, %, max. 30 ASTM D 2369ª Flash Point, F, min. 180 ASTM D 3278ª Vapor Pressure (at 77 F), mm Hg, max. 1.0 ASTM D 323ª Tack Free Time (at 77 F), minutes, max. 400 ASTMC 679 PCC Saturated Surface-Dry Bond Strength (24 hrs at 70 F +/- 1°), psi, min. 500 California Test 551 ªTested prior to adding initiator
1039.90.2 1 Mixing Requirements. The prime coat initiator shall consist of a metal drier and peroxide. If
supplied separately from the resin, at no time shall the metal drier be mixed directly with the peroxide.
1039.90.2 2 Storage. The containers shall be stored in a manner that will not allow leakage or spillage from one
material to contact the containers or materials of the other.
1039.90.3 Aggregates. The aggregates shall comply with Sec 1005, except as specified herein.
1039.90.3 1 Crushed Particles. Aggregate retained on the No. 8 sieve shall have a maximum of 45 percent
crushed particles as determined by AASHTO T 335.
1039.90.3 2 Absorption. The aggregate absorption shall not exceed one percent as determined by AASHTO T
85.
1039.90.3 3 Moisture Content. At the time of mixing with the resin, the moisture content of the aggregate, as
determined by AASHTO T 255, shall not exceed one half of the aggregate absorption.
1039.90.3 4 Temperature. The aggregate temperature shall be between 45 F and 100 F at the time of mixing.
1039.90.3 5 Combined Gradation. Aggregate for polyester polymer concrete shall comply with the following
requirements: Sieve Size1/2” Maximum % Passing by Weight3/8” Maximum % Passing by Weight ½” 100 100 3/8” 83 – 100 100 No. 4 65 – 82 62 – 85 No. 8 45 – 64 45 – 67 No. 16 27 – 48 29 – 50 No. 30 12 – 30 16 – 36 No. 50 6 – 17 5 – 20 No. 100 0 – 7 0 – 7 No. 200 0 - 3 0 - 3
1039.90.3 6 Fine Aggregate. The fine aggregate shall consist of natural sand.
1039.90.3 7 Finishing Sand. The sand for abrasive finish shall be commercial quality blast sand having at least
95 percent passing the No. 8 sieve and at least 95 percent retained on the No. 20 sieve when tested in accordance 627with AASHTO T 27. The absorption of the sand shall not exceed 1 percent when tested in accordance with AASHTO T 84.
1039.90.4 Polyester Resin Binder. The resin shall be an unsaturated isophthalic-styrene co-polymer
conforming to the following requirements: Property Requirement Test Method Viscosity (RVT, No. 1 Spindle, 20 rpm at 77 F), Pa-s 0.075 to 0.200ASTM D 2196ª Specific Gravity (at 77 F) 1.05 to 1.10ASTM D 1475ª Elongation (Type I at 0.45 inch/minute, thickness = 1/4" +/- 0.04), %, min. (Sampling Condition)35ASTM D 18h at 77 F & 50% RH + 5h at 158 FASTM D Tensile Strength (Type I at 0.45 inch/minute, thickness = 1/4" +/- 0.04), psi, min. (Sampling Condition)2500ASTM D 18h at 77 F & 50% RH + 5h at 158 FASTM D Styrene Content (by weight), % 40 to 50ASTM D 2369ª Silane Coupler (by weight of polyester-styrene resin), %, min. 1.0 PCC Saturated Surface-Dry Bond Strength (24 hrs at 70 F +/- 1 F), psi, min.500California Test 551 ª Tested prior to adding initiator
1039.90.4 1 Silane Coupler. The silane coupler shall be an organsilane ester,
gammamethacryloxpropyltrimethoxysilane.
1039.90.4 2 Hardener. The promoter/hardeners shall be compatible with suitable methyl ethyl ketone peroxide
(MEKP) and cumene hydroperoxide (CHP) initiators. MEKP initiators shall be used when the surrounding concrete temperatures are above 60 F. A blend of initiators may be used as approved by the engineer when the surrounding concrete temperature is 50 – 60 F. 628SECTION 1040 GUARDRAIL, END TERMINALS, ONE-STRAND ACCESS RESTRAINT CABLE AND THREE- STRAND GUARD CABLE MATERIAL 1040.1 Scope. This specification covers guardrail, end terminals, one-strand access restraint cable, three-strand guard cable, and all appurtenances required for installation. 1040.2 Basis of Acceptance. The basis of acceptance will be in accordance with specification compliance and from an approved qualified plant and accepted based on certification, quality control documentation, and tests on samples required by the engineer. 1040.2.1 Sampling, Testing and Acceptance Procedures. All suppliers furnishing components for MoDOT projects shall be qualified as herein described. All components will be subject to inspection by the engineer at the source, intermediate shipping terminal, or at destination. The engineer shall be allowed unlimited access to all facilities and records as required to conduct inspection and sampling in accordance with Sec 106 unless specified below. 1040.2.2 Application for Placement on Qualified List. To become qualified, a written request shall be sent by the supplier to Construction and Materials. The request shall include a “Pre-Qualified Section 1040, 1043, and 1044 Supplier Inclusion Certificate and Guarantee Statement” and a guarantee that all material to be used in fabrication will be in accordance with MoDOT specifications and pre-approval for any source of material will be received prior to use. 1040.2.3 Maintaining Qualification. To maintain qualification, the supplier shall maintain quality control documentation. The required documentation for each shipment of material used in production shall be kept on file for three years. The supplier shall notify Construction and Materials at least 24 hours prior to each shipment. 1040.2.4 Disqualification of a Supplier. A supplier may be disqualified to provide components for use on MoDOT projects based on the discretion of Construction and Materials, for reasons including, but not limited to, not maintaining required documentation, failure of material to consistently meet specifications, falsification of any documentation, misbranding of components, unsatisfactory performance in the field, or for other reasons indicating lack of consistent material quality. 1040.2.4.1 A supplier will not be considered for reinstatement until after one year from the date of removal for falsification of documents. 1040.2.4.2 Three notices of failure to meet specification requirements within a 12-month period will be cause for disqualification of the supplier for one year, effective from the date of the third notice. 1040.2.4.3 A supplier disqualified within one year of the end of a disqualification may be subject to permanent removal, with no application for reinstatement accepted for a period of three years. 1040.2.5 Reinstatement of a Supplier. Consideration of reinstatement of a supplier once disqualified will be no sooner than specified in Sec 1040.2.4, will require a written document from the supplier stating the reasons for disqualification and the action taken to correct those deficiencies, written concurrence from Construction and Materials that the problem has been suitably addressed, and followed by an application in accordance with Sec 1040.2.2. 1040.2.6 Sampling of Material. Random sampling of the material used in production will be conducted by the engineer to verify the material is in compliance with applicable specifications. Sampling size and frequency will be at the discretion of the engineer. 1040.2.7 MoDOT Identification Number. When the supplier contacts the engineer in accordance with Sec 1040.2.3, the engineer will assign a specific MoDOT identification number for each component. A Shippers form must accompany the products to the job site. 1040.3 Posts and Blocks. The same type of posts and blocks shall be used in a given run, except as shown on the plans or as approved by the engineer. 6291040.3.1 Wood Posts and Blocks. Wood posts and blocks for guardrail and one-strand access restraint cable shall be in accordance with Sec 1050. 1040.3.2 Steel Posts, Plates and Rails. Steel posts, anchor plates, bearing plates, soil plates, plate washers and channel rail shall be structural steel in accordance with AASHTO M 270, Grade 36, shall be of the dimensions and weights shown on the plans and shall be galvanized in accordance with AASHTO M 111. Bolts, nuts and washers shall be in accordance with the dimensions shown on the plans and shall be galvanized in accordance with AASHTO M 232 (ASTM A153), Class C, or may be mechanically galvanized. If mechanically galvanized, the coating thickness, adherence and quality requirements shall be in accordance with ASTM B695, Class 55. Any dimensional defects and structural discontinuities will be cause for rejection. The material to be welded shall be preheated in accordance with good welding practice, and welds shall be full-section and sound throughout. All welds shall be mechanically cleaned before galvanizing. No punching, drilling, cutting or welding will be permitted after galvanizing. 1040.3.3 Plastic Blocks. Plastic guardrail blocks shall meet the dimensional requirements shown on the plans. The blocks shall be a homogeneous product with a uniform texture, and shall have no cracking, chipping, flaking, peeling or splintering after fabrication. The blocks shall be prepared and tested in accordance with ASTM D4329-13 Cycle C. The blocks shall be of new stock, shall meet all applicable requirements of NCHRP 350 for NCHRP 350 compliant installations or MASH 2016 for MASH 2016 complaint installations, and shall meet the approval of Construction and Materials. 1040.3.3.1 Approval. Prior to approval and use of the plastic guardrail blocks, the manufacturer shall submit to Construction and Materials, the manufacturer’s name, the product brand name or model number, a copy of the NCHRP 350 or MASH 2016 test results, a copy of the FHWA eligibility letter, an MSDS and a sample block. 1040.3.3.2 Acceptance. Acceptance of the material will be based on the manufacturer’s certification and upon the results of such tests as may be performed by the engineer. 1040.4 Steel Beam Guardrail. Guardrail beams shall be of the class and type shown on the plans. Guardrail beams shall be in accordance with AASHTO M 180, Type 1 or Type 2. 1040.4.1 Test Specimens. Test specimens for mechanical properties, irrespective of the galvanization method, shall be prepared and tested in accordance with ASTM A653. 1040.4.2 End Sections. End sections and terminal connectors shall be of a class and type the same as or superior to that used for the beam to which the end sections and terminal connectors are attached. The physical properties shall be in accordance with AASHTO M 180. 1040.4.3 Fabrication. The beams, end sections and terminal connectors shall be shaped and punched as shown on the plans and ready for assembly when delivered. Only drilling or cutting necessary for special connections and for sampling will be permitted in the field. Warped or deformed beams will be rejected. Beams to be erected on a radius of 150 feet or less shall be shop curved to the approximate curvature of the installation. 1040.4.4 Markings. 1040.4.4.1 Beams. Beam markings shall be in accordance with AASHTO M 180, except the AASHTO specification number may be omitted if another designation for Class and Type is used. 1040.4.4.2 Transition Sections and Terminal Connectors. Transition sections and terminal connectors shall be marked in accordance with Sec 1040.4.4.1, except as follows. Durable tags securely attached to each section or connector may be used. If the transition section or terminal connector is Class B, the Class indicator will not be required. If the transition section or terminal connector is Type 2, the Type indicator will not be required. Heat numbers and coating designations will not be required. 1040.4.4.3 End Sections. No markings or tags will be required for end sections. 1040.4.4.4 Posts. Posts shall be marked such that the marking is exposed after installation, in such a manner as to indicate the manufacturer. 6301040.4.5 Brand Registration and Guarantee. The manufacturer shall submit a brand registration and guarantee, and current test results indicating compliance with this specification prior to delivery of any material. Once the brand registration and guarantee is approved, the manufacturer’s name will be added to the qualified list of guardrail fabricators. For Type I coated material, the brand registration and guarantee shall certify the material as being produced by the continuous galvanizing method. 1040.4.6 Acceptance. Acceptance will be by brand registration and guarantee, and any sampling deemed necessary by the engineer. The contractor or supplier shall provide equipment and personnel required to obtain samples as directed by the engineer. 1040.5 Crashworthy End Terminals. 1040.5.1 Material. Only new material shall be used in the fabrication of end terminals. The major items of the installations shall be the best standard products of a manufacturer regularly engaged in the production of that type of end terminal and shall be of the manufacturer's latest approved design. After installation, the end terminal shall redirect traffic face side vehicle impacts within the prescribed performance crash test criteria ranges. 1040.5.2 Manufacture’s Approval. Prior to approval and use of a end terminal, the manufacturer shall submit to MoDOT the manufacturer’s name, the product brand name or model number, a copy of the MASH 2016 test results, a copy of the FHWA eligibility letter, and shop drawings. 1040.5.3 Acceptance. Acceptance of the material will be based on the manufacturer’s certification and upon satisfactory field performance. 1040.5.4 Contractor’s Certification. Prior to installation, the contractor shall furnish to the engineer a manufacturer's certification that the units furnished are identical in material and design to successfully tested units. 1040.6 End Anchors, Bridge Anchors, and Approach Transitions. 1040.6.1 Steel Tube and Tube Block. Steel tubes for end anchors shall consist of structural steel tubing in accordance with ASTM A500, Grade B, or ASTM A501 and shall be galvanized in accordance with AASHTO M 111. Structural steel tubing blocks for guardrail shall consist of steel tubing in accordance with ASTM A500, Grade B, and shall be galvanized in accordance with AASHTO M 111. 1040.6.2 Cable. Cable shall be 3/4 inch in diameter, Type II, Class A in accordance with AASHTO M 30. 1040.6.3 Transition Cap Rail. The transition cap rail shall be in accordance with AASHTO M 270, Grade 36. 1040.6.4 Thrie Beam Rail and Transition Section. The thrie beam rail and transition section shall be galvanized in accordance with AASHTO M 180, Type 2. 1040.6.5 Approval. The cable assembly and anchor plate will be subject to approval by the engineer and shall have a minimum breaking strength of 20 tons. 1040.6.6 Markings. Thrie beam rail and transition sections shall be marked in accordance with Sec 1040.4.4. 1040.7 Cable and Fittings. 1040.7.1 One-Strand Access Restraint Cable. 1040.7.1.1 Cable. Cable shall be zinc-coated steel wire strand; 1/2-inch diameter; seven wire strand; Common, Siemens-Martin or High Strength grade; Class A coating; and shall be in accordance with ASTM A475. 1040.7.1.2 Hardware. Eyebolts, turnbuckles and clips for cable connections and end anchors shall be steel forgings in accordance with AASHTO M 102 or pearlitic malleable iron in accordance with ASTM A 220. All miscellaneous parts, comprising of cable connections, fasteners and end anchors, shall be galvanized in accordance with AASHTO M 232. 6311040.7.2 Three-Strand Guard Cable. 1040.7.2.1 Cable and Connecting Hardware. The cable and connecting hardware shall be in accordance with AASHTO M 30 and AASHTO M 269. The wire rope shall be Type 1, 3/4-inch diameter, 3 by 7 construction with a Class A coating. The rope, with connecting hardware, shall develop the breaking strength of a 25,000- pound single cable. Connecting hardware shall be galvanized in accordance with AASHTO M 232 or may be mechanically galvanized. If mechanically galvanized, the coating, thickness, adherence and quality requirements shall be in accordance with AASHTO M 232, Class C. Cast Steel components shall be in accordance with AASHTO M 103, Grade 70-40, Class 1. Malleable iron castings shall be in accordance with ASTM A47. Compensating devices shall have a spring constant of 0.46 psi, plus or minus 0.06 pound per inch, and permit 6 inches of travel, plus or minus one inch. All threaded parts on compensating cable end assemblies shall be in accordance with ASTM F568, Class 4.6, 3/4-10 threads. Socket baskets shall be designed for use with the cable anchor wedge as shown on the plans. Guard cable anchor brackets shall be manufactured from an AASHTO M 270, Grade 250 steel plate, and zinc-coated in accordance with AASHTO M 111. Dimensional tolerances not shown on the plans shall be consistent with the proper functioning of the part, including the part’s appearance and accepted manufacturing process. 1040.7.2.2 Cable Brackets. Steel used in the fabrication of the bracket shall be in accordance with ASTM A36. The bracket shall be galvanized after fabrication in accordance with AASHTO M 111. All fittings, including splices, shall be designed to use the wedge detail, and shall be of such section as to develop the full strength of the 3/4-inch, 25,000-pound round cable. Designs for a combination or single-unit compensating device and turnbuckle assembly shall be submitted for approval. Compensating devices shall have a spring rate of 0.46 ± 0.03 pound per inch, and shall permit 6 inches ± one inch of travel. All parts, except cable wedge, shall be hot- dip zinc coated in accordance with AASHTO M 232 or AASHTO M 298. 1040.7.2.3 Hook Bolts, Hex Bolts, Nuts and Washers. Hook bolts, hex bolts and washers shall be in accordance with ASTM A307. Cable hook nuts shall be 5/16-18 threads and in accordance with ASTM A563. Hook bolts, as installed, shall develop an ultimate pull open strength of 450 to 1,000 pounds applied in a direction normal to the axis of the post. Hooked anchor studs shall be in accordance with AASHTO M 314, except the threads and nominal diameter shall be 3/4-10 and in accordance with ASTM F568, Class 4.6. All items shall be galvanized in accordance with AASHTO M 232 or may be mechanically galvanized in accordance with AASHTO M 232, Class C. 1040.8 Certification. The contractor shall furnish the manufacturer’s certification for all material governed by this specification. Specifically, each certification shall indicate compliance with the requirements of each applicable section and as set forth in Table I. 1040.9 Repair of Galvanizing. Galvanized material shall be handled in a manner to avoid damage to the surface. No field punching, drilling, cutting or welding will be permitted after galvanizing. Any galvanized material on which the spelter coating has been damaged will be rejected or may be repaired in accordance with Sec 1081, with approval from the engineer. Table I - Certification Requirements Item Galvanizing Standard Steel Grade Other Wood Post and Blocks - - a Steel Posts, Plates and Brackets AASHTO M 111 AASHTO M 270, Grade 36 b Plastic Blocks - - g Guardrail Beam Sec 1040.4 Sec 1040.4 b, c Bolts, Nuts and Washers AASHTO M 232 ASTM A307 End Terminals Systems - - f End Anchors - Tubes - Transition Cap RailAASHTO M 111 AASHTO M 111ASTM A500/ASTM A501 AASHTO M 270, Grade 36b b One-Strand Access Restraint Cable - Cable - HardwareAASHTO M 30 AASHTO M 232AASHTO M 30 AASHTO M 102/ ASTM A220b b 632Three Strand Guard Cable - Cable - Hardware - Cast Steel Components - Malleable Iron Castings - Anchor Brackets - Cable Brackets - Hook and Hex Bolts - Hook Nuts - Hooked Anchor StudsAASHTO M30 AASHTO M 232 AASHTO M 232 AASHTO M 232 AASHTO M 111 AASHTO M 111 AASHTO M 232 AASHTO M 232 AASHTO M 232AASHTO M 30 & AASHTO M 269 AASHTO M 102/ASTM A220 AASHTO M 103 ASTM A47 AASHTO M 270 AASHTO M 270, Grade 36 ASTM A307 ASTM A563 AASHTO M 314b d d e d
a.Certification shall state that the material is in accordance with Sec 1050 and shall include a listing of the material supplied and a certified test report as detailed in Section 7.2 of AWPA, Standard M2, attesting to complete compliance with this specification.
b.Certification shall include, or have attached, specific results of laboratory tests for physical and chemical properties from samples representative of the material.
c.Shall have Brand Registration and Guarantee on file, including certification indicating the coating is either Type 1 by Continuous Galvanizing Method or Type 2.
d.All threaded parts of compensating cable end assemblies and hooked anchor studs shall be in accordance with ASTM F568.
e.All fittings for cable bracket, except the cable wedge, shall be in accordance with AASHTO M 232 or AASHTO M 298.
f.Certification shall state the name of the manufacturer and that the units furnished are identical in material and design as those tested for performance in accordance with Sec 606.30.
g.Certification shall state that the materials furnished are identical in chemistry, mechanical properties and geometry as those that passed the NCHRP 350 crash test, and as those that were approved by the Missouri Department of Transportation. 633SECTION 1041 POLYPROPYLENE CULVERT PIPE 1041.1 Scope. This specification covers polypropylene culvert pipe intended for use in the construction of culverts, sewers and similar uses. 1041.2 Basis of Acceptance. Acceptance of polypropylene culvert pipe will be based upon the pipe being in accordance with this specification. Pipe shall be provided from an approved manufacturer, and will be accepted based on certification, identification markings and results from tests required by the engineer. 1041.3 Material. All polypropylene culvert pipe, couplings and fittings shall be in accordance with ASTM F 2736 for double wall and ASTM F 2764 for triple wall, except as follows. 1041.3.1 Section properties shall be within the following limits: Minimum Maximum Nominal Size S (in.)Effective Pipe Wall Area Ae f f (in.2/in.)Pipe Wall Centroid to Inside Face yc (in.)Pipe Wall Moment of Inertia I (in.4/in.)Area Ratioa Aeff / AgExtreme Fiber Ratiob yc / cInside Diameter Di (in.)Outside Diameter Do (in.) Double Wall12 0.168 0.445 0.0314 0.8030.586 11.97 14.65 15 0.216 0.537 0.0538 0.8210.687 14.85 17.81 18 0.217 0.569 0.0747 0.7770.549 17.82 21.42 24 0.241 0.710 0.1318 0.7230.558 23.85 28.34 30 0.248 0.882 0.2732 0.6610.475 29.70 35.81 Triple Wall30 0.324 1.107 0.4416 0.6760.681 29.70 35.81 36 0.315 1.363 0.4808 0.6531.000 35.39 41.62 42 0.452 1.208 0.5554 0.8170.797 41.38 47.72 48 0.348 1.535 0.9460 0.5420.980 46.92 54.14 60 0.541 1.627 1.2088 0.7390.812 58.65 67.17 a Ag equals gross area of pipe wall per unit length of pipe (in2/in.). b c equals the distance from the pipe wall centroid to the outermost fiber (in.). 1041.3.2 The pipe shall not be perforated unless otherwise specified. 1041.3.3 Field joints of polypropylene pipe shall provide circumferential and longitudinal strength to maintain the pipe alignment, prevent separation of pipe and prevent infiltration of fill material. Coupling bands, if used, shall be of the same base material as the pipe. Prior to use, the design of coupling bands and fastening devices shall be submitted to and approved by Construction and Materials. Final acceptance of coupling bands and fastening devices will be based on field performance. 1041.3.4 The manufacturer shall provide to the engineer an itemized statement of the sizes, section properties and lengths of pipe in each shipment. 1041.4 Sampling, Testing and Acceptance Procedures. Manufacturers furnishing pipe to MoDOT projects shall be qualified as herein described. All pipe will be subject to inspection by the engineer at the source of manufacture, at an intermediate shipping terminal or at the destination. The engineer shall be permitted free access to all facilities and records as required to conduct inspection and sampling in accordance with Sec 106. 1041.4.1 Application for Placement on Qualified List. To become qualified, a written request shall be sent by the manufacturer to Construction and Materials with the following:
a.A QC plan for each plant from which pipe is to be fabricated for use on MoDOT projects. The QC plan shall be in accordance with Sec 1041.4.2, and shall provide that pipes be randomly selected for 634test by an independent testing laboratory, and that randomly selected pipes are representative of that manufacturer's pipe.
b.A statement certifying that the quality control procedures at the plant, at a minimum, meet the requirements set forth in the manufacturer’s QC plan.
c.Sources for each material to be used in the fabrication of pipe.
d.Certification that all pipe material to be used in the fabrication of pipe will be in accordance with MoDOT specifications.
e.Units of measurement, English or metric, used to fabricate the pipe. 1041.4.2 Manufacturer’s QC Plans. The QC plan for each plant shall include the following:
a.A list of personnel with corresponding authority and responsibility.
b.Qualifications of QC personnel, to include training received or to be given.
c.A description of how the manufacturer proposes to control production in order to assure all material and workmanship incorporated into the fabrication of pipe meets the applicable specification requirements.
d.The specific tests to be performed during or after production, frequency of these tests, the point where samples or inspections will be obtained or performed, and the format for recording test data. 1041.4.3 Maintaining Qualification. To maintain qualification, the manufacturer shall perform and maintain a QC program in accordance with the manufacturer’s QC plan approved by Construction and Materials. The manufacturer shall conduct tests and inspection to verify that adequate QC is maintained, and that the pipe furnished is in accordance with these specifications. The manufacturer shall maintain for three years a record of all test results and inspections for review by the engineer. The records shall show that each shipment of pipe has been inspected by the plant’s QC personnel. The record shall indicate the purchase order number or the project number, the route, county and date of inspection. The manufacturer shall notify Construction and Materials at least 24 hours prior to each shipment of pipe to a MoDOT project. Additional pipe may be considered part of the original shipment when the ordered quantity was underestimated or material was lost or damaged. A bill of lading in accordance with Sec 1041.6 shall be provided for each shipment of pipe. Each plant shall maintain a current list of QC personnel with corresponding authority and responsibility. All training given to QC personnel shall be documented with a brief description of the training and shall be kept on file at the plant. 1041.4.4 Disqualification of a Manufacturer. A manufacturer may be disqualified from providing pipe for use on MoDOT projects based on the discretion of Construction and Materials, for reasons including, but not limited to, failure of material to consistently meet specifications, falsification of any documentation, misbranding of the pipe, unsatisfactory performance in the field or for other reasons indicating lack of consistent material quality. 1041.4.4.1 A manufacturer will not be considered for reinstatement until after one year from the date of removal for falsification of documents. 1041.4.4.2 Three notices of failure to meet specification requirements within a 12-month period will be cause for disqualification of the manufacturer for one year, effective from the date of the third notice. 1041.4.4.3 A plant disqualified twice for any reason in any two-year period will be subject for permanent removal, with a minimal suspension of three years. 1041.4.5 Reinstatement of a Manufacturer or Plant. Consideration of reinstatement of a manufacturer once disqualified will be no sooner than specified in Sec 1041.4.4, will require a written document from the manufacturer stating the reasons for disqualification and the action taken to correct those deficiencies, written concurrence from Construction and Materials that the problem has been suitably addressed, followed by an application in accordance with Sec 1041.4.1. 6351041.4.6 Sampling of Material. Random sampling of the pipe will be conducted by the engineer to verify if the pipe and material are in accordance with these specifications. Samples of polypropylene pipe will be obtained from fabricated culvert sections in accordance with ASTM F 2736 or ASTM F 2764 at a frequency determined by the engineer. 1041.4.7 Inspection. Inspection will include an examination of the pipe for markings, deficiency in specified diameter, net length of fabricated pipe and any evidence of poor workmanship. The inspection may include taking samples. 1041.4.8 Testing. Specimen testing size and method of tests shall be in accordance with ASTM F 2736 or ASTM F 2764. The contractor or manufacturer shall provide the equipment and personnel to cut a sample from a section of pipe. The sample shall include the markings or a record of the markings for that section of pipe. 1041.4.9 Unacceptable Material. 1041.4.9.1 Any individual section of pipe failing to meet the marking, diameter, length or workmanship requirements of these specifications will be unacceptable. If 10 percent of the pipe in any lot fails to meet these requirements, the entire shipment of that pipe size may be rejected. 1041.4.9.2 If a test specimen taken in accordance with Sec 1041.4.8 fails to meet the requirements of ASTM F 2736 or ASTM F 2764, the pipe sampled will be rejected and the lot will be resampled. A resample will be of the same size as the original sample. The resample shall be in accordance with these specifications, or the entire shipment will be rejected. 1041.5 MoDOT Identification Number. When the manufacturer contacts the engineer in accordance with Sec 1041.4.3, the engineer will assign a specific MoDOT identification number for each size of pipe in the shipment. 1041.6 Bill of Lading. A bill of lading or delivery receipt for each shipment of pipe shall be furnished to the engineer at the shipping and destination points. The bill of lading shall contain an itemized statement of the sizes and lengths of pipe with the corresponding designated MoDOT identification number provided to the manufacturer for each size of pipe for that shipment. The bill of lading shall contain a certified statement. The certified statement shall be signed by an authorized representative of the manufacturer and shall state the following: “This certifies that the pipe and bands in this shipment are in accordance with MoDOT specifications and were fabricated at an approved plant.” 636SECTION 1042 HIGHWAY SIGN MATERIAL 1042.1 Scope. This specification covers the material used in signs and fastening devices, and the fabrication of signs. 1042.2 Material. Material shall be of new stock and shall be in accordance with the following, unless otherwise shown on the plans. 1042.2.1 Signs. Item Specification Aluminum Flat Sheets ASTM B 209, 6061-T6 or 5052-H38 Aluminum Extruded Sign PanelsASTM B221, 6063-T6 1042.2.2 Sign Appurtenances. Item Specification Aluminum Post Clip ASTM B 108, 356-T6 Aluminum Bolts ASTM B 211, 2024-T4 or 6061-T6 Aluminum NutsASTM B 211, 2024-T4, 6061-T6, 6262-T9 or 2017-T4 Aluminum Flat WashersASTM B 209, or Alclad 2024-T4 or 2024-T4 Aluminum Lock Washers ASTM B 211, 7075-T6 Aluminum Lock Nuts (Nylon Insert)ASTM B 211, 2017-T4 Aluminum Edge Molding ASTM B 221,6063-T6 Stainless Steel Bolts, Nuts, Screws and WashersASTM A 320 or SAE J405D, Austenitic Steel, Min. Yield 30,000 psi 1042.2.3 Certification. A manufacturer or supplier's Certification of Metal used for signing material listed above shall be furnished to the engineer at the fabrication plant at the time of material inspection. The contractor shall furnish to the engineer the fabricator's certification in accordance with Sec 903.3.5.2. 1042.2.4 Structural Signs. Structural signs shall be fabricated of 0.081-inch minimum extruded aluminum panels and mounted as shown on the plans. The maximum allowable deviation from flatness shall not exceed 0.010 inch per inch width of the panel. Shop drawings for approval from the engineer will be required for any variation in the assembly or mounting details. 1042.2.5 Sheet Signs. Flat sheet signs shall be fabricated as shown on the plans from sheet aluminum of the specified thickness. Flat sheet signs shall not have holes except those drilled or punched for proper mounting. 1042.2.6 Washers. Nylon washers recommended by the sign sheeting manufacturer shall be used between the bolt heads and sign faces on flat sheet aluminum signs. The washers shall be for use with 3/8-inch bolts and shall have a minimum outside diameter of 3/4 inch, and a nominal thickness of 1/16 inch. 1042.2.7 Retroreflective Sheeting. Retroreflective sheeting shall be in accordance with latest versions or ASTM D 4956 and AASHTO M 268, except as noted herein. Color and luminance values for all MoDOT types of reflective sheeting shall be in accordance with ASTM D 4956. Retroreflective sheeting shall have sufficient adhesion, strength and flexibility such that the sheeting can be handled, processed and applied according to the manufacturer's recommendations without appreciable stretching, tearing, cracking or other damage. Adhesive performance for retroreflective sheeting shall be in accordance with ASTM D 4956. The sheeting surface shall be in condition to be readily screen processed and compatible with transparent overlay films, plus recommended transparent and opaque screen process colors. The retroreflective sheeting manufacturer shall furnish information as to the type of solvent or solvents that may be used to clean the surface of the sheeting without 637detrimental loss of performance and durability. Retroreflective sheeting having a datum mark on the surface shall be oriented vertically. ASTM D 4956 Type IX, XI or AASHTO M 268 Type C or D retroreflective sheeting applied as legend and border for specific signing applications, without a datum mark on the surface of the sheeting, shall be evaluated for rotational sensitivity per AASHTO M 268, Section 3.3. Retroreflective sheeting products that do not meet the rotational sensitivity requirements of Section 3.3 shall follow guidelines detailed in AASHTO M 268 Section 3.3.1 and fabricated per AASHTO M 268 Section 3.3.2. 1042.2.7.1 ASTM D 4956 Type I, Class 1 retroreflective sheeting shall be enclosed lens glass-bead or prismatic sheeting. 1042.2.7.2 Sign Sheeting. Background sheeting applied to flat sheet and extruded panel signs shall be in accordance with ASTM D 4956 Type IV, Class 1. All yellow, orange and yellow green sheeted signs shall be fabricated with ASTM D 4956 Type IX, XI or AASHTO M 268 Type C or D fluorescent yellow, fluorescent orange and fluorescent yellow green sheeting respectively. Retroreflective sheeting shall be high intensity that is an unmetallized micro prismatic reflective material. 1042.2.7.3 Channelizers. All reflective sheeting for channelizers and drum-like channelizers shall be in accordance with ASTM D 4956 Type IX or XI for fluorescent orange sheeting and in accordance with ASTM D 4956 Type IV for orange or white sheeting. All retroreflective marking on channelizers shall be in accordance with ASTM D 4956, Supplemental Requirements, and Section S2. Reflective sheeting applied to channelizers shall be reboundable in accordance with ASTM D 4956. Retroreflective marking on cones will not be required. 1042.2.7.4 Advanced Warning Rails. All reflective sheeting for advanced warning rails shall be in accordance with ASTM D 4956 Type IV. 1042.2.7.5 Delineators. All retroreflective sheeting for delineators shall be in accordance with ASTM D 4956 Type IX or XI requirements, except permanent and temporary tubular delineators, which shall be ASTM D 4956 Type IV requirements. All permanent and temporary tubular delineators’ reflective sheeting shall be reboundable in accordance with ASTM D 4956. 1042.2.7.6 Retroreflective sheeting applied as legend and border shall be in accordance with ASTM D 4956, Type IX, XI or AASHTO Type C or D, Class 1.Retroreflective sheeting shall be an unmetallized cube corner microprismatic reflective material. 1042.2.7.7 Screen Print and Overlay. For screen printed transparent colored areas or transparent colored overlay films on white sheeting, the coefficient of retroreflection (RA) shall be no less than 70 percent of the original values for the corresponding color. 1042.2.8 Outdoor Exposure. Retroreflective sheeting, except for work zone signs, shall be submitted by the manufacturer to NTPEP for two years of 45-degree south-facing outdoor exposure. Retroreflective sheeting for work zone signs shall be submitted by the manufacturer to NTPEP for an exposure time of one year. Results shall be published by NTPEP and available for MoDOT review. For all NTPEP test decks, retroreflective sheeting shall have a coefficient of retroreflection at least 50 percent of the specified value for ASTM D 4956 Type I or 80 percent of the original reading for ASTM D 4956 Type IV, IX or XI. 1042.2.9 Manufacturer and Brand Name Approval. The manufacturer shall make available, upon request, NTPEP test results from all test decks, and certification to Construction and Materials, showing reflective material is in accordance with ASTM D 4956 specification. In addition, the manufacture shall, upon request, submit samples representing the retroreflective sheeting tested by NTPEP, and with compatible inks. These samples shall be accompanied by a product data sheet, an MSDS, technical bulletins on sign fabrication and any special fabrication instructions relative to the retroreflective sheeting submitted. Samples of retroreflective sheeting shall 10 x 10 inches and applied to an aluminum substrate. 1042.2.9.1 Materials that fail to provide satisfactory field performance will be evaluated and may be disqualified from future use on fabricated signs for MoDOT. All corrective actions made by MoDOT will control. 1042.2.10 Type of Characters. Letters, numerals, arrows, symbols, borders and other features of the sign message shall be of the type, size and series shown on the plans or as specified by the engineer. Completed letters, numerals and other units shall be formed to provide a continuous stroke width with smooth edges, and 638shall yield a flat surface free of air bubbles, wrinkles or other blemishes as determined by the engineer. Units of the sign message shown on the plans shall meet the requirements for the specified type. 1042.2.10.1 Screen Print, Transparent Overlay and Opaque Black Film. 1042.2.10.1.1 The letters, numerals, arrows, symbols and borders shall be applied to the background of the sign by the direct or reverse screen process. Messages and borders of a color darker than the sign field shall be applied to the retroreflective sheeting by the direct process. Messages and borders of a color lighter than the sign field shall be produced by the reverse screen process. Inks used in the silkscreen process shall be of the type to produce the desired color and durability when applied on retroreflective sheeting. Silkscreen inks shall be used in accordance with the manufacturer's recommendations. The ink shall produce the desired color when applied on retroreflective sheeting background and shall dry to a good film without running, streaking or sagging. The screening shall be done in a manner that results in a uniform color and tone, with sharply defined edges of legend and border without blemishes on the sign field that will affect the intended use. Signs after screening shall be dried in accordance with the manufacturer's recommendations to provide a smooth hard finish. Any signs on which blisters appear during the drying process will be rejected. 1042.2.10.1.2 Transparent overlay films may be used as a replacement for the reverse screen process, as recommended by the sheeting manufacturer. 1042.2.10.2 Direct Applied Characters. The letters, numerals, symbols, borders and other features of the sign message shall be cut from the color and type of sheeting shown on the plans, and applied to the sign field in accordance with the sheeting manufacturer’s recommendations. 1042.2.10.3 Allowable Variations. The design height of rounded letters or numerals shall be 1/64 inch of height greater than normal height, both on top and bottom of letter or numeral, where rounded. The loop portion of letters such as f, g and y, shall conform to the dimensions shown on the plans with the allowable tolerance. The following variations in dimensions of letters and numerals, regardless of character type, will be acceptable with all measurements made to the nearest 1/8 inch. Allowable Variation Nominal Height, inchesVariation in Height, inchesVariation in Width, inches 4 thru 12 -1/8 to +3/8 -1/4 to +1/4 Over 12 -1/8 to +3/8 -3/8 to +3/8 1042.3 Sign Fabrication. A sign shall consist of aluminum flat sheets or extruded panels retroreflectorized on the face side with all letters, numerals, symbols, borders, corners and route shields mounted on the face, and shall include all necessary mounting devices shown on the plans. Signs equal to or greater in width than six feet are considered structural (ST) and shall be fabricated on extruded panels. Signs less than six feet in width will be considered sheet (SH) signs and shall be fabricated with flat sheet. Any exceptions to these fabrication standards will be indicated on the plans. 1042.3.1 All signs shall be of the highest quality with consistent daytime and nighttime color and retroreflectivity throughout the sign and produced as follows. 1042.3.1.1 Except as otherwise allowed for extruded aluminum panels in Sec 1042.3.1.2, all aluminum substrate shall be given a chromate conversion coating in accordance with ASTM B 449, Class 2, or ASTM B 921, Class 2, and shall be prepared by one of the Treatment Sequence Options described in ASTM B 449, Appendix X2 or ASTM B 921. The chemicals and solvents shall be applied in strict accordance with the manufacturer’s recommendations. Sufficient laboratory facilities to test and control the concentration of the solutions used shall be maintained at the treating plant. A log of the concentration of treating solutions shall be maintained. Treated panels shall be handled in such a manner as to prevent contamination. Panels shall be stored in a dry, clean area free from dust, acid fumes or vapors. When aluminum is shipped to a secondary location for retroreflectorizing, adequate precautions shall be taken to ensure that the material arrives at the destination uncontaminated. 1042.3.1.2 In lieu of chromate conversion coating, sign sheeting may be applied to extruded aluminum panels in an untreated bare aluminum state if allowed by the sheeting manufacturer. The fabricator shall provide 639certification that the application process is approved by the manufacturer and does not void the sheeting warranty. The sheeting manufacturer shall be identified in the certification. 1042.3.1.3 All materials used to fabricate a sign legend, including retroreflective and non-retroreflective sheeting, used for background, letters, numerals, arrows, symbols, borders and other features of the sign message shall be from a single manufacturer. 1042.3.1.4 Retroreflective sheeting splices on structural signs shall be kept to a minimum. Rolled overlap splices in accordance with the sheeting manufacturer’s recommendations may be used, with no more than one allowed per panel. Retroreflective sheeting shall be placed on the individual extruded panels in accordance with the manufacturer’s recommendations. The sign panels may be clear coated or edge sealed after application of the retroreflective sheeting, if recommended by the sheeting manufacturer. If edge sealer is used, the sealer shall be applied to all splices and edges. The completed sign shall have good color matching of retroreflective sheeting and shall be free from air bubbles, wrinkles or other blemishes. 1042.3.1.5 Retroreflective sheeting applied to standard flat sheet signs shall not have splices on signs where the smallest dimension is less than 4 feet. One vertical overlap splice approximately 1/4 inch wide will be allowed on standard flat sheet signs where the smallest dimension is greater than 4 feet. Any special flat sheet signs requiring splicing other than noted for the standard flat sheet signs shall be as approved by the engineer. The sign panels may be clear coated or edge sealed after application of the retroreflective sheeting if recommended by the sheeting manufacturer. If clear finish is used, the finish shall be applied after screening of messages and borders. If edge sealer is used, the sealer shall be applied to all splices and edges. The completed sign face shall be free from air bubbles, wrinkles or other blemishes. 1042.3.2 Nuts on panel bolts used to connect extruded panels together to form a structural sign shall be torqued to 220 - 230 inch-pounds. 1042.3.3 Signs will be accepted on certification from the manufacture assuring all fabrication and sheeting specifications are in compliance with all applicable requirements specified herein. Periodic shop inspections of sign fabrication will be made at the discretion of MoDOT, to include contractor furnished signs for MoDOT projects. Routine shop inspections will include inspection and sampling of materials, inspection of treatment and fabrication processes, and of any signs completed at time of inspection. Inspections on delivered signs for maintenance operations will be conducted for quality assurance purposes by the appropriate district inspectors. Signs may be rejected at the fabrication shop and/or upon delivery based on unsatisfactory workmanship and/or material applications or based on any aspect of the product that is not in accordance with the specifications. The contractor will be charged with the transportation costs of sign inspectors for trips from Jefferson City, Missouri to which the inspectors must travel for signs provided to MoDOT projects. Transportation costs will be deducted by the Commission from monies due the contractor. 1042.3.4 Signs shall be packaged and shipped according to the reflective sheeting manufacture’s recommendations. Signs fabricated and shipped to MoDOT for maintenance operations shall be shipped in accordance with manufacture’s recommendations and in a manner that meets the requirements of the engineer. All signs shall include decals indicating sign production date, lot number of reflective sheeting used in the production of sign and other information necessary for proper sign fabrication. Upon shipment of signs to MoDOT, certifications shall be submitted thereafter to Construction and Materials. Required paperwork shall include a certification statement indicating signs meet all applicable requirements herein to include aluminum standard and extruded panel, reflective sheeting (manufacturer, series and color), and hardware certifications. Material quantities, such as square foot of flat sheet, extruded panels, if produced, reflective sheeting and a shipping list of all signs shall be included in the certification packet. 640SECTION 1043 FENCE MATERIAL 1043.1 Scope. This specification covers the material required in the construction of chain-link fence and woven wire fence. 1043.2 Basis of Acceptance. The basis of acceptance shall be in accordance with Sec 1040.2. 1043.3 Chain Link Fence Material. Material used in the construction of fences and gates shall consist of chain-link fence fabric, posts, rails, ties, bands, bars, rods, tension wire and other fittings and hardware designed to support the fabric in a vertical, taut position. 1043.3.1 Zinc Coated Steel Fabric. Zinc coated steel fabric shall be in accordance with AASHTO M 181, Type 1, Class D, with the following exceptions. The weight of zinc coating shall be at least 2.0 ounces per square foot of uncoated wire surface, determined from the average of all specimens representing the lot and no less than 1.8 ounces per square foot on an individual specimen. Sections of fencing with excessive lumps, beads and drops of zinc will be removed before determining weight of coating. 1043.3.2 Aluminum Coated Steel Fabric. Aluminum coated steel fabric shall be in accordance with AASHTO M 181, Type 2, with the following exceptions. An individual specimen shall have at least 0.30 ounce per square foot of uncoated wire surface on 0.148 or 0.192-inch specified diameter wire and no less than 0.25 ounce per square foot on 0.120-inch specified diameter wire. 1043.3.3 Vinyl Coated Steel Fabric. Vinyl coated steel fabric shall be in accordance with AASHTO M 181, Type IV, Class A or Class B. In addition to the referenced colors, brown will also be acceptable. 1043.3.4 Aluminum Alloy Fabric. Aluminum alloy fabric shall be in accordance with AASHTO M 181, Type III. 1043.3.5 Posts, Braces, Rails and Gate Frames. These members shall be in accordance with AASHTO M 181, Grade 1 or Grade 2, and of the shape and dimension shown on the plans. These members may be used with either Type I, Type II, Type III or Type IV fabric. 1043.3.5.1 Zinc Coated Steel Members. Zinc coated steel members shall be in accordance with ASTM F 1043, heavy industrial fence Group IA, with Type A interior and exterior coating, and the plans. 1043.3.5.2 Zinc Plus Organic Coated Steel Members. Zinc plus organic coated steel members shall be in accordance with ASTM F 1043, heavy industrial fence Group IC, with Type B or D interior coating and Type B exterior coating, and the plans. 1043.3.5.3 Aluminum Alloy Members. Aluminum alloy members shall be in accordance with ASTM F 1043, heavy industrial fence Group IB, and the plans. 1043.3.6 Tension Wire. Tension wire shall be in accordance with AASHTO M 181 Type I, Class I. 1043.3.7 Fabric Fasteners. Fabric fasteners shall consist of wire ties, hog rings and C-clips. Fasteners for use with zinc or aluminum coated steel fabric shall be in accordance with Sec 1043.3.7.1 or Sec 1043.3.7.2; those for use with aluminum alloy fabric shall be in accordance with Sec 1043.3.7.2; and those for use with vinyl coated steel fabric shall be in accordance with Sec 1043.3.7.3. Fasteners shall be capable of withstanding a 180- degree bend over the fasteners own diameter without fracture of the wire or loss of adherence of coating. The wire shall have a finished or coated diameter of no less than 0.143 inch, except C-clips for attaching fabric to H section posts shall have a finished or coated diameter of no less than 0.187 inch. Aluminum alloy C-clips will not be permitted for fastening fabric to H section posts. 1043.3.7.1 Zinc or Aluminum Coated Fabric Fasteners. Wire shall be zinc coated at a rate of no less than 0.70 ounce per square foot or aluminum coated at a rate of no less than 0.30 ounce per square foot. 1043.3.7.2 Aluminum Alloy Fabric Fasteners. Wire shall be of aluminum alloy having a minimum tensile strength of 16,000 psi. 6411043.3.7.3 Vinyl Coated Fabric Fasteners. Wire may be of steel or aluminum alloy and shall be uniformly coated with the same vinyl material as used to coat the fence fabric. Vinyl coating thickness shall be a minimum of 0.010 inch. Aluminum alloy wire shall have a minimum tensile strength of 16,000 psi. 1043.3.8 Miscellaneous Fittings and Hardware. Miscellaneous fittings and hardware shall be in accordance with AASHTO M 181. Aluminum alloy fittings shall not be used with zinc coated steel posts, rails or gate frames. 1043.3.9 Gates. Frames shall be fastened at the corners by clamps and braces, or by welding. If corners are to be welded, the ends of the vertical members shall be hemispherically notched to fit snugly to the horizontal members. The joint shall be uniformly and continuously fillet welded. The welded area and adjacent damaged coating shall be recoated by the hot-dip process or metallizing process; or covered with two coats of zinc-rich paint. The material for repair of welded areas and applications shall meet the approval of the engineer. Each gate frame shall be cross-braced with no less than two 3/8-inch adjustable truss rods. The filler for gates shall be chain-link fabric of the same kind used for the fence. This filler shall be attached to the frame with stretcher bars and wire ties or clamps. Gates 6 feet high or less shall be equipped with two hinges, and gates more than 6 feet high shall have three hinges. All gates, walks and drives, shall be equipped with a latch and locking attachment. Gatekeepers and center rests of an approved design shall be installed for double drive gates. 1043.3.10 Barbed Wire. Barbed wire for use with chain-link fence shall be zinc-coated steel, aluminum-coated steel or aluminum alloy, and shall be in accordance with AASHT0 M 280, with the following exceptions. Zinc- coated barbed wire shall consist of two No. 12 1/2, 13 1/2 or 15 1/2 gage line wires twisted with 4-point barbs uniformly spaced approximately 4 or 5 inches apart in accordance with and the minimum weight of coating shall be 0.80 ounce per square foot of uncoated wire surface for all gages. Aluminum-coated barbed wire shall be in accordance with the requirements for zinc-coated barbed wire, except that the coating shall be aluminum alloy. The weight of coating per square foot of surface shall be no less than 0.25 ounce for both line wires and barbs. However, barbs of suitable aluminum alloy will be permitted. Aluminum alloy barbed wire shall be aluminum alloy 5052-H38, ASTM B 211. Aluminum alloy barbed wire shall consist of two 0.110-inch line wires twisted with 4-point 0.080-inch diameter wire barbs spaced 5 inches apart. 1043.4 Woven Wire Fence Material. Woven wire fence shall be composed of woven wire, barbed wire, brace wire, posts, ties, fittings and hardware. 1043.4.1 Fabric. Fabric shall be made of zinc-coated or aluminum-coated steel wire. Zinc coated fabric shall be in accordance with AASHTO M 279, for Design Number 939-6-11, Grade 60 or 939-6-12.5, Grade 125. The minimum weight of zinc coating shall be Class 3 for all gages. Line wires shall have tension curves. Aluminum- coated fabric shall be in accordance with the requirements for zinc-coated fabric, except that the coating shall be aluminum alloy applied at the rate of no less than 0.25 ounce per square foot of uncoated wire surface. 1043.4.2 Barbed Wire. Barbed wire for use with zinc-coated steel fabric or aluminum- coated steel fabric shall be in accordance with Sec 1043.3.10. 1043.4.3 Wood Posts. Wood posts and braces shall be in accordance with Sec 1050. 1043.4.4 Steel Posts. Steel posts and braces shall be in accordance with Sec 1043.3.5. Corner, end and pull posts shall be pipe of the sizes and weights shown on the plans. Line posts shall be of the lengths and shapes shown on the plans. Posts shall have a nominal weight of 1.33 pounds per linear foot and a minimum weight of 1.28 pounds per linear foot, exclusive of anchor plate. 1043.4.5 Post Tops and Miscellaneous Hardware. Post tops and miscellaneous fittings and hardware shall be in accordance AASHTO M 181. 1043.4.6 Brace Wire. Brace wire shall be no less than 0.143 inch in diameter and shall be of material in accordance with Sec 1043.4.1. 1043.4.7 Staples. Staples shall be of the screw shank-type or equivalent, a minimum of 1 1/4 inches long, galvanized, and of good commercial quality. 1043.4.8 Wire Ties. Wire used for ties shall be in accordance with Sec 1043.3.7, except that the wire may have a minimum diameter of 0.115 inch. 6421043.4.9 Gates. Gates for woven wire fence shall be in accordance with Sec 1043.3.9, except that the filler shall be woven wire fabric meeting these specifications. 1043.5 Workmanship and Finish. Fabrication of chain-link or woven wire fencing material furnished under these specifications shall be in accordance with the sizes, shapes and dimensions shown on the plans. Excessive roughness, blisters, sal-ammoniac spots, bruises, flaking, voids in coating, frozen knuckles or other defects, if present to any considerable extent, will be considered cause for rejection. Polyvinyl chloride coating shall be without voids, tears, cracks or cuts that reveal the substrate. Welded seam pipe shall have smooth welds, without skips or gaps. Non-uniform or damaged organic topcoats will be considered cause for rejection whether caused by fabrication, shipping or handling on the job. All burrs at the ends of posts and rails shall be removed. 1043.6 Sampling and Testing. 1043.6.1 Sampling. Sampling of material shall be in accordance with the MoDOT's EPG 106.3.1. 1043.6.2 Testing. When fencing material is tested, tests shall be in accordance with the following methods. 1043.6.2.1 Weight. Weight of hot-dip zinc coatings shall be determined in accordance with AASHTO T 65 or, at the option of the engineer, material may be accepted on the basis of magnetic gauge determinations conducted in accordance with ASTM E 376. Weight of aluminum coating shall be determined in accordance with AASHTO T 213 or, at the option of the engineer, material may be accepted on the basis of magnetic gauge determinations conducted in accordance with ASTM E 376. 1043.6.2.2 Thickness. Thickness of zinc-rich organic coating shall be determined by magnetic gauge determinations conducted in accordance with ASTM E 376. Thickness of organic topcoat shall be determined by first determining the total thickness of the organic topcoat and exterior hot-dip zinc coating by magnetic gauge determinations conducted in accordance with ASTM E 376, then chemically stripping the organic topcoat and determining the thickness of only the exterior hot-dip zinc in accordance with AASHTO T 65 or ASTM E 376. The difference between the two measurements shall be the thickness of the organic topcoat. 1043.6.2.3 Tensile Strength. Tensile strength or breaking load shall be in accordance with AASHTO T 68. 1043.7 Inspection. The engineer shall have access at all times to all parts of the manufacturer's or fabricator's works that concern the manufacture or fabrication of material furnished under this specification. Each product or article furnished under this specification will be subject to inspection at the factory, fabricating plant, in laboratories of the engineer's choosing, or at the point of delivery. The engineer reserves the right to sample and test each product or article subsequent to acceptance at the place of manufacture or fabrication to determine conformance with the requirements of this specification or to verify certification. 1043.8 Certification. Certifications will be required as follows. 1043.8.1 Vinyl Coated Material. The contractor shall submit to the engineer certification that the vinyl material and vinyl coated fabric meet the requirements of these specifications. If vinyl coated items other than chain-link fabric are furnished, certification will also be required. 1043.8.2 Aluminum Alloy Material. The contractor shall submit to the engineer certification that the material is in accordance with the requirements specified. The certificate shall include or have attached a list or description of typical physical properties representative of the material. 1043.8.3 Organic Topcoated Material. The contractor shall submit to the engineer certification that the material is in accordance with the requirements specified and that the material is the same as prequalified by the engineer. 1043.9 Packaging and Marking. Packaging and marking of the material shall provide ease of handling, storage and identification. 1043.9.1 Each length of chain-link fabric, woven wire fabric or barbed wire shall be tightly rolled and firmly tied. Each roll shall carry a tag showing, as applicable to the product, the length, kind of base metal, type of 643coating, specified wire size, mesh size, design (style), height or width of fabric, and the producer name, brand or trademark of the manufacturer. 1043.9.8.2 Each bundle or container of posts, hardware and fittings shall be marked with the name, brand or trademark of the manufacturer, type of material (steel, cast iron, aluminum alloy number, etc.), type of coating and any additional data required for proper identification or to determine apparent conformance to specified quality requirements. 644SECTION 1044 POSTS FOR MARKERS AND DELINEATORS 1044.1 Scope. This specification covers galvanized steel and flexible posts used for mounting mile and object markers, delineators, drain and right of way markers and other similar purposes. 1044.2 Steel Posts. Posts shall be rerolled rail steel, in accordance with the mechanical requirements of ASTM A 499, Grade 60, and to the chemical requirements of ASTM A 1. 1044.2.1 Shape and Dimensions. Posts shall be of a channel or modified channel section. Posts for mile markers, object markers and delineators shall be of the dimensions and weights (masses) shown on the plans. 1044.2.2 Drainage and Right of Way Markers. Posts for drainage and right of way markers shall weigh no less than 1.80 or more than 2.25 pounds per foot, all tolerances included, and shall be of the lengths shown on the plans. Permissible variations in length will be a maximum of one inch under and 2 inches over that shown on the plans. Posts shall have no less than five drilled or punched 3/8-inch holes along the centerline of the web. Holes shall be on 2-inch centers, beginning one inch from the top of posts. Anchors or pointed ends on posts will not be required. 1044.2.3 Fiberglass Composite Right of Way Markers. Fiberglass reinforced polymer composite posts for right of way markers shall be 3 and 3/4 inches wide of a multi rib design weighing no less than 0.35 pounds per foot and shall be of the color and length as shown on the plans. The markers shall have a right of way decal meeting the description as shown on the plans. The markers shall be pointed on one end for installation into the ground to the depth as shown on the plans. 1044.2.4 Galvanizing. Posts shall be galvanized after fabrication in accordance with AASHTO M 111. 1044.3 Channel Post Delineator. Channel post for delineators shall be manufactured from ductile ASTM A 36 or ASTM A 1011 Gr 60 and as shown on the plans. Posts shall be hot dipped galvanized after manufacture in accordance with Sec 1080. Damaged coating shall be repaired in accordance with Sec 1081. The contractor shall furnish to the engineer three copies of the fabricator’s certification that the material supplied is in accordance with the requirements specified. 1044.4 Perforated Square Steel Tube Posts. 1044.4.1 Material. 1044.4.1.1 Steel. Steel shall be in accordance with ASTM A 1011, Grade 50, for hot rolled carbon sheet steel, structural quality. The average minimum yield strength after cold-forming shall be a minimum of 50,000 psi. 1044.4.1.2 Coating. Posts shall be galvanized in accordance with ASTM A 653, G90. The corner weld shall be zinc coated after the scarfing operation. The steel shall also be coated with a chromate conversion coating and a clear organic polymer topcoat. Both the interior and the exterior of the post shall be galvanized. 1044.4.2 Dimensions. 1044.4.2.1 Dimensional Tolerances. All dimensional tolerances shall be in accordance with ASTM A 513, excepted as noted. 1044.4.2.2 Length. The length of each post shall be as shown on the plans. 1044.4.2.3 Weight Per Foot. The weight per foot shall be in accordance with the following or as specified: Perforated Square Steel Tube Post Requirements Size ThicknessWeight Tolerance 2 in. x 2 in.12 Gauge2.42 lbs/ft±0.12 lbs/ft 1044.4.3 Cross Section. The cross section of the post shall be square tube formed of 12 gage steel, carefully rolled to size and shall be welded directly in the corner by high frequency resistance welding and externally 645scarfed to agree with corner radii. 1044.4.4 Hole Punching. All holes shall be 7/16 ± 1/64 inch in diameter on one-inch centers on all four sides down the entire length of the post. The holes shall be on the centerline of each side in true alignment and opposite each other directly and diagonally. 1044.4.5 Telescoping Properties. Finished posts for telescoping post systems shall be in accordance with the general dimensional requirements and shall permit consecutive square tubes to telescope freely, for no less than 10 feet without the necessity of matching any particular face to any other face. The finished posts shall be straight, and shall have a smooth, uniform finish. All holes and ends shall be free from burrs, and ends shall be cut square. 1044.4.6 Connecting Bolts and Nuts. Bolts used to connect posts to bases shall be 5/16 inch, 18NC threads, bent-truss head bolts in accordance with ASTM A 307, Grade A. The bolts shall be mechanically zinc galvanized in accordance with ASTM B 695, Class 25. The nuts shall be 5/16 inch, 18NC threads, serrated flange nuts in accordance with ASTM A 194 and zinc electroplated in accordance with ASTM B 633. 1044.4.7 Certification. The fabricator shall furnish to the engineer, a certification stating that the posts furnished comply with all requirements of this specification. The certification shall include or have attached specific results of tests of the mechanical and chemical properties. The certification shall accompany each shipment of the material to the destination. 1044.5 Acceptance. Acceptance of posts furnished under this specification will be based on Sec 1040.2 and on the results of any tests deemed necessary by the engineer at destination to ascertain compliance with these specifications. If requested, two posts shall be furnished for testing purposes from such lots as the engineer may determine. 646SECTION 1045 PAINT FOR STRUCTURAL STEEL 1045.1 Scope. This specification covers paint, paint material and coating systems for use on structural steel. 1045.2 Paint and Paint Material. 1045.2.1 General. All single component paints shall be ready-mixed at the factory to comply with the specification formula for the type of paint ordered; shall be well ground to a uniform consistency and smooth texture; shall be free from dirt, water and other foreign matter; shall be of such consistency to have good application, covering and leveling properties; and shall dry within the specified period to a good film without running, streaking or sagging. 1045.2.1.1 Any paint that has livered or hardened or thickened to any extent in the container, or in which the pigment has settled such that the paint cannot be readily broken up with a paddle to a smooth uniform paint of good application consistency, will be rejected. 1045.2.1.2 All percentages and proportions shall be on a weight basis unless otherwise stated. 1045.2.1.3 All VOC content requirements specified shall be a maximum when thinned for application. 1045.2.2 Sampling. Each batch or lot of paint shall be sampled and approved prior to use. Each batch or lot of each component of multiple-component paints shall be sampled and approved prior to use. 1045.2.3 Packaging and Labeling. The lining of the containers shall not react with the paint. All components shall bear a label on which shall be clearly shown the name of the manufacturer, the kind of paint, lot number, shelf life, date of manufacture and net weight of contents. The lot number and date of manufacture shall be stamped, stenciled or painted directly onto the container using a weatherproof, durable material. 1045.2.4 Determination of Quantities. Quantities of paint shall be determined by volume. One gallon shall equal 231 cubic inches at 77 F. 1045.3 High Solids Inorganic Zinc Silicate Coating. 1045.3.1 Description. High solids inorganic zinc coating shall be a solvent base multiple-component material which, when mixed and applied in accordance with Sec 1081, cures without the use of a separate curing solution. High solids inorganic zinc coating shall be in accordance with AASHTO M 300, Type IA. The VOC content shall not exceed 3.50 pounds per gallon. If thinning is necessary for application, the maximum VOC content after thinning shall not exceed 3.50 pounds per gallon. 1045.3.2 Manufacturer and Brand Name Approval. Prior to approval and use of high solids inorganic zinc, the manufacturer shall submit to Construction and Materials a certified test report from an approved testing laboratory showing specific test results conforming to all quantitative and resistance test requirements of these specifications. The certified test report shall also contain the exact ratio, by weight, of each component of the coating used for the tests, the lot tested, the manufacturer's name, brand name of coating and date of manufacture. Upon approval from the engineer of this certified test report, further resistance tests will not be required, except as hereinafter noted, of that manufacturer for that brand name of coating. New certified test results shall be submitted any time the manufacturing process or the coating formulation is changed, and may be required by the engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. All resistance testing shall be performed on duplicate sets of test panels, and upon completion of the prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to Construction and Materials. 1045.3.3 Alternate Approval. If approved by Construction and Materials, compliance with all specified requirements for the system under NTPEP or Northeast Protective Coating Committee (NEPCOAT), in addition to the physical property requirements of this specification, may be substituted for the manufacturer and brand name approval requirements of Sec 1045.3.2. The manufacturer shall provide documentation identifying specific products evaluated, along with the manufacturer’s code numbers and/or report code numbers. 1045.4 High Solids Epoxy System G Intermediate Coating. 6471045.4.1 Description. The coating shall be a multiple-component, modified epoxy primer with an amine/amide- type curing system compatible as an intermediate coat over high solids inorganic zinc primer or organic zinc primer and suitable for topcoating with polyurethane. 1045.4.2 Mixed Coating. The color shall be gray (Federal Standard 595b No. 26373) or brown (Federal Standard 595b No. 30045) unless otherwise specified. The color of the intermediate coat shall match the color of the finish coat, unless otherwise approved by the engineer. The physical properties of the mixed paint shall be as follows: High Solids Epoxy System G Intermediate Coating Item Requirement Viscosity, Krebs-Stormer, 77 F KU 80-130 VOC Content, max., lb/gal 3.50 Fineness of Grind, Hegeman Gage, min. 4 Sag Resistance, Leneta Anti-Sag Meter, mils wet, min. 8 Dry to Touch, hours, max. 3 Dry to Handle, hours, max. 6 1045.4.3 Packaging and Labeling. Packaging and labeling shall be in accordance with Sec 1045.2.3. 1045.4.4 Manufacturer and Brand Name Approval. Prior to approval and use of the specified coating system, the manufacturer shall submit to Construction and Materials a one-gallon unit of each coat of the coating system proposed. The manufacturer shall also submit a certified test report from an approved independent testing laboratory showing specific test results obtained on the specified coating system for Relative Humidity Resistance ASTM D 1735 or D 2247, 3000 hours, Salt Fog Resistance ASTM B 117, 3000 hours and Accelerated Weathering ASTM G 153 Cycle 1 (Carbon Arc), 4000 hours. ASTM G 155, Cycle 2, Xenon Arc or G 154, Cycle 2 QUV (Fluorescent UV-Condensation Type using Type A lamps) may be used as an alternate to Carbon Arc. 1045.4.4.1 All coats of the system to be tested shall be applied to steel test panels that have been prepared according to AASHTO M 300. Each coat of the system shall be from the same manufacturer. Test panels for salt fog exposure shall be scribed as specified in ASTM D 1654 and, when rated according to ASTM D 1654, each panel shall receive a rating of 7 or greater. Test panels shall not exhibit more than slight rusting, undercutting, discoloration, fading, blistering, chalking, loss of gloss or change in color. Accelerated weathering resistance testing shall be performed on test panels that have received finish coats in the specified colors for which approval is being requested. After 4,000 hours of testing for accelerated weathering resistance, each color of the finish coat shall show a difference in color of no greater than 3 ∆E, when compared to the control panel. Color change measurements shall be made in accordance with Section 6.2 CIE 1976 L*a*b* of ASTM D 2244. All resistance testing shall be performed on duplicate sets of test panels, and upon completion of the prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to Construction and Materials. 1045.4.4.2 The manufacturer shall provide documentation that the specified coating system has performed satisfactorily for three years. The document shall include the name, address and telephone number of the proprietary agency and location of the structures. Upon approval of the coating by the engineer, further submittals for preliminary approval will not be required of that manufacturer for that brand name of coating, except as hereinafter noted. A new sample, new testing data and new test panels shall be submitted any time the manufacturing process or the batching proportions are changed. The engineer may withdraw manufacturer and brand name approval when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. All data submitted for preliminary approval will be considered confidential to MoDOT. 1045.4.5 Alternate Approval. If approved by Construction and Materials, compliance with all specified requirements for the system under NTPEP or NEPCOAT, in addition to the physical property requirements of this specification, may be substituted for the manufacturer and brand name approval requirements of Sec 1045.4.4. If approval is requested under NTPEP or NEPCOAT, the accelerated weathering requirements stated 648in Sec 1045.4.4 will apply. The manufacturer shall provide documentation identifying specific products evaluated, along with the manufacturer’s code numbers and/or report code numbers. 1045.5 Polyurethane System G Finish Coating. 1045.5.1 Description. The coating shall be a multiple-component, aliphatic acrylic polyurethane suitable for use over High Solids Epoxy Intermediate Coating. The coating shall cure to a semi-gloss to high gloss, abrasion resistant surface and shall provide an easily cleanable finish. 1045.5.2 Mixed Coating. The mixed coating properties shall be as follows: Polyurethane System G Finish Coating Physical Property Requirement Color, Federal Standard 595bGray 26373Brown 30045 Viscosity, Krebs-Stormer, 77 F, KU 65-96 VOC Content, lb/gal , max. 3.50 Fineness of Grind, Hegeman Gage, min. 6 Sag Resistance, Leneta Anti-Sag Meter, mils wet, min. 8 Dry to Touch, hours, max. 4 Dry to Handle, hours, max. 8 1045.5.3 Packaging and Labeling. Packaging and labeling shall be in accordance with Sec 1045.2.3. 1045.5.4 Manufacturer and Brand Name Approval. Manufacturer and brand name approval shall be in accordance with Sec 1045.4.4 or Sec 1045.4.5. If approval is requested under Sec 1045.4.5, the accelerated weathering requirements stated in Sec 1045.4.4 will apply. The manufacturer shall provide documentation identifying specific products evaluated, along with the manufacturer’s code numbers and/or report code numbers. 1045.6 Waterborne Acrylic System H Intermediate and Finish Coating. 1045.6.1 Description. The intermediate coating shall be a single component waterborne acrylic compatible as a coating over high solids inorganic zinc primers or organic zinc primers. The finish coating shall be a single component waterborne acrylic suitable for use over a waterborne acrylic intermediate coating. The finish coating shall cure to a tough, abrasion resistant surface that performs well in weathering exposures. The gray finish coat shall cure to a semi-gloss finish and the brown finish coat shall cure to a low-gloss finish. 1045.6.2 Mixed Coating. The color of the intermediate coat shall be gray (Federal Standard 595b No. 26373) or brown (Federal Standard 595b No. 30045) unless otherwise specified. The color of the intermediate coat will normally be required to match the color of the finish coat. The mixed coating properties shall be as follows: Waterborne Acrylic System H Intermediate and Finish Coating Physical Property Requirement Color, Finish Coat, Federal Standard 595bGray 26373Brown 30045 Viscosity, Krebs-Stormer, 77 F, KU 80-100 VOC Content, lb/gal, max. 3.50 Fineness of Grind, Hegeman Gage, min. 7 Sag Resistance, Leneta Anti-Sag Meter, mils wet, min. 8 Dry to Handle, hours, max. 2 1045.6.3 Packaging and Labeling. Packaging and labeling shall be in accordance with Sec 1045.2.3. 1045.6.4 Manufacturer and Brand Name Approval. Prior to approval and use of waterborne acrylic intermediate and finish coats, the manufacturer shall obtain manufacturer and brand name approval in 649accordance with Sec 1045.4.4 or Sec 1045.4.5, except that, after the 4000 hour testing for accelerated weathering resistance, the Federal Standard 595b 30045 (brown) color of the finish coat shall show a difference in color of no greater than 4 ∆E when compared to the control panel. If approval is requested under Sec 1045.4.5, the accelerated weathering requirements stated in Sec 1045.4.4 will apply. The manufacturer shall provide documentation identifying specific products evaluated, along with the manufacturer’s code numbers and/or report code numbers. 1045.7 Polysiloxane System I Finish Coating. 1045.7.1 Description. The coating shall be a multiple-component, epoxy-based Polysiloxane suitable for use over High Solids Inorganic Zinc, Organic Zinc, or High Solids Epoxy Intermediate Coating. The coating shall cure to a semi-gloss to high gloss, abrasion resistant surface and shall provide an easily cleanable finish. 1045.7.2 Mixed Coating. The mixed coating properties shall be as follows: Polysiloxane System I Finish Coating Physical Property Requirement Color, Federal Standard 595b Gray 26373 Brown 30045 Viscosity, Krebs-Stormer, 77 F, KU Within Manufactures submitted range VOC Content, lb/gal, max 2.0 Fineness of Grind, Hegeman Gage, min. 6 Sag Resistance, Leneta Anti-Sag Meter, mils wet, min.8+ Dry to Touch, hours, max. 3 Dry to Handle, hours, max. 8 1045.7.3 Packaging and Labeling. Packaging and labeling shall be in accordance with Sec 1045.2.3. 1045.7.4 Manufacturer and Brand Name Approval. Manufacturer and brand name approval shall be in accordance with Sec 1045.4.4 or Sec 1045.4.5. If approval is requested under Sec 1045.4.5, the accelerated weathering requirements stated in Sec 1045.4.4 will apply. The manufacturer shall provide documentation identifying specific products evaluated, along with the manufacturer’s code number and/or report code numbers. 1045.8 Aluminum Epoxy-Mastic Primer. 1045.8.1 Description. The coating shall be a one-coat system aluminum epoxy-mastic primer designed for adhesion to rusty steel, aged galvanized steel and other uses. Aluminum epoxy-mastic primer will not be permitted for use on any surface that is to be in contact with fresh concrete. The epoxy-mastic shall be a two- component, modified epoxy-primer containing metallic-aluminum flake. 1045.8.2 Pigment. The primary pigment shall be metallic-aluminum. 1045.8.3 Vehicle. The vehicle shall be an epoxy-type. The curing agent shall have suitable insensitivity to moisture to allow trouble-free application. 1045.8.4 Mixed Coating. 1045.8.4.1 The coating shall be well-ground, not caked, skinned or badly settled in the container. The mixed coating, when applied in one coat, shall be capable of achieving 5 mils dry film thickness without runs or sags. 1045.8.4.2 The mixed coating properties shall be as follows: Aluminum Epoxy-Mastic Primer Physical Property Requirement Dry to touch, hours, max.24 Dry hard, days, max. 5a VOC Content, lb/gal, max.3.50 650aWhen air-cured at a temperature of 75 F or above to a hard, tough film by evaporation of solvent and chemical reaction. 1045.8.5 Resistance Tests. Test panels of steel in accordance with ASTM D 609, and having dimensions of 2 x 5 x 1/8 inch shall be prepared by sandblasting all surfaces to a white metal condition in accordance with Structural Steel Painting Council SP5 (SSPC-SP5-82). The cleaned panels shall then be exposed to outdoor weather for 30 days or until uniform rusting occurs. The panel shall then be hand cleaned with a wire brush in accordance with SSPC-SP2-82. A 6-mil dry coating of the epoxy-mastic shall then be applied in one coat in accordance with the manufacturer's current recommendations. The coating shall be cured as recommended by the manufacturer. Fresh Water, Salt Water, and Weathering and Salt Fog resistance tests, as detailed herein, shall be performed on one or more test panels. The material will not be approved if any individual test panel fails any of the resistance tests specified herein. 1045.8.5.1 Fresh Water Resistance. Panels shall be scribed down to base metal with an "X" of at least 2-inch legs, and shall be immersed in fresh tap water at 75 ± 5 F. The panels shall show no rusting, blistering or softening beyond 1/16 inch from the scribe mark, when examined after 30 days. Discoloration of the coating will be permitted. 1045.8.5.2 Salt Water Resistance. Panels shall be scribed down to base metal with an "X" of at least 2-inch legs and immersed in five percent sodium chloride at 75 ± 5 F. The panels shall show no rusting, blistering or softening beyond 1/16 inch from the scribe mark upon examination after 7, 14 and 30 days. Discoloration of the coating will be permitted. The sodium chloride solution shall be replaced with fresh solution after each examination. 1045.8.5.3 Weathering and Salt Fog Resistance. Panels shall be tested in the weatherometer in accordance with ASTM G 154 QUV (Fluorescent UV-Condensation Tape using Type A Lamps) for 300 hours using a test cycle consisting of four hours light followed by four hours condensation. After this period, the panels shall be removed and scribed with an "X" of at least 2-inch legs down to base metal. The test panels shall then be tested in accordance with ASTM B 117. After 1,000 hours of continuous exposure, the coating shall show no loss of bond, nor shall the coating show rusting or blistering beyond 1/16 inch from the center of the scribe mark. 1045.8.6 Packaging and Labeling. Packaging and labeling shall be labeled in accordance with Sec 1045.2.3. 1045.8.7 Approval and Prequalification. 1045.8.7.1 Manufacturer and Brand Name Approval. Prior to approval and use of the epoxy-mastic primer, the manufacturer shall submit to Construction and Materials a one-gallon sample of the coating and a certified test report from an approved independent testing laboratory showing specific test results conforming to all quantitative and resistance test requirements of these specifications. The certified test report shall contain the exact ratio, by weight, of the pigment component to the vehicle component of the epoxy-mastic used for the tests, the lot tested, the manufacturer's name, brand name of the epoxy-mastic, and date of manufacture. In addition, the manufacturer shall submit a complete set of tested panels that have undergone each required resistance test. The set of panels submitted shall include one untested control panel that has been prepared in accordance with Sec 1045.8.5. Upon approval by Construction and Materials of this certified test report, further resistance tests will not be required of that manufacturer for that brand name of epoxy-mastic primer, except as noted. New certified test results shall be submitted any time the manufacturing process or the epoxy-mastic formulation is changed, and may be required by the engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements specified herein. 1045.8.7.2 Final Acceptance. Final acceptance of the epoxy-mastic primer will be based on a manufacturer's certification submitted by the contractor to the engineer and on results of tests conducted on samples of the material. Each lot of each component will be sampled and tested prior to approval or use of the material. 1045.9 Gray Epoxy-Mastic Primer. 1045.9.1 Description. This specification covers a one-coat gray epoxy-mastic primer system designed for adhesion to rusty steel, aged galvanized steel and other uses, including uses in contact with freshly poured Portland cement concrete. The epoxy-mastic shall be a multiple-component modified epoxy containing gray pigmentation, and shall be in accordance with the requirements specified herein. 6511045.9.2 Pigment. The pigmentation shall be any pigment or combination of pigments formulated to offer the intended protective properties to the cured coating, and shall be totally non-reactive to the constituents contained in both cured and uncured Portland cement concrete. 1045.9.3 Vehicle. The vehicle shall be an epoxy type. The curing agent shall have suitable insensitivity to moisture to allow trouble-free application. 1045.9.4 Mixed Coating. 1045.9.4.1 The provisions of Sec 1045.8.4.1 will apply. 1045.9.4.2 The mixed coating properties shall be as follows: Gray Epoxy-Mastic Primer Physical Property Requirement Color, Federal Standard 595b Gray 26373 Viscosity, (Krebs-Stormer, 25 C) KU 90 - 120 Volatile Organic Content, lb/gal, max. 3.50 Dry to touch, hours, max. 24 Dry hard, days, max. 7a aWhen air-cured at a temperature of 75 F or above to a hard, tough film by evaporation of solvent and chemical reaction. 1045.9.5 Resistance Tests. Test requirements and approval criteria shall be in accordance with Sec 1045.8.5. 1045.9.6 Packaging and Labeling. Packaging and labeling shall be in accordance with Sec 1045.2.3. 1045.9.7 Approval and Prequalification. 1045.9.7.1 Manufacturer and Brand Name Approval. Manufacturer and brand name approval shall be in accordance with Sec 1045.8.7.1. 1045.9.7.2 Final Acceptance. Final acceptance will be in accordance with Sec 1045.8.7.2.
1045.10 Organic Zinc-Rich Primer.
1045.10.1 Description. This specification covers an organic zinc-rich primer system designed for adhesion to
field-blasted steel and suitable for use under an epoxy System G intermediate coating, waterborne acrylic System H intermediate coating or polysiloxane System I finish coating. This specification also covers organic zinc for repair of existing galvanized steel, touch-up of inorganic-zinc coated steel and other uses. The organic zinc-rich primer shall be a multiple-component material which, when mixed and applied in accordance with Sec 1081, cures without the use of a separate curing solution. The organic zinc-rich coating shall be in accordance with ASTM A325 Class B requirements for slip coefficient and creep resistance on faying surfaces and other requirements specified herein. The VOC content shall not exceed 3.50 pounds per gallon. If thinning is necessary for application, the maximum VOC content after thinning shall not exceed 3.50 pounds per gallon.
1045.10.2 Manufacturer and Brand Name Approval. Prior to approval and use of organic zinc-rich primer,
the manufacturer shall submit to Construction and Materials a certified test report from NTPEP showing specific test results conforming to all quantitative and resistance test requirements of these specifications. The certified test report shall also contain the exact ratio, by weight, of each component of the coating used for the tests, the lot tested, the manufacturer's name, brand name of coating and date of manufacture. Upon approval from the engineer of this certified test report, further resistance tests will not be required, except as hereinafter noted, of that manufacturer for that brand name of coating. New certified test results shall be submitted any time the manufacturing process or the coating formulation is changed and may be required by the engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. All resistance testing shall be performed on duplicate sets of test panels, and upon completion of the 652prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to Construction and Materials. 653SECTION 1046 PIPE LINER 1046.1 Scope. This specification covers material requirements for pipe liner. 1046.2 Material. Pipe liner shall be in accordance with one of the following.
a.HDPE pipe in accordance with ASTM F 714, maximum DR 32.5.
b.HDPE pipe in accordance with ASTM D 3350 cell classification 345464C. This pipe liner shall have approved dimensions on file with Construction and Materials.
c.HDPE pipe in accordance with ASTM F 894 open profile, Class RSC 100 or RSC 160.
d.PVC pipe in accordance with ASTM F 949, except that the PVC pipe and fittings shall be made of a PVC compound having a minimum call classification of 12454B, in accordance with ASTM D 1784. The joining method for PVC pipe shall be by elastomeric material in accordance with ASTM F 949. 1046.3 Pipe Marking. Each length of pipe liner furnished shall be permanently marked by the manufacturer with the manufacturer's name and applicable ASTM designation. 1046.4 Certification and Acceptance. The contractor shall furnish a manufacturer's certification to the engineer that the pipe liner was manufactured, tested, and is in accordance with this specification. Acceptance of the material will be based on the manufacturer's certification and statement, pipe liner identification markings and upon the results of such tests as may be performed by the engineer. 1046.5 Inspection. 1046.5.1 The engineer may inspect the fabricated pipe liner at the manufacturing plant, intermediate distribution point or destination. The manufacturer shall furnish to the engineer an itemized statement of the sizes and lengths of pipe liner in each shipment. The engineer shall have access to the manufacturing plant or intermediate distribution point for inspection. Each facility shall provide the means to safely inspect all aspects of production or storage. Any previously rejected pipe liner included in a later lot will be cause for rejection of the entire lot. A lot will be defined as all the material presented for inspection at one time. 1046.5.2 Inspection will include an examination of the pipe liner for markings, variance from specified diameter, net length of fabricated pipe liner, and any evidence of poor workmanship. The inspection may include taking samples. 1046.6 Rejection. 1046.6.1 Any individual section of pipe liner failing to meet the marking, diameter, length or workmanship requirements of these specifications will be rejected. 1046.6.2 If a pipe liner fails to meet the requirements, the pipe liner sampled will be rejected and the lot will be resampled. A resample will be of the same size as the original sample. The resample shall comply in all respects or the entire shipment will be rejected. 654SECTION 1047 POLYETHYLENE CULVERT PIPE 1047.1 Scope. This specification covers polyethylene culvert pipe used for the construction of culverts and other uses specified in the contract documents. 1047.2 Basis of Acceptance. Acceptance of polyethylene culvert pipe will be based on the pipe being provided by a qualified manufacturer, certification, manufacturer quality control documentation, identification markings and tests on samples of the material as required by the engineer. 1047.3 Material. Polyethylene culvert pipe, couplings and fittings shall be in accordance with AASHTO M 294 for corrugated or AASHTO M 335 for steel reinforced. In case of conflict with AASHTO M 294 or AASHTO M 335, these specifications shall govern. 1047.3.1 Section properties shall be within the following limits: Corrugated Minimum Maximum Nominal Size S (in.)Effective Pipe Wall Area Ae f f (in.2/in.)Pipe Wall Centroid to Inside Face yc (in.)Pipe Wall Moment of Inertia I (in.4/in.)Area Ratioa Ae f f / AgExtreme Fiber Ratiob yc / cInside Diameter Di (in.)Outside Diameter Do (in.) 12 0.163 0.382 0.0313 0.6990.494 12.02 14.60 15 0.202 0.413 0.0465 0.7680.447 14.83 17.82 18 0.209 0.569 0.0653 0.7490.554 17.83 21.42 24 0.233 0.669 0.1317 0.6670.552 23.71 27.98 30 0.2330 0.757 0.2415 0.8160.448 29.46 34.98 36 0.294 1.058 0.3153 0.6830.588 35.44 41.92 42 0.331 1.140 0.5395 0.6930.564 40.98 48.18 48 0.323 1.095 0.4682 0.6810.543 47.12 54.34 60 0.438 1.477 0.8150 0.7510.766 58.90 66.97 a Ag equals gross area of pipe wall per unit length of pipe (in2/in.). b c equals the distance from the pipe wall centroid to the outermost fiber (in.). Steel Reinforced Minimum Maximum Nominal Size S (in.)Wall Steel Area A (in.2/ft)Wall Steel Moment of Inertia I (in.4/in.)Rib Radius of Gyration r (in.)Rib Width/ Thickness Ratio b / t 24 0.348 0.00063 0.144 8.97 30 0.344 0.00086 0.170 10.03 36 0.404 0.00122 0.187 10.36 42 0.461 0.00152 0.195 9.91 48 0.379 0.00218 0.257 11.90 60 0482 0.00352 0.290 11.88 1047.3.2 The pipe shall be Type S and not be perforated unless specified otherwise. 1047.3.3 Field joints shall provide circumferential and longitudinal strength to maintain the pipe alignment, prevent separation of pipe and prevent infiltration of fill material. Coupling bands, if used, shall be of the same base material as the pipe. Corrugations in the bands shall have the same configuration as the corrugations in the pipe ends being connected. Prior to use, the design of coupling bands and fastening devices shall be submitted to 655and approved by Construction and Materials. Final acceptance of coupling bands and fastening devices will be based on field performance. 1047.3.4 The manufacturer shall provide to the engineer an itemized statement of the sizes, section properties and lengths of pipe in each shipment. 1047.3.5 Pipe may be fabricated using English units of measurement. Pipe fabricated using English measurements shall meet the diameter dimensions shown on the plans. Pipe tolerances will be in accordance with AASHTO M 294 or AASHTO M 335. 1047.4 Sampling, Testing and Acceptance Procedures. All manufacturers furnishing pipe meeting the requirements of AASHTO M 294,for MoDOT projects shall be qualified as described herein. All manufacturers furnishing pipe meeting the requirements of AASHTO M 335 for MoDOT projects shall meet the quality control and assurance requirements of the appendix section in M 335 and these specifications. All pipes will be subject to inspection by the engineer at the source of manufacture, at an intermediate shipping terminal or at destination. The engineer shall be allowed unlimited access to all facilities and records as required to conduct inspection and sampling in accordance with Sec 106. 1047.4.1 Application for Placement on Qualified List. To become qualified to furnish pipe meeting AASHTO M 294, a written request shall be sent by the manufacturer to Construction and Materials, and shall include the following information:
a.A copy of the manufacturer’s current National Product Evaluation Program(NTPEP) audit compliance.
b.The pipe manufacturer’s certified analysis certificate setting forth the name or brand of pipe to be furnished, the specified type, category, grade and class of polyethylene compounds. The certificate shall be sworn for the manufacturer by a person having legal authority to bind the company. The certificate shall have attached a certified test report from an approved independent testing laboratory showing specific results of tests performed on each diameter pipe to be furnished, conforming to all requirements of these specifications. Pipes shall be randomly selected for test by the independent testing laboratory and shall be representative of that manufacturer's pipe.
c.A guarantee that all pipe furnished shall be in accordance with the specification requirements, shall bear a suitable identification brand or mark and shall be replaced without cost to the Commission when not in accordance with the specified requirements. The guarantee shall be worded such that the guarantee will remain in effect as long as the manufacturer continues to furnish material. The manufacturer shall conduct tests and measurements as necessary to ensure the material produced complies with all specification requirements. These tests and measurements shall be identified by the identification symbols or code used on the pipe in a manner that will permit the manufacturer to produce specific reports showing test results representative of specific lots of polyethylene pipe. Copies of reports of these tests shall be kept on file and shall be submitted to the engineer upon request. The brand shall be removed or obliterated by the manufacturer on all material where control tests, as outlined herein, are not in accordance with this specification.
d.Units of measurement, English or metric, used to fabricate the pipe. 1047.4.2 Maintaining Qualification. To maintain qualification to furnish pipe meeting AASHTO M 294, the manufacturer shall perform and maintain a quality control program in accordance with the NTPEP Certification Program. The manufacturer’s NTPEP certification shall be maintained. The manufacturer shall maintain for three years a record of all test results, inspections and the bill of lading for each shipment of material used in the production of pipe and for each shipment of pipe. The manufacturer shall notify Construction and Materials at least 24 hours prior to each shipment of pipe to a MoDOT project. Additional pipe may be considered part of the original shipment when the ordered quantity was underestimated or material was lost or damaged. A bill of lading in accordance with Sec 1047.6 shall be provided for each shipment of pipe. 1047.4.3 Disqualification of a Manufacturer. A manufacturer may be disqualified to provide pipe for use on MoDOT projects based on the discretion of Construction and Materials, for reasons including, but not limited to, not maintaining NTPEP certification, failure of material to consistently meet specifications, falsification of 656documentation, misbranding of pipe, unsatisfactory performance in the field or for other reasons indicating lack of consistent material quality. 1047.4.3.1 In the case where a manufacturer loses NTPEP certification and was not disqualified for any other reason, reinstatement will be considered when the manufacturer is recertified by NTPEP. 1047.4.3.2 A manufacturer will not be considered for reinstatement until after one year from the date of removal for falsification of documents. 1047.4.3.3 Three notices of failure to meet specification requirements within a 12-month period will be cause for disqualification of the manufacturer for one year, effective from the date of the third notice. 1047.4.3.4 A manufacturer disqualified within one year of the end of a disqualification may be subject to permanent removal, with no application for reinstatement accepted for a period of three years. 1047.4.4 Reinstatement of a Manufacturer. Consideration of reinstatement of a manufacturer once disqualified will be no sooner than specified in Sec 1047.4.3, will require a written document from the manufacturer stating the reasons for disqualification and the action taken to correct those deficiencies, written concurrence from Construction and Materials that the problem has been suitably addressed, followed by a new application in accordance with Sec 1047.4.1. 1047.4.5 Sampling of Material. Random sampling of the pipe will be conducted by the engineer to verify pipe and material is in accordance with this specification. Samples of polyethylene pipe will be obtained from fabricated culvert sections in accordance with AASHTO M 294 or AASHTO M 335 at a frequency determined by the engineer. 1047.4.6 Inspection. Inspection will include an examination of the pipe for markings, deficiency in specified diameter, net length of fabricated pipe and evidence of poor workmanship. The inspection may include taking samples. 1047.4.7 Testing. Specimen testing size and method of tests shall be in accordance with AASHTO M 294 or AASHTO M 335. The contractor or manufacturer shall provide the equipment and personnel to cut a sample from a section of pipe. The sample shall include the markings or a record of the markings for that section of pipe. 1047.4.8 Unacceptable Material. 1047.4.8.1 Any individual section of pipe failing to meet the marking, diameter, length or workmanship requirements of these specifications will be unacceptable. If 10 percent of the pipe in any lot fails to meet these requirements, the entire shipment of that pipe diameter may be rejected. 1047.4.8.2 If a test specimen taken in accordance with Sec 1047.4.7 fails to be in accordance with AASHTO M 294 or AASHTO M 335, the pipe sampled will be rejected, and the lot will be resampled. A resample will be from the same diameter of pipe as the original sample. The resample shall be in accordance to these specifications or the entire shipment will be rejected. 1047.5 MoDOT Identification Number. When the manufacturer contacts the engineer in accordance with Sec 1047.4.2, the engineer will assign a specific MoDOT identification number for each size of pipe in the shipment. 1047.6 Bill of Lading. A bill of lading or delivery receipt for each shipment of pipe shall be furnished to the engineer at the shipping and destination points. The bill of lading shall contain an itemized statement of the sizes and lengths of pipe, with the corresponding designated MoDOT identification number provided to the manufacturer for each size of pipe for that shipment. The bill of lading shall contain a certified statement. The certified statement shall be signed by an authorized representative of the manufacturer and shall state the following: “This certifies that the pipe and bands in this shipment are in accordance with MoDOT specifications, were fabricated at an approved plant and were fabricated from the following brand names:” 657SECTION 1048 PAVEMENT MARKING MATERIAL 1048.1 Scope. This specification covers all temporary pavement markings, permanent pavement markings and drop-on glass beads. 1048.1.1 Certification and Acceptance. All material contained in Sec 1048 shall be in accordance with the following requirements. 1048.1.1.1 To obtain approval of the material, the manufacturer shall submit material and application specifications, samples of the material, and a history of satisfactory use to Construction and Materials for testing and evaluation. The sample quantity submitted shall be at the discretion of Construction and Materials. The approval process shall not be initiated prior to obtaining the concurrence of Construction and Materials. Following testing and evaluation, satisfactory material will be placed on a qualified list. 1048.1.1.2 For acceptance on a project, the contractor shall furnish to the engineer a manufacturer's certification stating the manufacturer and trade name, lot or batch number and that all material furnished is similar to the material originally qualified. Acceptance of the material will be based on the manufacturer's certification, the results of such tests that may be performed by the engineer and satisfactory performance in the field. 1048.1.1.3 The material may be inspected and sampled at the point of manufacture, at an intermediate shipping terminal or at destination. The engineer shall be allowed access to all facilities and records as required to conduct inspection and sampling. The contractor shall adequately mix the contents of all shipping containers prior to obtaining samples or transferring partial containers of material to tanks on the striping equipment. SECTION 1048.10 TEMPORARY PAVEMENT MARKING MATERIALS.
1048.10.1 Temporary Paint Materials. This specification covers all temporary paint materials. All materials
contained in Sec 1048.20.1 may also be used as Temporary Paint Materials.
1048.10.1 1 Cold Weather Pavement Marking Paint.
1048.10.1 1.1 Acrylic Copolymer Fast Dry Pavement Marking Paint.
1048.10.1 1.1.1 Description. Acrylic copolymer fast dry pavement marking paint shall be capable of receiving
and holding glass beads for producing retroreflective pavement marking.
1048.10.1 1.1.2 Material. The paint shall contain no more than 3,200 ppm lead or more than 800 ppm
chromium based on dry weight, and shall have limited VOC content as noted herein.
1048.10.1 1.1.2.1 General. The finished paint shall be formulated and manufactured from first-grade material
and shall be a fast drying, solvent-based, acrylic copolymer resin type paint capable of withstanding air and roadway temperatures without bleeding, staining, discoloring or deforming. The dried paint film shall be capable of maintaining original dimensions and placement without chipping, spalling or cracking. The dry paint film shall not deteriorate because of contact with normal roadway chemicals or materials.
1048.10.1 1.1.2.2 Durability Testing. Determination of conformance to this specification will include, but will
not be limited to, the evaluation of test data from NTPEP or other MoDOT approved facilities. The maintained retroreflectivity and durability shall be in accordance with the following requirements after being installed on at least one NTPEP test deck in a northern, wet climate region for a minimum of six months, including December, January and February.
1048.10.1 1.1.2.3 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient of
retroreflective luminance (RL) in accordance with the requirements of ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and bituminous surfaces shall be expressed in millicandelas per footcandle per square foot and shall be at least 100 for 15-meter geometry or 75 for 30- meter geometry, when measured in the wheel path area.
1048.10.1 1.1.2.4 Durability. Paint shall have a durability rating of at least 4 for both concrete and bituminous
surfaces when tested in the wheel path area of the NTPEP test deck. 6581048.10.1.1.1.3 Mixed Paint.
1048.10.1 1.1.3.1 The mixed paint shall be strained before filling, using a screen or a sieving device no coarser
than 40 mesh.
1048.10.1 1.1.3.2 The VOC content of the finished paint shall be less than 1.25 pounds of volatile organic
matter per gallon of total non-volatile paint material when tested in accordance with ASTM D 3960.
1048.10.1 1.1.3.3 The paint shall have the following physical properties.
Property Requirement Viscosity, KU 80 - 95 Laboratory Dry Time, ASTM D 711, minutes, max. 10
1048.10.1 1.1.4 Color. For white, the color shall closely match Color Chip 37925 of Federal Standard 595b. For
yellow, the color shall closely match Color Chip 33538 of Federal Standard 595b. Color determination will be made for markings and the diffuse daytime color of the markings shall be in accordance with the below CIE Chromaticity coordinate limits. Color determination for liquid marking materials will be made over the black portion of a 2A or 5C Leneta Chart or equal, at least 24 hours after application of a 15-mil wet film. Color readings will be determined in accordance with the requirements of ASTM E 1349 using CIE 1931 2-degree standard observer and CIE standard illuminant D65. CIE Chromaticity Coordinate Limits (Initial) Color1 2 3 4 x y x y x y x y White0.3340.3570.3340.3170.2970.3570.2970.317 Yellow0.5310.4830.5310.4290.4710.4830.4710.429
1048.10.1 1.1.4.1 Contrast Ratio. The contrast ratio shall be a minimum of 0.98 when drawn down as a 15-mil
wet film on a 2A or 5C Leneta Chart or equal, and air-dried for 24 hours. The contrast ratio shall be calculated as follows: Contrast ratio = Black/White.
1048.10.1 1.1.4.2 Reflectance. The daylight directional reflectance of a 15-mil wet film applied to a 2A or 5C
Leneta Chart or equal and dried for a minimum of 24 hours shall be 84% minimum for the white paint and 50% minimum for the yellow paint.
1048.10.1 1.1.5 Acceptance.
1048.10.1 1.1.5.1 Except as noted, each batch or lot of paint shall be sampled and approved by the engineer
prior to use.
1048.10.1 1.1.5.2 No paint shall be used that is more than 15 months old.
1048.10.1 1.1.5.3 In addition to the requirements of Sec 1048.1.1, the certification supplied by the manufacturer
shall include reference to the specific NTPEP test deck to which the paint formulation was applied, including NTPEP identification numbers and report numbers.
1048.10.1 1.2 Cold Weather Waterborne Pavement Marking Paint.
1048.10.1 1.2.1 Description. These specifications cover waterborne traffic paint for application on bituminous
or Portland cement concrete pavements by department-owned spray equipment at application temperatures of 35 to 150ºF (2 to 66ºC). The paint shall be capable of receiving and holding glass beads for producing reflectorized traffic markings.
1048.10.1 1.2.2 Materials. The paint shall not contain more than 500 ppm lead and/or more than 780 ppm
chromium based on dry weight and shall have limited Volatile Organic Content (VOC), as noted herein. 6591048.10.1.1.2.2.1 Acrylic Emulsion Polymer. The acrylic emulsion polymer used in the manufacture of the paint shall be Dow Fastrack XSR or preapproved equivalent. Later generation acrylic emulsions may be substituted only after concurrence of the Chemical Laboratory Director.
1048.10.1 1.2.2.2 General. The finished paint shall be formulated and manufactured from first-grade materials
and shall be a fast drying, water based, acrylic resin type paint capable of withstanding air and roadway temperatures without bleeding, staining, discoloring, or deforming. The dried paint film shall be capable of maintaining its original dimensions and placement without chipping, spalling, or cracking. In addition, it shall not deteriorate because of contact with sodium chloride, calcium chloride, mild alkalies and acids, or other ice control materials, or oil, gasoline or diesel fuel drippings from vehicles.
1048.10.1 1.2.2.3 Maintained retroreflectivity. Photometric quantity to be measured is coefficient of
retroreflective luminance (RL) in accordance with the requirements of ASTM E1710 for 30-meter geometry. The average RL for concrete and asphalt surfaces shall be expressed in millicandelas per square meter per lux (milicandelas/m2/lux) and shall be at least 75 for 30 meter geometry, when measured in the wheel path area.
1048.10.1 1.2.2.4 Mixed Paint. The mixed paint shall conform to the following requirements.
1048.10.1 1.2.2.4.1 The paint shall be strained before filling, using a screen or strainer not coarser than 40 mesh
or equivalent.
1048.10.1 1.2.2.4.2 The volatile content of the finished paint shall contain less than 150 grams of volatile
organic matter per liter in accordance with ASTM D3960.
1048.10.1 1.2.2.4.3 The paint shall have the following properties:
1048.10.1 1.2.2.4.3.1 Physical Properties.
Property Requirement Weight per Gallon @77 F, lbs Report Viscosity, KU 75-92 Grind (Hegman Gage), min. 3 Laboratory Dry Time, ASTM D 711, minutes, max.10 Dry Through Time, minutes, max 150
1048.10.1 1.2.2.4.3.2 Color. For white the color shall closely match Color Chip 37925 of Federal Standard
595b. For yellow, the color shall closely match Color Chip 33538 of Federal Standard 595b. Color determination will be made for markings and the diffuse daytime color of the markings shall conform to the below CIE Chromaticity coordinate limits. Color determination for liquid marking materials will be made over the black portion of a 2A or 5C Leneta Chart (or equal) at least twenty-four (24) hours after application of a 15- mil wet film. Color readings will be determined in accordance with the requirements of ASTM E1349 using CIE 1931 2º standard observer and CIE standard illuminant D65. CIE Chromaticity Coordinate Limits (Initial) Color1 2 3 4 x y x y x y x y White0.3340.3570.3340.3170.2970.3570.2970.317 Yellow0.5310.4830.5310.4290.4710.4830.4710.429
1048.10.1 1.2.2.4.3.3 Flexibility. The paint shall show no cracking or flaking when tested in accordance with
Federal Specification TT-P-1952B.
1048.10.1 1.2.2.4.3.4 Water Resistance. The paint shall show no cracking or flaking when tested in accordance
with Federal Specification TT-P-1952B.
1048.10.1 1.2.2.4.3.5 Freeze-Thaw Stability. The paint shall show no coagulation or change in consistency
greater than 10 Kreb Units, when tested in accordance with Federal Specification TT-P-1952B. 6601048.10.1.1.2.2.4.3.6 Heat Stability. The paint shall show no coagulation, discoloration or change in consistency greater than 10 Kreb Units, when tested in accordance with Federal Specification TT-P-1952B.
1048.10.1 1.2.2.4.3.7 Dilution Test. The paint shall be capable of dilution with water at all levels without
curdling or precipitation such that the wet paint can be readily cleaned up with water only.
1048.10.1 1.2.2.4.3.8 Storage Stability. After 30 days storage in three-quarters filled, closed container, the paint
shall show no caking that cannot be readily remixed to a smooth, homogeneous state, no skinning, livering, curdling, or hard settling. The viscosity shall not change more than 5(10) Kreb Units from the viscosity of the original sample.
1048.10.1 1.2.2.4.3.9 Contrast Ratio. The minimum contrast ratio (hiding power) shall be 0.99 for White and
0.98 for Yellow when drawn down with a 0.015 film applicator on a 2A or 5CLeneta Chart (or equal) and air- dried for 24 hours. Contrast Ratio = Black/White.
1048.10.1 1.2.2.4.3.10 Reflectance. The daylight directional reflectance of the white paint shall not be less than
87 percent and not less than 50 percent for yellow paint of a 15 mil wet film applied to a 2A or 5C Leneta Chart (or equal). After drying for a minimum of 24 hours measure the reflectance of the paint over the black portion of the chart using colorimeter, ASTM E 1347.
1048.10.1 1.2.2.4.3.11 Bleeding. The paint shall have a minimum-bleeding ratio of 0.97 when tested in
accordance with Federal Specification TT-P-1952B. The asphalt saturated felt shall conform to ASTM D 226 for Type I.
1048.10.1 1.2.2.4.3.12 Dry Through Time. The paint shall be applied to a non-absorbent substrate at a wet film
thickness of 15 ± 1 mils and placed in a humidity chamber controlled at 90 ± 5 percent R.H. and 72.5 ± 2.5ºF. The dry through time shall be determined according to ASTM D 1640.
1048.10.1 1.2.5 Acceptance. The Missouri Department of Transportation reserves the right to make field tests
of material after receipt of bids, but prior to award to determine the paint's suitability for application in its equipment and for purposes of determining compliance with drying time requirements of this specification.
1048.10.1 1.2.5.1 Stability in Storage. After storage for periods up to twelve (12) months from the date of
manufacture, the paint shall comply with the following requirements: a) The pigment shall not settle badly or cake in the container, nor shall the paint skin or thicken in storage sufficiently to cause an undesirable change in consistency, nor show spoilage. b) The paint shall comply with all other provisions of these specifications and be capable of being re-dispersed with a paddle or mixer to a smooth uniform condition of usable consistency.
1048.10.2 Temporary Removable Pavement Marking Tape.
1048.10.2 1 General. Temporary removable pavement marking tape shall be capable of being removed and
shall leave no objectionable or misleading image or damage to the pavement after removal.
1048.10.2 2 The tape shall have a minimum specific luminance as shown for White and Yellow per ASTM D
4592, expressed as millicandelas/m2/lux. The tape shall be applied to an 8 x 36-inch panel per instrument recommendation for pavement marking tape and measured in accordance with MoDOT Test Method TM 8 at prescribed CEN geometry.
1048.10.2 3 Adhesive. Tape shall have a pre-coated pressure sensitive adhesive requiring no activation
procedures. The adhesive shall be resistant to normal roadway chemicals or materials.
1048.10.2 4 Durability. The tape shall be weather-resistant and show no appreciable fading, lifting or shrinkage
during the tape’s useful life. Samples of the tape applied to standard specimen plates and tested in accordance with Federal Test Method No. 141, Method 6192, for 1,000 cycles, using a CS-17 wheel and 1,000-gram load shall not expose the backing material over more than five percent of the abraded area.
1048.10.3 Temporary Non-Removable Pavement Marking Tape.
6611048.10.3.1 Reflectance. The tape shall have minimum specific luminance as shown for White and Yellow per ASTM D 4592, expressed as millicandelas/m2/lux). The tape shall be applied to an 8 in. x 36 in. panel per instrument recommendation for pavement marking tape and measured in accordance with MoDOT Test Method TM 8 at prescribed CEM geometry.
1048.10.3 2 Adhesive. Tape shall have pre-coated pressure sensitive adhesive requiring no activation
procedures. The adhesive shall be resistant to normal roadway chemicals or materials.
1048.10.3 3 Durability. The tape shall be weather-resistant and show no appreciable fading, lifting or shrinkage
during the tape’s useful life. Samples of the tape applied to standard specimen plates and tested in accordance with Federal Test Method No. 141, Method 6192, for 1000 cycles, using a CS-17 wheel and 1000-gram load shall not expose the backing material over more than five percent of the abraded area.
1048.10.4 Temporary Raised Pavement Markers.
1048.10.4 1 General. The brand name and manufacturer shall be stamped or indelibly printed on each container.
1048.10.4 2 Temporary Raised Pavement Markers. Markers shall consist of an L-shaped or T-shaped flexible
polymer body with a minimum of 6.0 squre inches of ASTM Type V reflective sheeting on both faces of the vertical section. The marker base shall have affixed a pressure-sensitive adhesive, protected by a release paper, for application to the pavement surface. When required per Sec 620.10.5.3.2, a protective sleeve that prevents contamination of the reflective faces during pavement surface treatment operations shall be affixed to each marker in a minimum of two locations. The protective sleeve shall be easily removable after the surface treatment operation is complete
1048.20 Permanent Pavement Marking Materials.
1048.20.1 Pavement Marking Paint Materials.
1048.20.1 1 Standard Acrylic Waterborne Pavement Marking Paint.
1048.20.1 1.1 Description. Standard acrylic waterborne pavement marking paint shall be capable of receiving
and holding glass beads for producing retroreflective pavement marking.
1048.20.1 1.2 Material. The paint shall contain no more than 3200 ppm lead or more than 800 ppm chromium,
based on dry weight.
1048.20.1 1.2.1 General. The finished paint shall be formulated and manufactured from quality material and
shall be a fast-drying, water-based, acrylic resin-type paint capable of withstanding air and roadway temperatures without bleeding, staining, discoloring or deforming. The dried paint film shall be capable of maintaining original dimensions and placement without chipping, spalling or cracking. The dry paint film shall not deteriorate from contact with normal roadway chemicals or materials.
1048.20.1 1.2.2 Acrylic Emulsion Polymer. The acrylic emulsion polymer used in the manufacture of the paint
shall be Rohm & Haas E-2706, Dow DT211 or equal. Later generation acrylic emulsions may be substituted as approved by the engineer.
1048.20.1 1.2.3 Durability Testing. The provisions of Sec 1048.20.1.2.2.3 will apply.
1048.20.1 1.2.3.1 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient of
retroreflective luminance (RL) in accordance with the requirements of ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and bituminous surfaces shall be expressed in millicandelas/lux/m2 and shall be at least 100 for 15-meter geometry or 75 for 30-meter geometry, when measured in the wheel path area.
1048.20.1 1.2.3.2 Durability. Paint shall have a durability rating of at least 4 on both concrete and bituminous
surfaces when tested in the wheel path area of the NTPEP test deck..
1048.20.1 1.3 Mixed Paint. The provisions of Sec 1048.20.1.2.3 shall apply.
6621048.20.1.1.4 Acceptance.
1048.20.1 1.4.1 Except as noted, each batch or lot of paint shall be sampled and approved by the engineer prior
to use.
1048.20.1 1.4.2 No paint shall be used that is more than 15 months old.
1048.20.1 1.4.3 In the addition to the requirements of Sec 1048.1.1, the certification supplied by the
manufacture shall include reference to specific NTPEP test deck to which the paint formulation was applied, including NTPEP identification numbers and report numbers.
1048.20.1 2 High Build Acrylic Waterborne Pavement Marking Paint.
1048.20.1 2.1 Description. Acrylic waterborne pavement marking paint shall be capable of receiving and
holding glass beads for producing retroreflective pavement marking.
1048.20.1 2.2 Material. The paint shall contain no more than 3,200 ppm lead or more than 800 ppm chromium,
based on dry weight.
1048.20.1 2.2.1 General. The finished paint shall be formulated and manufactured from quality material and
shall be a fast-drying, water-based, acrylic resin-type paint capable of withstanding air and roadway temperatures without bleeding, staining, discoloring or deforming. The dried paint film shall be capable of maintaining original dimensions and placement without chipping, spalling or cracking. The dry paint film shall not deteriorate from contact with normal roadway chemicals or materials.
1048.20.1 2.2.2 Acrylic Emulsion Polymer. The acrylic emulsion polymer used in the manufacture of the paint
shall be Rohm & Haas HD-21, Dow DT400 or equal.
1048.20.1 2.2.3 Durability Testing. Determination of conformance to this specification will include, but will
not be limited to, the evaluation of test data from NTPEP or other MoDOT approved facilities. The maintained retroreflectivity and durability shall be in accordance with the following requirements after being installed on at least one NTPEP test deck in a northern climate region for at minimum of six months, including December, January and February.
1048.20.1 2.2.3.1 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient of
retroreflective luminance (RL) in accordance with the requirements of ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and bituminous surfaces shall be expressed in millicandelas per footcandle per square foot and shall be at least 100 for 15-meter geometry or 75 for 30- meter geometry, when measured in the wheel path area.
1048.20.1 2.2.3.2 Durability. Paint shall have a durability rating of at least 4 for both concrete and bituminous
surfaces when tested in the wheel path area of the NTPEP test deck.
1048.20.1 2.3 Mixed Paint.
1048.20.1 2.3.1 The paint shall be strained before filling using a screen or a sieving device no coarser than 40
mesh or equivalent.
1048.20.1 2.3.2 The volatile content of the finished paint shall contain less than 150 grams of volatile organic
matter per liter in accordance with ASTM D 3960.
1048.20.1 2.3.3 The paint shall have the following physical properties:
Acrylic Waterborne Pavement Marking Paint Physical Properties Property Requirement Viscosity, 77 F, KU 83-98 Grind (Hegman Gage), minimum 3 Laboratory Dry Time, ASTM D 711, @ 15 mil, minutes, max. 10 Laboratory Dry Time, ASTM D 711, @ 25 mil, minutes, max. 25 663Dry Through Time, minutes, max. 150
1048.20.1 2.3.3.1 Color. For white, the color shall closely match Color Chip 37925 of Federal Standard 595b.
For yellow, the color shall closely match Color Chip 33538 of Federal Standard 595b. Color determination will be made for markings and the diffuse daytime color of the markings shall be in accordance with the below CIE Chromaticity coordinate limits. Color determination for liquid marking material will be made over the black portion of a 2A or 5C Leneta Chart or equal, at least 24 hours after application of a 15-mil wet film. Color readings will be determined in accordance with the requirements of ASTM E 1349 using CIE 1931 2-degree standard observer and CIE standard illuminant D65. CIE Chromaticity Coordinate Limits (Initial) Color1 2 3 4 x y x y x y x y White0.3340.3570.3340.3170.2970.3570.2970.317 Yellow0.5310.4830.5310.4290.4710.4830.4710.429
1048.20.1 2.3.3.2 Flexibility. The paint shall show no cracking or flaking when tested in accordance with
Federal Specification TT-P-1952B.
1048.20.1 2.3.3.3 Water Resistance. The paint shall conform to Federal Specification TT-P-1952B. There shall
be no blistering or appreciable loss of adhesion, softening or other deterioration after examination.
1048.20.1 2.3.3.4 Freeze-Thaw Stability. The paint shall show no coagulation or change in consistency greater
than 10 Kreb Units when tested in accordance with Federal Specification TT-P-1952B.
1048.20.1 2.3.3.5 Heat Stability. The paint shall show no coagulation, discoloration or change in consistency
greater than 10 Kreb Units when tested in accordance with Federal Specification TT-P-1952B.
1048.20.1 2.3.3.6 Dilution Test. The paint shall be capable of dilution with water at all levels without curdling
or precipitation such that the wet paint can be readily cleaned up with water only.
1048.20.1 2.3.3.7 Storage Stability. After 30 days of storage in a 3/4 filled, closed container, the paint shall
show no caking that cannot be readily remixed to a smooth, homogeneous state, and shall show no skinning, livering, curdling or hard settling. The viscosity shall change no more than 5 Kreb Units from the viscosity of the original sample.
1048.20.1 2.3.3.8 Contrast Ratio. The minimum contrast ratio (hiding power) shall be 0.96 when drawn down
with a 0.005 bird film applicator on a 2A or 5C Leneta Chart or equal and air-dried for 24 hours. The contrast ratio shall be calculated as follows: Contrast Ratio = Black/White.
1048.20.1 2.3.3.9 Reflectance. The daylight directional reflectance of a 15-mil wet film, applied to a 2A or 5C
Leneta Chart or equal and dried for a minimum of 24 hours, shall be no less than 84 percent for the white paint and no less than 50 percent for the yellow paint.
1048.20.1 2.3.3.10 Bleeding. The paint shall have a minimum bleeding ratio of 0.97 when tested in accordance
with Federal Specification TT-P-1952B. The asphalt saturated felt shall be in accordance with ASTM D 226 for Type I.
1048.20.1 2.3.3.11 Dry Through Time. The paint shall be applied to a non-absorbent substrate at a wet film
thickness of 15 ± 1 mil and placed in a humidity chamber controlled at 90 ± 5 percent relative humidity and 72.5 ± 2.5 F. The dry through time shall be determined in accordance with ASTM D 1640, except that the pressure exerted shall be the minimum needed to maintain contact with the thumb and film.
1048.20.1 2.4 Acceptance.
1048.20.1 2.4.1 Except as noted, each batch or lot of paint shall be sampled and approved by the engineer prior
to use. 6641048.20.1.2.4.2 No paint shall be used that is more than 15 months old.
1048.20.1 2.4.3 In addition to the requirements of Sec 1048.1.1, the certification supplied by the manufacturer
shall include reference to the specific NTPEP test deck to which the paint formulation was applied, including NTPEP identification numbers and report numbers.
1048.20.2 Durable Pavement Marking Materials.
1048.20.2 1 Plural Component Pavement Marking Materials.
1048.20.2 1.1 Epoxy Pavement Marking Materials.
1048.20.2 1.1.1 Fast Cure Epoxy Pavement Marking Materials.
1048.20.2 1.1.1.1 General. Epoxy pavement marking material shall not contain toxic heavy metals. The
material shall be two-component, 100 percent solids and formulated and tested to perform as a pavement marking material with glass beads applied to the surface. The two components shall be epoxy resin and an amine curing agent.
1048.20.2 1.1.1.2 Toxicity. Upon heating to application temperature, the material shall not release fumes that are
toxic to persons or property. Upon curing, the material shall be completely inert, with all components fully reacted and environmentally benign.
1048.20.2 1.1.1.3 No Track Time. The material shall have a no-track time of 10 minutes or less, when mixed in
the proper proportions and applied at a 25-mil wet film thickness at 75 ± 2 F with the proper application of glass beads and when tested in accordance with ASTM D 711. The material shall fully cure under a constant surface temperature of 32 F or above.
1048.20.2 1.1.1.4 Adhesion to Concrete. The pavement marking material shall have a high degree of adhesion
to the concrete surface such that there is a 100 percent concrete failure when tested in accordance with ACI 503, Appendix A.1. The prepared specimens shall have a film thickness of 15 ± 1 mil and shall be applied to concrete with a minimum compressive strength of 4,000 psi. The concrete surface shall be 90 ± 2 F when the material is applied. The applied material shall be cured for 72 hours at 75 ± 2 before performing the test.
1048.20.2 1.1.1.5 Hardness. The material shall have a minimum Shore D Hardness of 75 when tested in
accordance with ASTM D 2240.
1048.20.2 1.1.1.6 Tensile Strength. The material shall have a minimum tensile strength of 5,000 psi after 72
hours of cure at 75 ± 2 F when tested in accordance with ASTM D 638.
1048.20.2 1.1.1.7 Compressive Strength. The material shall have a minimum compressive strength of 10,000
psi after 72 hours of cure at 75 ± 2 F when tested in accordance with ASTM D 695.
1048.20.2 1.1.1.8 Abrasion Resistance. The material shall have a maximum abrasion resistance of 150 mg at
15 ± 1 mil thickness after 72 hours of cure and with a CS-17 wheel under a load of 1,000 grams for 1,000 cycles, when tested in accordance with ASTM C 501.
1048.20.2 1.1.1.9 Yellowness Index. The material shall have a maximum yellowness index of 6 before the QUV
test and a maximum of yellowness index of 23 after the 72-hour QUV test, when tested in accordance with ASTM D 1925.
1048.20.2 1.1.1.10 Color. The finished white color shall be free from tint, furnishing good opacity and visibility
under both daylight and artificial light. The finished yellow color shall closely match Federal Test Standard 595 - Color Chip Number 13538.
1048.20.2 1.1.1.11 Drop-on Glass Beads. Glass beads shall be in accordance with Sec 1048.30.
1048.20.2 1.1.1.12 Qualification. In addition to the requirements of Sec 1048.1.1, the material shall have been
field tested at NTPEP test decks in a northern, wet climate region for a minimum of six months. The maintained 665retroflectivity and durability shall be in accordance with the following requirements after being installed on at least one NTPEP test deck for a minimum of six months, including December, January and February.
1048.20.2 1.1.1.12.1 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient
of retroreflective luminance (RL) in accordance with ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and asphalt surfaces shall be expressed in millicandelas per footcandle per square foot and shall be at least 125 for 15-meter geometry or 100 for 30-meter geometry, when measured in the wheel path area.
1048.20.2 1.1.1.12.2 Durability. Paint shall have a durability rating of at least 5 for both concrete and asphalt
surfaces when tested in the wheel path area of the NTPEP test deck.
1048.20.2 1.1.1.13 Packaging. The manufacturer's name and address, product name, color, manufacturing date,
date of expiration and if the material is Part A or B shall be visible on the containers. In addition to the requirements of Sec 1048.1.1, the certification supplied by the manufacturer shall include reference to the specific NTPEP test deck to which the paint formulation was applied, including NTPEP identification numbers and report numbers.
1048.20.2 1.2 Polyurea Pavement Marking Material.
1048.20.2 1.2.1 Polyurea Pavement Marking Material. Polyurea pavement marking material shall not contain
toxic heavy metals. It shall be two components, 100 percent solids, and formulated and tested to perform as a pavement marking material with glass beads applied to the surface.
1048.20.2 1.2.2 Toxicity. Upon heating to application temperature, the material shall not release fumes that are
toxic to persons or property. Upon curing, the material should be completely inert, with all components fully reacted and environmentally benign.
1048.20.2 1.2.3 No Track Time. The material shall have a no-track time of 10 minutes or less when mixed in
the proper proportions and applied at 20 mils wet film thickness at 75 ± 2 F with the proper application of glass beads and when tested in accordance with ASTM D 711. The material shall fully cure under a constant surface temperature of 32 F or above.
1048.20.2 1.2.4 Adhesion to Concrete. The pavement marking material shall have a high degree of adhesion to
the concrete surface such that there is a 100 percent concrete failure when tested in accordance with ACI 503, Appendix A.1. The prepared specimens shall have a film thickness of 15 ± 1 mils and be applied to concrete with a minimum compressive strength of 4,000 psi. The concrete surface shall be 90 ± 2 F when the material is applied. The applied material shall be cured for 72 hours at 75 ± 2 F before performing the test.
1048.20.2 1.2.5 Hardness. The material shall have a minimum Shore D Hardness of between 70 and 100 when
tested in accordance with ASTM D 2240.
1048.20.2 1.2.6 Abrasion Resistance. The material shall have a maximum abrasion resistance of 150 mg at 15
± 1 mils thickness after 72 hour curing time and with a CS-17 wheel under a load of 1,000 grams for 1,000 cycles, when tested in accordance with ASTM C 501.
1048.20.2 1.2.7 Yellowness Index. The material shall have a maximum yellowness index of 6 before the QUV
test and a maximum of 23 after the 72 hour QUV test, when tested in accordance with ASTM D 1925.
1048.20.2 1.2.8 Color. The finished white color shall be free from tint, furnishing good opacity and visibility
under both daylight and artificial light. The finished yellow color shall be defined by Federal Test Standard 595 - Color Chip Number 13538, using Federal Tests Standard 141 (Method 4252).
1048.20.2 1.2.9 Accelerated Weathering. The material shall have been field tested at NTPEP test decks for a
minimum of six months. The material shall have satisfactory results from the NTPEP test deck.
1048.20.2 1.2.10 Drop-on Glass Beads. Glass beads shall be in accordance with Sec 1048.30.
1048.20.2 1.2.11 Qualification. In addition to the requirements of Sec 1048.1.1, the material shall have been
field tested at NTPEP test decks in a northern, wet climate region for a minimum of six months. The maintained 666retroflectivity and durability shall be in accordance with the following requirements after being installed on at least one NTPEP test deck for a minimum of six months, including December, January and February.
1048.20.2 1.2.11.1 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient of
retroreflective luminance (RL) in accordance with ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and asphalt surfaces shall be expressed in millicandelas per footcandle per square foot and shall be at least 125 for 15-meter geometry or 100 for 30-meter geometry, when measured in the wheel path area.
1048.20.2 1.2.11.2 Durability. Paint shall have a durability rating of at least 5 for both concrete and asphalt
surfaces when tested in the wheel path area of the NTPEP test deck.
1048.20.2 1.2.12 Packing. The pavement marking material shall be shipped to the job site in strong, substantial
containers. The manufacturer shall include the MSDS with each shipment. The manufacturer's name and address, name of the product, lot number and/or batch number, color, tare weight, manufacturing date, date of expiration, mixing proportions and if it is Part A or B shall be contained on a label and/or painted on the containers.
1048.20.2 2 Durable Preformed Pavement Marking Materials.
1048.20.2 2.1 Cold Applied Preformed Pavement Marking Tape Materials.
1048.20.2 2.1.1 Application. After application, the tape shall be immediately ready to receive traffic.
1048.20.2 2.1.2 Composition. Cold applied preformed pavement marking tape shall consist of a mixture of
polymeric material and pigments with beads distributed throughout the cross-sectional area and with a reflective layer of glass beads embedded in the surface. The marking shall be capable of adhering to bituminous or concrete surfaces by a flexible conforming backing. A primer may be required to precondition the pavement surface.
1048.20.2 2.1.3 Dimensions. The marking tape as supplied shall be free of cracks, and have edges true, straight,
and unbroken. The actual width of the rolls of preformed tape shall be no less than the nominal (stated) width and no more than 1/8 in. greater than the nominal width. The length shall be no less than the length stated.
1048.20.2 2.1.4 Adhesion. The tape shall be supplied with a precoated factory-applied pressure sensitive
adhesive. The marking tape shall have minimum adhesion values as shown in table 2 of ASTM D1000.
1048.20.2 2.1.5 Color. The white and yellow marking tape shall conform to the requirements of ASTM D6628.
1048.20.2 2.1.6 Reflectance. The tape shall have a minimum specific luminance as shown for White and
Yellow per ASTM D 4505, expressed as millicandelas /m2/lux. The tape shall be applied to an 8 x 36-inch panel per instrument recommendation for pavement marking tape and measured in accordance with MoDOT Test Method TM 8 at prescribed CEN geometry.
1048.20.2 2.1.7 Index of Refraction. The glass beads mixed into the pliant polymer shall have a minimum
index of refraction of 1.50 when tested by the oil immersion method. If ceramic elements are used in the pavement marking, the ceramic elements shall have a minimum index of refraction of 1.70 when tested using the liquid oil immersion method. Ceramic beads with an index of refraction greater than 1.80 shall not be used.
1048.20.2 3 Durable Intersecton Marking Materials.
1048.20.2 3.1 Preformed Thermoplastic Material.
1048.20.2 3.1.1 General. Pavement marking material shall not contain toxic heavy metals. The material shall be
solid, formulated and tested to perform as a pavement marking material with glass beads uniformly throughout the marking.
1048.20.2 3.1.2 Toxicity. Upon heating to application temperature, the material shall not release fumes that are
toxic to persons or property. Upon curing, the material shall be completely inert, with all components fully reacted and environmentally benign. 6671048.20.2.3.1.3 Adhesion to Pavement. The pavement marking material shall have a high degree of adhesion to the pavement surface. The product shall be applied per manufactures specification on a clean dry surface.
1048.20.2 3.1.4 Abrasion Resistance. The material shall have a maximum abrasion resistance of 150 mg with a
CS-17 wheel under a load of 1,000 grams for 1,000 cycles, when tested in accordance with ASTM C 501.
1048.20.2 3.1.5 Yellowness Index. The material shall have a maximum yellowness index of 6 before the QUV
test and a maximum of yellowness index of 23 after the 72-hour QUV test, when tested in accordance with ASTM D 1925.
1048.20.2 3.1.6 Color. The finished white color shall be free from tint, furnishing good opacity and visibility
under both daylight and artificial light. The finished yellow color shall closely match Federal Test Standard 595 - Color Chip Number 33538.
1048.20.2 3.1.7 Qualification. In addition to the requirements of Sec 1048.1.1, the material shall have been
field tested at NTPEP test decks in a northern, wet climate region for a minimum of six months. The maintained retroflectivity and durability shall be in accordance with the following requirements after being installed on at least one NTPEP test deck for a minimum of six months, including December, January and February.
1048.20.2 3.1.8 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient of
retroreflective luminance (RL) in accordance with ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and asphalt surfaces shall be expressed in millicandelas per footcandle per square foot and shall be at least 125 for 15-meter geometry or 100 for 30-meter geometry, when measured in the wheel path area.
1048.20.2 3.1.9 Durability. Paint shall have a durability rating of at least 5 for both concrete and asphalt
surfaces when tested in the wheel path area of the NTPEP test deck.
1048.20.2 3.1.10 Packaging. The manufacturer's name and address, product name, color, manufacturing date,
date of expiration of the material. In addition to the requirements of Sec 1048.1.1, the certification supplied by the manufacturer shall include reference to the specific NTPEP test deck to which the product was applied, including NTPEP identification numbers and report numbers.
1048.20.2 3.2 Plural Component Intersection Marking Materials.
1048.20.2 3.2.1 Epoxy Materials.
1048.20.2 3.2.1.1 General. Epoxy Materials used for intersection markings shall be in accordance with Sec
1048.20.2 1.1.
1048.20.2 3.2.2 Polyurea Materials.
1048.20.2 3.2.2.1 General. Polyurea Materials used for intersection markings shall be in accordance with Sec
1048.20.2 1.2.
1048.20.2 3.3 Cold Applied Tape Intersection Marking Material.
1048.20.2 3.3.1 General. Cold Applied Tape Materials used for intersection markings shall be in accordance
with Sec 1048.20.2.2.1. SECTION 1048.30 DROP-ON GLASS BEADS.
1048.30.1 General. When tested in accordance with MoDOT Test Method TM 70 for water resistance, the
beads shall show no readily discernible dulling and the amount of 0.1 normal hydrochloric acid needed to titrate the filtrate shall not exceed 4.5 mL. When tested in accordance with MoDOT Test Method TM 70 for calcium chloride and sodium sulfide resistance, the beads shall show no readily discernible darkening or dulling.
1048.30.2 Type P Drop-On Glass Beads. Type P beads shall be manufactured from glass of a composition that
is highly resistant to traffic wear and to the effects of weathering. If coating is required to meet the performance 668requirements for the specific marking material used, the beads shall be coated to ensure satisfactory embedment and adhesion.
1048.30.2 1 Refractive Index. Type P beads shall have a minimum refractive index of 1.51 when tested in
accordance with AASHTO M 247.
1048.30.2 2 Roundness. All Type P beads passing the No. 30 sieve shall have a minimum of 75 percent true
spheres when tested in accordance with ASTM D 1155 or AASHTO PP-74. All Type P beads retained on the No. 20 and No. 30 sieves shall have a minimum of 80 percent true spheres as determined by ASTM D 1155 or AASHTO PP-74.
1048.30.2 3 Gradation. Type P beads shall meet the following gradation requirements when tested in
accordance with ASTM D 1214.
U.S. Standard Sieve No.Percent Retained 20 3-10 30 15-35 50 45-75 70 0-10 Pan 0-5
1048.30.3 Type L Drop-On Glass Beads. Type L beads shall be embedment coated and manufactured from
glass of a composition that is highly resistant to traffic wear and to the effects of weathering. The beads shall be in accordance with AASHTO M 247, Type 1, except as follows.
1048.30.3 1 Coating. The beads shall be coated to ensure satisfactory embedment and adhesion when applied to
uncured traffic marking material. The coating shall be tested in accordance with MoDOT Test Method TM 70.
1048.30.3 2 Roundness. Type L beads shall have a minimum of 80 percent rounds per screen for the two
highest sieve quantities, and no more than 3 percent angular particles per screen, as determined by ASTM D 1155 or AASHTO PP-74. The remaining sieve fractions shall be determined by ASTM D 1155 or AASHTO PP- 74to be no less than 65 percent rounds.
1048.30.3 3 Gradation. Type L beads shall meet the following gradation requirements when tested in
accordance with ASTM D 1214: Type L Bead Gradation Requirements Sieve Size Percent Passing No. 12 100 No. 14 95 - 100 No. 16 80 - 95 No. 18 10 - 40 No. 20 0 - 5 No. 25 0 - 2
1048.30.4 Type 1 Drop-On Glass Beads. Type 1 beads shall be moisture-resistant and manufactured from glass
of a composition that is highly resistant to traffic wear and to the effects of weathering. Glass beads shall be in accordance with AASHTO M 247, Type 1. 669SECTION 1049 PRECAST CONCRETE BOX CULVERTS 1049.1 Scope. This specification covers precast concrete box culverts. 1049.2 Acceptance. The basis of acceptance will be with producer's QMP in accordance with Sec 1001.14. 1049.2.1 Lot Size Definition. A lot is defined as one day's production. 1049.2.2 Quality Control. The producer QMP shall define quality control testing and inspection frequencies and shall include the following minimum requirements. 1049.2.2.1 Compressive strength of cylinders or cores shall be taken at a minimum of once per lot in accordance with ASTM C1577. Compressive strength testing shall also be performed to control handling and curing operations. Cylinders shall be cured in accordance with AASHTO T23 field curing procedures. 1049.2.2.2 Air and slump of fresh concrete shall be taken a minimum of once per lot. 1049.2.2.3 Aggregate gradation, absorption and deleterious shall be checked a minimum of once per month per aggregate source in accordance with Sec 1005. 1049.2.2.4 Steel placement shall be checked and documented for each unit. 1049.2.2.5 Finished dimensions shall be checked and documented for each unit. 1049.2.2.6 All equipment used for testing shall be maintained and calibrated in accordance with AASHTO R18 or equivalent program. 1049.2.2.7 Concrete plant(s) shall be calibrated and monitored in accordance with the producer's QMP. 1049.2.3 Quality Assurance. The QMP shall reference an industry organization or define independent QA testing frequencies including the following: Tested Propertya Test MethodIndependent QA Air T152 Twice a year Slump T119 Twice a year Coarse Aggregate Deleterious TM71 Twice a year Coarse Aggregate Absorption T85 Twice a year Compressive Strength T22 Twice a year Absorption (per mix) T280 Once a year a All samples shall be taken at the precast plant 1049.2.4 MoDOT Hold Points. 1049.2.4.1 MoDOT shall verify steel placement prior to concrete pour. 1049.2.4.2 Prior to shipping, producers shall notify MoDOT and obtain a MoDOT identification number(s). 1049.2.4.3 Repair methods and completion of repairs for non-conforming work shall be approved by the engineer. 1049.2.5 MoDOT Quality Assurance and Auditing. The engineer may perform QA testing and audit the producer's QMP, documentation and production at any time, which may include coring of the precast units at the producer's expense. 1049.2.6 Deficient Work. A procedure addressing deficient work in accordance with Sec 1001.14. 1049.2.6.1 Filling of form tie cavities and repair of other defects shall be in accordance with Sec 703. 6701049.2.7 Non-Conforming Work. A procedure addressing non-conforming work in accordance with Sec 1001.14. 1049.3 Material. 1049.3.1 Cement. Cement shall be in accordance with Sec 1019. 1049.3.2 Fly Ash. Fly ash shall be in accordance with Sec 1018. 1049.3.3 Ground Granulated Blast Furnace Slag. Ground granulated blast furnace slag shall be in accordance with the requirements of Sec 1017. 1049.3.4 Aggregate. Fine and coarse aggregate for the concrete mixture shall be in accordance with Sec 1005, except the requirements for gradation and percent passing the No. 200 sieve will not apply. 1049.3.5 Steel Reinforcement. Reinforcement shall be in accordance with Sec 1036.3. 1049.3.6 Concrete Mixture. Concrete shall be a minimum of 5,000 psi in accordance with ASTM C1577 and the mix design shall be approved by the engineer. Admixtures or blends may be used with approval from engineer. 1049.4 Design. Except as otherwise specified herein, precast concrete box sections for the culvert shall be in accordance with ASTM C 1577. Designs shall be submitted to the inspecting District. 1049.4.1 Substituted precast concrete box culvert sections shall be designed for the earth cover shown on the plans for the cast-in-place box culvert, and shall be equal in height and cross sectional area or as approved by the engineer. 1049.4.2 Special Designs. The producer shall request approval of any modified and special designs which differ from the designs in ASTM C 1577. The request for such modified and special designs shall fully describe any deviations from those standards, including a drawing showing wall thickness, concrete design strength, the type, size and placement of reinforcement, and inside or outside dimensions of both of the box sections. 1049.4.3 The minimum barrel length for box or end section shall be 2 feet. 1049.4.4 End sections may be precast or cast-in-place. If precast, the barrel, floor and wing walls shall be cast as an integral unit. In either case, the end sections shall be constructed to the same dimensions, shapes, and with the same reinforcement as shown on the plans for cast-in-place culvert. 1049.4.5 Segmented end sections may be provided, but will be considered a modified design and will require approval as such. 1049.4.6 Toe walls shall be provided on both the upstream and downstream ends as shown on the plans, and may be cast-in-place or precast. Precast toe walls shall be connected to the end section floor. 1049.5 Manufacture. 1049.5.1 Curing. Curing shall be in accordance with Sec 1026 until the concrete has developed the specified compressive strength. 1049.5.2 The producer shall ensure that the placing, finishing and consolidating of concrete is in accordance with their producer quality management plan. Temperatures shall be maintained to prevent detrimental effects to precast production and the following:
a.Concrete placed in cold weather shall be protected from freezing during the curing period by the use of a heated, weatherproof enclosure. Concrete shall not be placed on or against reinforcing steel or other surfaces with temperatures lower than 35 F. No concrete shall be placed when the enclosure ambient temperature is below 35 F. 671The temperature of the mixed concrete when placed shall be no higher than 90 F. The forms and reinforcing steel shall be cooled by acceptable methods to an ambient temperature of 90 F or lower. 1049.5.3 Permissible Variations. Dimensions, position of reinforcement, area of reinforcement and haunch dimensions shall be in accordance with ASTM C1577. 1049.6 Marking. The following information shall be legibly marked on each box section by indentation, waterproof paint or other approved means. Box section span, rise, maximum and minimum design earth cover and specification designation.
a.Date of manufacture.
b.Name or trademark of the manufacturer.
c.Indicator required by the QC program.
d.Sample Identification Number.
e.Station where the unit will be installed.
f.Each section shall be clearly marked on either the inner or the outer surface during the process of manufacture. In addition, the word "top" shall be lettered with waterproof paint on the inside of the top surface. 1049.7 MoDOT Identification Number. The producer shall contact the engineer, a minimum of one business day, prior to shipping precast products. The engineer shall assign a specific MoDOT identification number for each size and type of product in the shipment. 1049.7.1 Prior to delivery to the jobsite, the source, intermediate agent, shipper or contractor's representative shall notify the inspecting District by fax or electronically a minimum of one business day or earlier, prior to the impending shipment of precast material. This notification shall include a shipping form (Precast Shipping Form) and will include, at minimum, the following:
a.Contract Number and Project Number.
b.Receiving Purchaser/Contractor.
c.Type and quantity of material.
d.Date of expected delivery to the jobsite.
e.Manufacturer's name.
f.Stationing or structure number on precast unit, if applicable. 1049.7.2 The precast unit shall be clearly and permanently marked by the precaster with the ID number in accordance with Sec 1049.7 prior to shipment. Requests for alternate precast labeling shall be submitted to the inspecting District for approval. Material without proper identification number shall not be permitted for use on a project. 1049.8 Delivery. A bill of lading or delivery receipt for each shipment shall be furnished to the engineer at the destination point. The bill of lading shall contain an itemized statement of the sizes and lengths of precast units with the corresponding designated MoDOT identification number provided to the manufacturer for each size and type of precast unit for that shipment. The bill of lading shall contain a certified statement. The certified statement shall be signed by an authorized representative of the manufacturer and shall state the following: "This certifies that the precast products in this shipment are in accordance with MoDOT specifications." 673SECTION 1050 LUMBER, TIMBER, PILING, POSTS AND POLES 1050.1 Scope. This specification covers wood products as defined in the AWPA Standards. 1050.2 Posts. 1050.2.1 Posts and Blocks for Guardrail. Posts and blocks for guardrail shall be furnished in accordance with AASHTO M168, rectangular, standard rough sawn or planed, and of the size and length shown on the plans. Posts and blocks shall be pressure treated in accordance with Sec 1050.6. All framing and boring shall be completed before treatment. 1050.2.2 Posts for Fence. Posts for fence shall be round and of the sizes and lengths shown on the plans. Posts shall be pressure-treated in accordance with Sec 1050.6. Allowable tolerances for size and length will be as follows: Fence Post Tolerances Dimension Tolerance ≤4-inch diameter+1/2, No minus tolerance > 4-inch diameter+1 inch, No minus tolerance All Lengths (any diameter)No limit on over length, Minus 1 inch 1050.2.2.1 Grade. Wood for posts shall be sound, free of decay, excessive knots and of end splits and seasoning checks that might affect serviceability. Posts shall be free of multiple crooks, except crooks in one plane only in accordance with Sec 1050.2.2.2 will be permitted. 1050.2.2.2 Straightness. A straight line drawn from the center of one end of the post to the center of the opposite end shall not deviate from the longitudinal axis of the post at any point more than one percent of the length of the post. 1050.2.2.3 Manufacture. Posts shall be clean peeled to remove all bark, except that strips of inner bark no more than 1/2 inch wide or more than 3 inches long will be permitted to remain on the peeled post. All protruding knots shall be trimmed flush, and all spurs and splinters shall be removed. The natural taper of round posts shall be followed in machine peeling operations. The ends of all posts shall be cut square, except posts to be driven shall be machine-pointed on the small end prior to treatment. 1050.2.3 Posts for One-Strand Access Restraint Cable. Posts for one-strand access restraint cable may be round or rectangular, as shown on the plans. Round posts shall be in accordance with Sec 1050.2.2. Rectangular posts shall be standard rough sawn or planed, and of the grade specified in Sec 1050.2.2.1. All posts shall be in accordance with Sec 1050.6. 1050.2.4 Posts for Signs. Posts for signs shall be rectangular, rough sawn or surfaced four sides (S4S), with square cut ends, and shall be of the grade, size and length shown on the plans. Posts shall be pressure-treated in accordance with Sec 1050.6. Other preservatives and wood species shall be in accordance with applicable AWPA Standards. If framing and boring is completed after pressure treatment, field treatment shall be in accordance with Sec 1050.7. 1050.2.4.1 Permanent. Project sign posts shall be treated to Use Category (UC) 4B. 1050.2.4.2 Temporary. Post for temporary use shall be treated to UC 4A. 1050.3 Lumber and Timber. 1050.3.1 Species and Grade Requirements. Unless otherwise specified, lumber and timber to be used as a permanent part of a structure shall be one of the species shown in Table I or other treatable species as specified 674in the AWPA Standards, and of the grade specified on the plans. Lumber and timber for temporary structures shall be of the species and grades shown on the plans. 1050.3.2 Dressing Requirements. Lumber and timber shall be standard rough sawn or shall be surfaced as specified in the contract. Lumber and timber shall be cut to exact lengths or to permissible variations in lengths shown in the contract documents. 1050.3.3 Treatment. If treatment is specified, lumber and timber shall be pressure-treated in accordance with Sec 1050.6. 1050.4 Electric Substation, Service and Span Wire Assembly Poles. 1050.4.1 Electric Substation and Services Poles. Electric substation and service poles shall be of the length and class specified in the contract documents, and shall be in accordance with ANSI O5.1. Poles shall be pressure treated in accordance with Sec 1050.6. Poles may be gained and drilled in the field after treatment. Areas exposed shall be treated in accordance with Sec 1050.7 before cross-arms or equipment are mounted. 1050.4.2 Span Wire Assembly Poles. Span wire assembly poles shall be of the length specified in the contract and shall be in accordance with ANSI 05.1, Class IV, unless otherwise specified. The poles shall be pressure treated in accordance with Sec 1050.6. All poles shall have a minimum diameter of 6 3/4 inches, measured at the top of the pole. 1050.4.3 Pole Crossarms. The species, grade and treatment of crossarms to be erected on substation and service poles will be shown on the plans. 1050.5 Round Timber Piles. 1050.5.1 Material. All round timber piles shall be in accordance with ASTM D 25, except for size, which shall be in accordance with Table I for the class specified in the contract. 1050.5.2 Chemical Treatment. Piles shall be pressure treated in accordance with Sec 1050.6. Framing and boring will not be required before treatment. Exposed untreated areas resulting from framing of treated piling shall be field treated in accordance with Sec 1050.7. Untreated piles for use in unexposed locations or in temporary bridges shall be of the species approved by the engineer. 1050.6 Timber Preservatives. Pressure preservative treatment shall be in accordance with current AASHTO Standard M-133 and current AWPA Standards. 1050.6.1 Responsibility for Quality. The contractor shall use preservatives that meet these specifications or the treated material will be subject to rejection, or to approved retreatment with an approved preservative. 1050.7 Care After Treatment. Care shall be taken in handling pressure-treated material to avoid damage. Cant hooks, peavies, pickaroons and end cant hooks shall not be used on the side surfaces of treated material. All handling of treated round stock with pointed tools shall be confined to the ends. If damaged material is permitted for use by the engineer, or framing at site is required, remediation following current AWPA Standard M4 shall be followed. 1050.8 Inspection Requirements. 1050.8.1 Inspection. All material shall be inspected for compliance with these specifications in accordance with AWPA Standard M2. 1050.8.1.1 Timber products treated within the State of Missouri or within 100 air miles of the border may be inspected by MoDOT personnel. 1050.8.1.2 The inspection of lumber, timber, piling, posts and poles shall be performed by the supplier or an approved inspection agency, and the cost for inspection shall be at the contractor’s expense. 1050.8.2 Inspection Agency. An approved inspection agency will be a laboratory, accredited by the American Lumber Standards Committee, P.O. Box 210, Germantown, MD. Inspection agencies not accredited by the 675American Lumber Standards Committee shall submit for approval a resume to Construction and Materials. The resume of the agency shall include the agency’s history of inspection of timber and treated products, a listing of state highway agencies which have approved the inspection agency and a listing of state agencies for which the inspection agency has performed inspection. 1050.9 Certification. The contractor shall furnish to the engineer certification from the supplier or inspection agency that the material furnished is in accordance with these specifications. Certification shall include or shall have attached a listing of the material being supplied. Except as noted, the certification shall have attached a certified test report, as detailed in Section 7.2 of AWPA Standard M2, from the supplier or inspection agency attesting to complete compliance with AWPA and these specifications. Electric substation, service and span wire assembly poles will not require certified test reports.
1050.10 Acceptance. Acceptance of material will be based on satisfactory supplier's certification or inspection
agency certifications, and upon results of any tests deemed necessary by the engineer at destination to ascertain compliance with these specifications. TABLE I Circumferences and Diameters of Timber Piles, (in.) Length ftClass ATipClass BTipClass CTip3 ft From Butt 3 ft From Butt 3 ft From Butt Min Max Min Min Max Min Min Max Min CirDiaCirDiaCirDiaCirDiaCirDiaCirDiaCirDiaCirDiaCirDia Up to 50471557182893812632025838126320258 Over 50471557182584113632022738126320227 676SECTION 1051 SLOTTED DRAIN 1051.1 Scope. This specification covers slotted drain. 1051.2 Pipe. The pipe portion of the slotted drain shall be 16 gage. The material and fabrication of the pipe shall be in accordance with Sec 1020. The diameter of the pipe shall be as shown on the plans. 1051.3 Slotted Drain Grate Assembly. The grate assembly of Type A, B or C slotted drain shall be fabricated as shown on the plans. The grate assembly shall be 6 inches high unless otherwise specified on the plans. 1051.3.1 Type B and Type C slotted drain grate assemblies shall be fabricated from 3/16-inch thick ASTM A 36 structural steel. The entire grate assembly shall be hot dip galvanized, prior to attachment to the pipe, in accordance with AASHTO M 111. 1051.3.2 Type A slotted drain guide assemblies shall be fabricated from 14 gage galvanized steel meeting the same material requirements as the pipe. The drain guide slot shall be assembled with mechanical interlocks requiring no welding. 1051.4 All coupling devices and other necessary fittings shall be in accordance with Sec 1020. 677SECTION 1052 MECHANICALLY STABILIZED EARTH WALL SYSTEM COMPONENTS 1052.1 This specification covers material requirements for metallic soil reinforcement, non-metallic soil reinforcement, concrete facing panels for large block wall systems, and concrete blocks for small block wall systems that are supplied as part of mechanically stabilized earth wall systems. All precast items shall be in accordance with Sec 1001. SECTION 1052.10 METALLIC SOIL REINFORCEMENT.
1052.10.1 Scope. This specification covers metallic soil reinforcement and the accompanying attachments
utilized in mechanically stabilized earth wall systems.
1052.10.2 Reinforcement Strips. Metallic soil reinforcement strips shall be in accordance with the
specifications of the manufacturer of the wall system and the contract documents. The minimum grade of steel for strips and connection devices shall be AASHTO M 270, Grade 36.
1052.10.3 Reinforcement Mesh. Metallic soil reinforcement mesh shall be in accordance with the
specifications of the manufacturer of the wall system and the contract documents. The minimum grade of steel for strips and connection devices shall be either AASHTO M 270 Grade 36, ASTM A 1011 Grade 50 or ASTM A 463 Grade 50. Welding shall be in accordance with AASHTO M 55.
1052.10.4 Fasteners. Fasteners shall consist of either AASHTO M 164 hexagon head bolts or AASHTO M 164
hexagonal cap screws with nuts and washers.
1052.10.5 Galvanizing and Aluminizing. All soil reinforcement material shall be either galvanized or
aluminized. Galvanized soil reinforcement shall be in accordance with AASHTO M 111. Aluminized soil reinforcement shall be in accordance with ASTM A 463 Aluminized Type 2-100, SS, Grade 50, Class 2. Fasteners, including bolts, nuts and washers, shall be galvanized in accordance with AASHTO M 232. All connection devices shall be galvanized in accordance with either AASHTO M 111 or M 232.
1052.10.6 Certification. The manufacturer of the wall system shall certify in writing that the soil reinforcement,
connections and fasteners meet the minimum requirements directed by the design and this specification. The contractor shall provide this certification and any other supporting documentation to the engineer prior to the material being delivered to the construction site. SECTION 1052.20 NON-METALLIC SOIL REINFORCEMENT.
1052.20.1 Scope. This specification covers non-metallic or geosynthetic soil reinforcement utilized in
mechanically stabilized earth wall systems.
1052.20.2 Geogrids. Non-Metallic or geosynthetic soil reinforcement shall be of a polymeric nature and shall
consist of a geogrid determined by the wall manufacturer or supplier.
1052.20.2 1 The geogrid shall be dimensionally stable and shall be able to maintain geometry during transport,
handling and installation.
1052.20.2 2 The geogrid manufacturer shall maintain a quality control program to ensure that the manufactured
material meets the requirements of the index tests shown below. Sampling and conformance testing for the index tests shown in the table shall be done in accordance with ASTM D 4354. Geogrids Property Test Procedure Specific Gravity (HDPE only) ASTM D 1505 Wide Width Tensile ASTM D 4595, GRI GG1 Melt Flow (HDPE and PP only)ASTM D 1238 Inherent Viscosity (PET only) ASTM D 4603, GRI GG8 Hydrolysis Resistance (PET only)GRI GG7 678UV Oxidation Resistance ASTM D 4355 Survivability ASTM D 5261
1052.20.3 Certification. The manufacturer of geogrid shall certify in writing that the geogrid is in accordance
with this specification. The certification shall include the roll numbers and identification, the sampling procedures, the results of the quality control tests along with the tests used, and the Minimum Average Roll Value (MARV) for each roll. This certification and any other supporting documentation shall be provided to the engineer prior to the material being delivered to the construction site. SECTION 1052.30 MSE PANEL AND SOUND WALLS.
1052.30.1 Scope. This specification covers the concrete facing panels used as part of mechanically stabilized
earth wall systems and sound wall systems.
1052.30.2 Acceptance.
1052.30.2 1 Lot Definition. A production lot will be defined as a group of panels and precast posts that will be
represented by a single compressive strength sample, and shall consist of either 40 panels and or precast posts or single day's production, whichever is less.
1052.30.2 2 Quality Control. The QMP shall define QC testing and inspection frequencies including the
following.
1052.30.2 3 Compressive strength of cylinders or cores shall be taken at least once a lot in accordance with
AASHTO M199. Compressive strength testing may also be performed to control handling and curing operations. Cylinders shall be cured in accordance with AASHTO T23 field curing procedures. For field cure compressive strength samples sufficient cylinders shall be cured in the same manner as the panels and precast posts and tested in accordance with AASHTO T22, shall represent the initial strength of the concrete. In addition, a set of cylinders shall be cured in accordance with AASHTO T23 and tested at 28 days. The average compressive strength of these cylinders, when tested in accordance with AASHTO T22, shall represent the compressive strength of the production lot.
1052.30.2 4 Air content testing shall be performed in accordance with AASHTO T152 or AASHTO T196. Air
content samples shall be taken at the beginning of each day's production and at the same time as compressive samples are taken to ensure compliance with this specification.
1052.30.2 5 Slump testing shall be performed in accordance with AASHTO T119. The slump shall be
determined at the beginning of each day's production and at the same time as the compressive strength samples are taken.
1052.30.2 6 Aggregate gradation and quality shall be checked at least once a month per aggregate source to
ensure compliance with the specifications.
1052.30.2 7 Steel placement shall be checked for each unit.
1052.30.2 8 All equipment used for testing shall be maintained and calibrated in accordance with AASHTO
R18 or equivalent program.
1052.30.2 9 QC shall ensure the concrete plant is calibrated, monitored, and maintained in a manner sufficient
to provide uniform compliant concrete.
1052.30.2 10 Quality Assurance. The QMP shall reference an industry organization or define independent QA
testing frequencies including the following: Tested Propertya Test MethodIndependent QA Air T152 Twice a year Slump T119 Twice a year Coarse Aggregate Deleterious TM71 Twice a year 679Coarse Aggregate Absorption T85 Twice a year Compressive Strength T22 Twice a year Absorption (per mix) T280 Once a year a All samples shall be taken at the precast plant.
1052.30.2 11 MoDOT QA and Auditing. The engineer may perform MoDOT QA testing or audit the
producer's QMP, documentation and production at any time, which may include coring of the precast units at the producer's expense.
1052.30.2 12 Other Criteria. Concrete facing panels, coping and precast posts will not be accepted if any of
the following defects in physical characteristics are found: imperfect molding, honeycombing or open texture concrete, cracked or severely chipped panels and precast posts, soil reinforcement attachment devices improperly installed/damaged, lifting inserts not useable, exposed reinforcing steel, and color variation on the front face of the panel due to excess form oil or other reasons.
1052.30.3 Material.
1052.30.3 1 Concrete. Concrete material, proportioning, air entraining, mixing, slump and transporting of
concrete shall be in accordance with Sec 501, except as noted in this section.
1052.30.3 2 Aggregate. Fine and coarse aggregate for the concrete mixture shall be in accordance with Sec
1005, except that the requirements for gradation and percent passing the No. 200 sieve will not apply.
1052.30.3 3 Steel Reinforcement. Reinforcement shall be in accordance with Sec 1036.
1052.30.4 Design. Shop drawings shall be approved by the Bridge Division when the MSE wall is constructed
in conjunction with a bridge abutment.
1052.30.4 1 The concrete shall be an approved MoDOT mix that is air-entrained, with a minimum compressive
strength of 4,000 psi at 28 days. No additional admixtures will be permitted unless approved by the engineer.
1052.30.4 Casting. The panels shall be cast in such a manner that the acceptance criteria of this specification are
met. Soil reinforcement connection devices shall not be in contact with or attached to the reinforcing steel in the concrete facing panels.
1052.30.5 Manufacturing.
1052.30.5 1 Casting. The panels and precast posts shall be cast in such a manner that the acceptance criteria of
this specification are met. Soil reinforcement connection devices shall not be in contact with or attached to the reinforcing steel in the concrete facing panels.
1052.30.5 2 Curing. One of the following methods shall be used. Curing as recommended by the wall
designer. Curing membrane, in accordance with Sec 1055, may be applied and if used shall be left intact until the strength requirements are met. Steam and moisture curing methods shall be in accordance with Sec 1029.
1052.30.5 3 Tolerances.
1052.30.5 3.1 Panel and Post Systems. Shall be in accordance with approved shop drawings. Any variations
from the approved shop drawings such as dimensions, materials, or finish must be approved by the wall manufacturer. Post dimensions for sound walls shall be within 1/4 inch in width and depth and within one inch along the length dimension.
1052.30.5 3.2 Panel Dimensions. Panel connection devices shall be within one inch of the specified dimension.
The panel face and thickness dimensions shall be within 1/8 inch of the specified dimension. All other dimensions or items shall be within 1/4 inch of the specified dimensions.
1052.30.5 3.3 Panel Squareness. Squareness, as determined by the difference between the two diagonals, shall
not exceed 1/2 inch. 6801052.30.5.3.4 Panel Surface Finish. Surface defects on smooth formed surfaces measured over a length of 5 feet shall not exceed 1/8 inch. Surface defects on the textured finish surfaces, measured over a length of 5 feet, shall not exceed 3/8 inch.
1052.30.5 4 Other Criteria. Concrete facing panels, coping and precast posts will not be accepted if any of the
following defects in physical characteristics are found: imperfect molding, honeycombing or open texture concrete, cracked or severely chipped panels and precast posts, soil reinforcement attachment devices improperly installed/damaged, lifting inserts not usable, exposed reinforcing steel, and color variation on the front face of the panel due to excess form oil or other reasons.
1052.30.6 Marking. The date of manufacture, production lot number and piece mark shall be clearly scribed on
an unexposed face of each panel.
1052.30.7 MoDOT Identification Number. When the manufacturer contacts the engineer one business day, or
earlier, in advance of shipping precast products the engineer will assign a specific MoDOT identification number for each size and type of product in the shipment.
1052.30.7 1 Prior to delivery to the jobsite, the source, intermediate agent, shipper or contractor's representative
shall notify the inspecting District by fax or electronically a minimum of one business day, or earlier, prior to the impending shipment of precast material. This notification shall include a shipping form (Precast Shipping Form) and will include, at minimum, the following:
a.The specific contract number.
b.Receiving Purchaser/Contractor.
c.Line number for which the material will be used.
d.Type and quantity of material.
e.Date of expected delivery to the jobsite.
f.Manufacturer's name.
g.Stationing or structure number on precast unit, if applicable.
h.Panel type, quantity and wall number for MSE panels.
1052.30.7 2 Upon approval, the precaster will receive an identification number. The precast unit shall be
clearly and permanently marked by the precaster with the ID number as required by appropriate 1000 specification prior to shipment. Requests for alternate precast labeling shall be submitted to the inspecting District for approval. Material without proper identification number(s) will not be permitted for use on a project.
1052.30.8 Handling, Storage and Shipping. All panels shall be free of chips, discoloration, cracks, fractures,
and any other defects determined to be detrimental to the cosmetic value or to the performance characteristics of the panels. The panels shall not be subjected to excessive bending stresses and the panel connection devices and exposed exterior finish shall be protected from damage.
1052.30.9 Documentation. Copies of test results for all required tests, and any other supporting documentation
shall be in accordance with Sec 1001.14.
1052.30.10 Delivery. A bill of lading or delivery receipt shall be furnished to the engineer at the destination
point. The bill of lading shall contain an itemized statement of the sizes and lengths of precast units with the corresponding MoDOT identification number provided to the manufacturer for each size and type of precast unit for that shipment. The bill of lading shall contain a certified statement. The certified statement shall be signed by an authorized representative of the manufacturer and shall state the following: "This certifies that the precast products in this shipment are in accordance with MoDOT specifications." 681SECTION 1052.40 SMALL BLOCK WALL SYSTEMS - CONCRETE BLOCKS.
1052.40.1 Scope. This specification covers the concrete blocks used as part of small block mechanically
stabilized earth wall systems. Wet cast blocks shall be produced in accordance with Sec 1052.30. Dry cast blocks shall be produced at stated below.
1052.40.2 Acceptance. Acceptance will be based upon manufacture test results compliant with the following
requirements.
1052.40.2 1 Freeze Thaw Testing. The concrete blocks shall be tested for freeze-thaw durability in accordance
with ASTM C1262. Freeze-thaw durability shall be based on tests from five specimens made with the same material, concrete mix design, manufacturing process and curing method conducted not more than 18 months prior to delivery. Test results will be required for each project.
1052.40.2 2 Units that are not exposed to deicing salts shall be in accordance with the following testing
requirements. When tested in water, the weight loss of each of five test specimens at the conclusion of 100 cycles shall not exceed 1.0 percent of its initial weight; or the weight loss of each of four of the five test specimens at the conclusion of 150 cycles shall not exceed 1.5 percent of its initial weight.
1052.40.2 3 Test results for units that are exposed to deicing salts shall be tested in a 3 percent saline solution
and shall be in accordance with the following:
a.When tested in 3 percent saline solution the weight loss of each of five test specimens at the conclusion of 40 cycles shall not exceed 1.0 percent of the initial weight; or the weight loss of each of four of the five test specimens at the conclusion of 50 cycles shall not exceed 1.5 percent of its initial weight.
1052.40.2 4 Compressive Strength. Acceptance of the compressive strength of the concrete blocks will be
based on production lots in compliance with ASTM C140. Acceptance of the compressive strength of a production lot will occur if the compressive strength test results is equal to or greater than the design strength at 28 days. The engineer of record shall evaluate and approve acceptance of deviations below design strength.
1052.40.2 5 Absorption. The manufacturer shall sample and test units based on production lots for absorption
in accordance with ASTM C140.
1052.40.2 6 Dimensional Tolerances. Concrete blocks shall be manufactured within the following tolerances:
a.The length and width of each concrete block shall be within 1/8 inch of the specified dimension.
b.The height of each concrete block shall be within 1/16 inch of the specified dimension.
c.When a broken face finish is used, the dimension of the front face shall be within one inch of the theoretical dimension of the concrete block.
1052.40.2 7 Other Criteria. All concrete blocks shall be sound and free of cracks or other defects that would
interfere with the proper placement of the blocks or significantly impair the strength or permanence of the construction. At the time of the delivery to the work site the concrete blocks shall:
a.A maximum water absorption of 5 percent.
b.Minor cracks incidental to the usual method of manufacture or minor chipping resulting from shipment and delivery will not be grounds for rejection. Minor cracks will be defined as cracks that are no wider than 1/64 inch and no longer than 25 percent of the block height.
c.Any exposed face of a concrete block shall be free of chips, cracks or other imperfections when viewed from a distance of 30 feet under diffused lighting. Up to 5 percent of a shipment may contain slight cracks or small chips no larger than one inch.
1052.40.2 8 Concrete blocks shall not be accepted if any of the requirements specified above or the following
defects in physical characteristics are found: 682(a) Defects indicating imperfect molding.
b.Defects indicating honeycomb or open texture concrete.
c.Cracked or severely chipped blocks.
d.Color variation on front face of blocks.
1052.40.3 Material.
1052.40.3 1 Concrete. Concrete material, proportioning, air entraining, mixing, slump and transporting of
concrete shall be in accordance with Sec 501, except as noted in this section. Coloring pigments, integral water repellants, finely ground silica and other constituents shall be previously directed as suitable for use and shall be in accordance with applicable ASTM standards, or evidence shall be provided to prove the product is not detrimental to the durability of the concrete blocks or any material customarily used in masonry construction.
1052.40.3 2 Aggregate. Fine and coarse aggregate for the concrete mixture shall be in accordance with Sec
1005, except that the requirements for gradation and percent passing the No. 200 sieve will not apply.
1052.40.4 Design. The concrete mixture shall have a minimum compressive strength of 4,000 psi at 28 days.
The design including all contents of the mixture and curing method shall be submitted to the engineer for approval prior to use.
1052.40.5 Manufacturing.
1052.40.5 1 Finish Color. Color and finish shall be as shown on the plans. If no color or finish is specified on
the plans, the contractor shall provide a color and finish to the engineer for approval.
1052.40.6 Certification. The manufacturer of the concrete blocks shall certify that the concrete blocks are in
accordance with this specification. This certification, copies of test results for all required tests, and any other supporting documentation shall be provided to the engineer prior to the material being shipped to the construction site. 683SECTION 1053 CONCRETE SEALER AND CONCRETE CRACK FILLER SECTION 1053.10 PENETRATING CONCRETE SEALER
1053.10.1 Scope. This specification covers concrete sealers for the protection of concrete against damage from
de-icing chemicals.
1053.10.2 Acceptance. All material under this specification shall be obtained from a source identified on the
PAL designated for this specification. All material under this specification will be inspected and accepted in accordance with Sec 106. ASTM and AASHTO specifications, when referenced, control only the physical and chemical properties of the material.
1053.10.3 The sealer shall be a alkyltrialkoxysilane, with low oligomer and polymer compound content. The
chemical composition shall meet the following requirements: Property Specification Purity 95% minimum monomer by weight Solvent Less than 5% by weight Residue Less than 2% by weight Density Per the manufacturer's recommendation Flash Point ASTM D93: greater than 125 degrees F Dry Time ASTM D1640 Sec 7.5.1: One hour or less
1053.10.3 1The ASTM D1640 test shall be performed on a concrete surface. This concrete shall be a mix design
called for in Sec 1053.10.3.2. The application rate shall be the same rate specified in Sec 703.
1053.10.3 2 The sealer shall meet the following performance criteria based on a single application at the
application rate specified in Sec 703. MoDOT reserves the right to verify any qualification tests at their expense on any field application. Test specimens shall be produced using either the MoDOT Class B-2 concrete in accordance with Sec 501 or the concrete mix specified by the test being performed. Test Test MethodDuration Max Absorption / Cl- Water Immersion ASTM C64248 hours0.5 percent by weight (mass) Water Immersion ASTM C64250 days1.5 percent by weight (mass) Salt Water Ponding (based on non-abraded specimen)AASHTO T25990 days80% min reduction in Cl- absorption & 0.50 lbs/cu yd Cl- at a depth of 1/2” - 1” max
1053.10.3 3 The sealer shall not permanently stain, discolor or darken the concrete. Application of the sealer
shall not alter the surface texture or form a coating on the concrete surfaces.
1053.10.3 4 The sealer shall not leave residue on glass, painted metal or automobiles.
1053.10.3 5 The sealer shall not reduce the bond of pavement markings or reduce the skid resistance of the
surface being sealed. Any sealer determined to have these adverse effects will be removed from the pre- qualified list.
1053.10.3 6 The sealer shall be delivered to the project in unopened containers with the manufacturer’s label
identifying the product and with the seal(s) intact. Each container shall be clearly marked by the manufacturer with the following information:
a.Manufacturer's name and address.
b.Product name.
c.Date of manufacture and expiration date. 684(d) Lot identification.
e.Storage requirements.
1053.10.4 Manufacturer and Brand Name Approval. Prior to approval and use of concrete sealers, the
manufacturer shall submit to Construction and Materials a certified test report from an approved testing laboratory showing specific test results conforming to the requirements of these specifications. The certified test report shall also contain the manufacturer’s name, product brand name, lot number and date of manufacture. Upon approval of the certified test report by the engineer the manufacturer and brand name will be added to the PAL designated for this specification. New certified test results shall be submitted any time the manufacturing process or the sealer formulation is changed, and may be required by the engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. SECTION 1053.20 CONCRETE CRACK FILLER
1053.20.1 Scope. This specification covers concrete crack fillers for the protection of concrete against damage
from de-icing chemicals.
1053.20.2 Acceptance. All material shall be obtained from a source identified on the PAL designated for this
specification, except as otherwise listed below. All materials under this specification will be inspected and accepted in accordance with Sec 106.
1053.20.3 The concrete crack filler shall be a low viscosity polymer. The chemical composition shall meet the
following requirements: Property Test Method Specification Viscosity AASHTO D-2393 Less than or equal to 25 cps Gel Time AASHTO T-237Less than or equal to 20 minutes @ 70 deg F Tensile StrengthASTM D638 Greater than or equal to 1500 psi Elongation ASTM D638 Greater than or equal to 5% Solids Content Greater than or equal to 95% Flash Point ASTM D1310 Greater than or equal to 50 deg F Cure Rate AASHTO T-237 Less than or equal to 3 hrs@ 70 deg F
1053.20.4 The concrete crack filler shall meet the procedures and the application rates as specified in Sec 704.
MoDOT reserves the right to verify any qualification tests at their expense on any field application.
1053.20.5 Manufacturer and Brand Name Approval. Prior to approval and use of concrete crack fillers, the
manufacturer shall submit to Construction and Materials a certified test report from an approved testing laboratory showing specific test results conforming to the requirements of these specifications. The certified test report shall also contain the manufacturer’s name, product brand name, lot number and date of manufacture. Upon approval of the certified test report by the engineer the manufacturer and brand name will be added to the PAL designated for this specification. New certified test results shall be submitted any time the manufacturing process or the crack filler formulation is changed, and may be required by the engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. 685SECTION 1054 CONCRETE ADMIXTURES 1054.1 Scope. This specification covers air-entraining admixtures, water-reducing admixtures, retarding admixtures, accelerating admixtures and latex emulsion admixtures for concrete. 1054.2 Acceptance. All material under this specification shall be obtained from a source identified on the PAL designated for this specification. All material under this specification will be inspected and accepted in accordance with Sec 106. 1054.3 Air-Entraining Admixtures. Air-entraining admixtures shall be in accordance with AASHTO M 154, except as modified herein. 1054.3.1 Certification. The manufacturer shall submit a certification to Construction and Materials prior to approval. The certification shall provide the following:
a.The brand name and designation.
b.The composition or description of the admixture.
c.The manufacturing ranges for percent total solids and pH by AASHTO T 200.
d.The infrared spectrum.
e.The manner in which the material will be identified on containers.
f.The material is in accordance with these specifications. 1054.3.1.1 Certifications shall include or have attached specific test results as required in Sec 1054.3.1.2 or Sec 1054.3.1.3. 1054.3.1.2 For an air-entraining admixture other than that specified in Sec 1054.3.1.3, the certification shall include results of tests conforming to the requirements of AASHTO M 154. Tests for bleeding, bond strength and volume change will not be required. 1054.3.1.3 For an air-entraining admixture that is an aqueous solution of vinsol resin manufactured by neutralizing the resin with sodium hydroxide, the certification shall include results of tests showing the ratio of sodium hydroxide to vinsol resin. The certification or test report shall also state that no other additive or chemical agent is present in the solution. 1054.3.2 Packaging and Marking. The containers in which air-entraining admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. A delivery ticket showing this information shall accompany bulk shipments. If the manufacturer supplies air-entraining admixtures in more than one concentration, the concentration shall be designated on the container, or for bulk shipments, in a prominent manner on the delivery ticket. 1054.4 Water-Reducing Admixtures. Water-reducing admixtures shall be in accordance with AASHTO M 194, Type A, except as modified herein. High range water-reducing admixtures, when permitted for use, shall be in accordance with AASHTO M 194, Type F or Type G. 1054.4.1 Certification. The manufacturer shall submit certification to Construction and Materials prior to approval. 1054.4.1.1 The certification shall provide the following:
a.The brand name and designation.
b.The composition or description of the admixture.
c.The manufacturing ranges for specific gravity at 77 F and percent total solids. 686(d) The infrared spectrum.
e.The manner in which the material will be identified on containers.
f.The material is in accordance with these specifications. 1054.4.1.2 The certification shall include or have attached specific test results in accordance with AASHTO M 194, Type A, F or G, as applicable, and the recommendation for use, including amounts to be added. 1054.4.2 Packaging and Marking. The containers in which water-reducing admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. A delivery ticket showing this information shall accompany bulk shipments. 1054.5 Retarding Admixtures. Retarding admixtures shall be in accordance with AASHTO M 194, Type B or D, except as modified herein. 1054.5.1 Certification. The manufacturer shall submit certification to Construction and Materials prior to approval. 1054.5.1.1 The certification shall provide the following:
a.The brand name and designation.
b.The composition or description of the admixture.
c.The manufacturing ranges for specific gravity at 77 F and percent total solids.
d.The infrared spectrum.
e.The manner in which the material will be identified on containers.
f.The material is in accordance with these specifications. 1054.5.1.2 The certification shall include or have attached specific test results in accordance with AASHTO M 194, Type B or D, and the recommendation for use, including amounts to be added. 1054.5.2 Packaging and Marking. The containers in which retarding admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. A delivery ticket showing this information shall accompany bulk shipments. 1054.6 Accelerating Admixtures. Accelerating admixtures shall be in accordance with AASHTO M 194, Type C or E, except as modified herein. 1054.6.1 Certification. The manufacturer shall submit certification to Construction and Materials prior to approval. 1054.6.1.1 The certification shall provide the following:
a.The brand name and designation.
b.The composition or description of the admixture.
c.The manufacturing ranges for specific gravity at 77 F and percent total solids.
d.The infrared spectrum.
e.The manner in which the material will be identified on containers.
f.The material is in accordance with these specifications. 6871054.6.1.2 The certification shall include or have attached specific test results in accordance with AASHTO M 194, Type C or E, and the recommendation for use, including amounts to be added. 1054.6.2 Packaging and Marking. The containers in which accelerating admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. A delivery ticket showing this information shall accompany bulk shipments. 1054.7 Latex Emulsion Admixtures. Latex emulsion admixtures shall be non-toxic, film-forming, polymeric emulsion in water to which all stabilizers have been added at the point of manufacture. The admixture shall be a styrene-butadiene latex emulsion in which at least 90 percent of the non-volatiles are styrene-butadiene polymers. 1054.7.1. Properties. The admixture shall be homogeneous, uniform in composition and shall be in accordance with the following requirements when tested with the procedures shown in Report No. FHWA RD 78 35, April 1978, Styrene-Butadiene Latex Modifiers for Bridge Deck Overlay Concrete: Property Requirement Color White Polymer Type Styrene-Butadiene Percent Solids 46 - 53 pH5.0 - 12.0, the pH may not vary more than ± 1 from the pH of matl. submitted for prequalification. Particle Size1400 to 2500 Angstroms, the mean particle size shall not vary more than ± 300 Angstroms from the mean diameter of material submitted for prequalification. Viscosity± 20 centipoises of the viscosity of material submitted for prequalification. Percent Coagulum 0.10 percent by weight, max. Freeze-Thaw Stability0.10 percent by weight max. coagulum after 2 freeze-thaw cycles. Surface Tension 50.0 dynes/cm, max. Percent Butadiene 30 to 40 by weight 1054.7.2 Certification. The manufacturer shall submit certification to Construction and Materials prior to approval. 1054.7.2.1 The certification shall provide the following:
a.The brand name and designation.
b.The composition or description of the admixture.
c.The manufacturing ranges for specific gravity at 77 F by AASHTO T 157, percent total solids by ASTM D 1644, Method A and pH by AASHTO T 200.
d.The infrared spectrum.
e.The manner in which the material will be identified on containers.
f.The material is in accordance with these specifications. 1054.7.2.2 The certification shall include or have attached specific test results in accordance with this specification. 1054.7.3 Packaging and Marking. The containers in which latex emulsion admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and 688net quantity. A delivery ticket showing this information shall accompany bulk shipments. 689SECTION 1055 CONCRETE CURING MATERIAL 1055.1 Scope. This specification covers material to be used for the purpose of curing concrete. 1055.2 Liquid Membrane-Forming Curing Compounds. 1055.2.1 Acceptance. All material under this specification shall be obtained from a source identified on the PAL designated for this specification. If the manufacturer is different from the source supplying the material, the manufacturer shall also be listed. All material under this specification will be inspected and accepted in accordance with Sec 106. 1055.2.2 Material. 1055.2.2.1 General. Water retention properties for all curing compounds shall be determined by ASTM Test Method C 156. The vehicle class of all curing compounds shall be Class A. 1055.2.2.2 Type 1-D Curing Compounds. Type 1-D liquid membrane-forming curing compounds shall be in accordance with ASTM C 309 for Type 1-D, clear or translucent with fugitive dye. 1055.2.2.3 Type 2 Curing Compounds. Type 2, liquid membrane-forming curing compounds shall be in accordance with ASTM C 309 for Type 2, white pigmented. 1055.2.2.4 Bridge Curing Compounds. Bridge curing compounds shall be liquid membrane-curing compounds in accordance with ASTM C 309 for Type 1-D or Type 2 and shall be designated to be dissipating. All bridge curing compounds shall be manufactured such that the curing compounds may be removed prior to dissipation. 1055.2.3 Documentation. 1055.2.3.1 Certification For Qualification. Prior to use and in addition to the required PAL documentation, the manufacturer shall submit certification to Construction and Materials, setting forth the brand name and designation, the composition or description of the curing material, the manner in which the material will be identified on the containers, and shall list typical values of current tests for consistency, drying time, reflectance and moisture retention. 1055.2.3.2 Additional Certification. Certification for bridge curing compounds shall include a statement that the product is manufactured to dissipate. The certification shall specify the method by which removal of the compound prior to dissipation or removal of residual material from the surface can be accomplished. 1055.2.3.3 Shipment Documentation. For each shipment of material, the source shall maintain the manufacturer’s certification and test results showing that the product is in accordance with this specification. The manufacturer’s certification and test results shall be made available upon request. 1055.3 Other Concrete Curing Material. 1055.3.1 Acceptance. All material under this specification shall be obtained from a source identified on the PAL designated for this specification. All material under this specification will be inspected and accepted in accordance with Sec 106. 1055.3.2 Material. 1055.3.2.1 Waterproof Paper. Waterproof paper shall be in accordance with ASTM C 171. 1055.3.2.2 Polyethylene Sheeting. Polyethylene sheeting shall be in accordance with Sec 1058 for curing Portland cement concrete. 1055.3.2.3 White Burlap-Polyethylene Sheeting. White burlap-polyethylene sheeting shall be in accordance with ASTM C 171. 6901055.3.2.4 Burlap and Mats of Jute or Cotton. Burlap shall be fabric made from jute or other suitable fibers. Jute mats shall consist of two plies of burlap stitched together to maintain the shape and stability of the unit. Cotton mats shall consist of filler or cotton batts covered with unsized cloth or burlap, and tufted or stitched to maintain the shape and stability of the unit. Burlap, mats or other synthetic material equivalents shall, in the judgment of the engineer, be of such construction and in such a condition as required to adequately maintain free moisture on the surface of the concrete with the type of system being used to provide the water. Material shall be free from deleterious matter harmful to concrete. 1055.3.3 Documentation. The distributor shall maintain certification that the material supplied is in accordance with these specifications. The certification shall be made available upon request. 691SECTION 1056 CONCRETE TINTING AND STAINING MATERIAL SECTION 1056.10 CONCRETE TINTING MATERIAL
1056.10.1 Description. This work item shall consist of providing a concrete tinting material to aesthetically
color concrete as shown on the plans.
1056.10.2 Material Requirements. This material shall consist of a homogeneous mixture mineral oxide
pigment of an approved tint with such other additives as deemed necessary by the manufacturer. The tinting material shall conform to the specification outlined on ASTM C979. The material shall be free from oil, grease, dirt and nonferrous particles. The tinting material shall not contain any material that might promote oxidation of the iron particles if exposed to air and moisture, or that might have any detrimental effect on concrete. The contractor shall supply the engineer with a maufacturer's certification indicating that the material supplied is in accordance with this specification.
1056.10.3 Construction Requirements. The contractor shall incorporate the tinting material into the concrete
through mixing with the aggregate, cementitious material and water in accordance with the manufacturer's recommendation. The dry shake method; whereby the tinting material powder, combined with dry cement and sand, is sprinkled onto the concrete and worked into the surface through finishing; shall not be allowed. SECTION 1056.20 CONCRETE STAINING MATERIAL
1056.20.1 Description. This work item shall consist of providing a field concrete stain to aesthetically color
concrete exteriors as shown on the plans.
1056.20.2 Material Requirements. The material shall be two-coat, pigmented acrylic resin system which
penetrates into the concrete surface to provide water repellency, semi-opaque aesthetic color and salt resistance and shall form a breathable film allowing trapped moisture vapor to safely migrate through the coating without blistering or peeling. The contractor shall supply the engineer with a manufacturer's certification indicating that the material supplied is in accordance with this specification.
1056.20.3 Construction Requirements. The concrete surface shall be fully cured a minimum of 28 days prior
to application of the aesthetic concrete stain. The absence of moisture in the concrete surface shall be verified with standard test ASTM D4263. Pressure washing with a minimum of 3,000 psi shall be used to remove all foreign matter, form oils, waxes, curing compounds, laitance, efflorescence and dirt. Sand blasting will not be permitted for cleaning. The cleaned surface shall be free of blemishes, discolorations, surface voids and conspicuous form marks to the satisfaction of the engineer. The concrete stain shall be adequately mixed within its container until homogenous in color. Application of the stain shall be in accordance with the manufacturer's recommendations including allowable ambient conditions. Application of the stain will not be allowed during rain. All manufacturers’ safety precautions shall be submitted to the engineer prior to work and followed during staining. 692SECTION 1057 MATERIAL FOR JOINTS 1057.1 Scope. This specification covers joint material to be used as specified or as shown on the plans. 1057.2 Acceptance. All material under this specification shall be obtained from a source identified on the PAL designated for this specification. 1057.3 Dowel Bars. Dowels for transverse joints shall be in accordance with the requirements for plain rounds of AASHTO M 31. The dowels shall be epoxy coated in accordance with Sec 1036, except the coating thickness shall be a 5-mil minimum, the flexibility of coating requirement will not apply and the cut ends will not be required to be coated. The dowels shall be free of cutting burrs and other projections. Dowel supporting units shall be in accordance with one of the types shown on the plans. 1057.3.1 Alternative Dowel bars manufactured with steel in accordance with ASTM A 1035 may be used in lieu of AASHTO M 31. Alloy Types CM and CS shall be used. The dowel bars manufactured with this type steel will not be required to be epoxy coated. Grades 100 and 120 may be used. 1057.3.2 Graphite Grease. The free end of the dowel bar shall be coated with an approved graphite grease for a length of 11 inches. Graphite grease shall contain a minimum of 25 percent graphite, and the graphite content shall be certified by the manufacturer or shown on the container label. Graphite grease shall be applied with a thin, uniform coating that will result in a thorough covering of the free end of the bar. 1057.3.3 Pre-Dipped Bondbreaker. In lieu of the graphite grease application, the dowel bar basket supplier may supply completed basket units pre-dipped in an approved bondbreaker solution. The bondbreaker solution shall not be applied in a spray or field application. The resulting dry dowel bar coating shall be visually evident. The coating shall be uniformly applied without excessive drips or thickness. Dirty or excessively scraped dowel bar units will be rejected. Rejected units may be used if the units are fully cleaned of all dirt and bondbreaker coating and graphite grease is applied according to these specifications. The dowel basket supplier shall provide a certification for the coating with each shipment, certifying the bondbreaker product name, manufacturer and date of coating application. 1057.4 Tie Bars. Tie bars for longitudinal joints and construction joints shall be round, deformed and in accordance with AASHTO M 31, except for tie bars that are to be bent and straightened shall be in accordance with AASHTO M 31, Grade 40. Tie bars shall not be bent and straightened more than one time. Tie bars shall be epoxy coated in accordance with Sec 1036, except the coating thickness shall be a 5-mil minimum, the flexibility of coating requirement will not apply and the cut ends will not be required to be coated. 1057.4.1 Alternative. Tie bars manufactured with steel in accordance with ASTM A 1035 may be used in lieu of AASHTO M 31. Alloy Types CM and CS shall be used. The tie bars manufactured with this type of steel will not be required to be epoxy coated. Grades 100 and 120 may be used for straight bars. For tie bars that are to be bent and straightened, ASTM A 1035 steel shall not be used. 1057.5 Concrete and Asphalt Joint Sealer, Hot-Poured Elastic Type. The sealer material shall be in accordance with ASTM D 6690, Type II. The joint sealer material shall be packed and shipped in suitable commercial containers clearly marked with the name of the material, the name of the manufacturer, brand name, weight, batch number, pouring temperature recommended by the manufacturer and maximum safe heating temperature. 1057.6 Pavement Joint Forming Material. 1057.6.1 Preformed Fiber Expansion Joint Filler. Preformed fiber expansion joint filler material shall be in accordance with AASHTO M 213. Percent asphalt content shall be tested in accordance with AASHTO T 42 or 164 with the following modifications: Oven dry test strips at 104 ± 3 C for one hour. Cool and weigh approximately 50 g into an extraction bowl. Cover test portion in the bowl with a chlorinated solvent, such as trichloroethylene, and allow sufficient time for solvent to soak the test portion. Follow test procedure outlined in AASHTO T 164 section 12.3 and 12.4, except discard extract and washings. Carefully transfer extracted test strips and scrap residue from the filter ring into a tared weighing pan. Oven dry at 104 ± 3 C for one (1) hour and cool in a desiccators. Calculate the percent asphalt content by weight on an oven dry basis per ASTM D 545 subsection 7.5.4. In cases of dispute, AASHTO T 42 test results will control. 6931057.6.2 Semi-rigid, Closed-cell Polypropylene Foam, Preformed Expansion Joint Filler. This material shall be semi-rigid, closed-cell polypropylene foam, preformed expansion joint filler in accordance with ASTM D8139. 1057.7 Joints for Concrete Structures. 1057.7.1 Plastic Waterstop. The plastic waterstop shall consist of a basic resin of polyvinyl chloride (PVC) with additional resins, plasticizers and stabilizers as necessary to produce a durable material with a high fatigue point, resistant to acid and alkali solutions, showing little deterioration under accelerated aging tests and shall meet the approval of the engineer. The plastic waterstop shall have a tensile strength of no less than 1,800 psi and an ultimate elongation of no less than 200 percent. The waterstop shall be a continuous strip, ribbed on both sides, and with a hollow bulb center, a “U” shaped reinforced center-pleat section, or other approved type of center section. 1057.7.2 Rubber Waterstop. The rubber water stop shall consist of a durable, elastic, cured rubber compound capable of effectively sealing joints in concrete against the infiltration of moisture. 1057.7.2.1 Physical Properties. The rubber waterstop shall be in accordance with the following requirements:
a.Hardness - The Shore A durometer hardness shall be 60 - 70.
b.Elongation - The elongation shall be no less than 450 percent.
c.Tensile Strength - The tensile strength shall be no less than 3,000 psi.
d.Water Absorption - The water absorption shall be a maximum of five percent by weight (mass) after immersion in water for two days at 158 F.
e.Tensile Strength After Aging - The tensile strength of the test specimen, after accelerated aging test of seven days at 158 F, shall be no less than 80 percent of the tensile strength prior to the aging test. The tensile strength of the test specimen, after accelerated aging test of 48 hours in oxygen at 158 F and 300 psi, shall be no less than 80 percent of the tensile strength prior to the test.
f.Compression Set - The compression set after 22 hours at 158 F shall be no more than 30 percent. 1057.7.2.2 Visual Inspection. The waterstop shall be manufactured in such a manner that the finished product will have an integral cross section that will be dense, homogeneous, and free from porosity and other imperfections. Minor surface defects, such as surface peel covering less than one square inch, and surface cavities or bumps less than 1/4 inch in the longest lateral dimension and less than 1/16 inch deep, will be permitted. 1057.7.3 Copper Sheeting for Flashing. Copper sheeting shall be of soft grade containing no less than 99.7 percent copper and shall be capable of being bent cold through an angle of 180 degrees flat upon itself without evidence of cracking. Test specimens shall have an elongation in 2 inches of at least 20 percent. The weight per square foot of the sheeting to be used will be shown on the plans. Tolerances in thickness shall be in accordance with ASTM B 248. 1057.7.4 Preformed Sponge Rubber Expansion and Partition Joint Filler. This material shall be in accordance with AASHTO M 153, Type I, Sponge Rubber. 1057.8 Plastic Joint Compound for Vitrified Clay and Concrete Pipe. Plastic joint compound shall be a homogeneous blend of bituminous or butyl rubber material, inert filler and suitable solvents or plasticizing compounds thoroughly mixed at the factory to a uniform consistency suitable for sealing joints of vitrified clay and concrete pipe. The physical requirements of the compound shall be in accordance with ASTM C 990. Trowel grade material shall conform to the following requirement: Bitumen, soluble in soluble chlorinated solvent, such as Trichloroethylene, percent by weight, min45 694Ash, percent by weight 15-50 Penetration, standard cone, 150 g, 5 sec, 25 C - uses 12 ounce can, d mm110-275 Primer, as recommended by the manufacturer, shall be used with extruded rope or flat tape types, if required to maintain the material in position while pipe sections are being joined. 1057.9 Tubular Joint Seal. Tubular joint seal shall be manufactured from extruded closed-cellular rubber, the base polymer being a blend of nitrile and vinyl meeting the physical requirements of ASTM D 1056, Type 2, Class C, Grade 1, and the chemical resistance requirements of ASTM C990. The seal shall be a single continuous part conforming to the joint shape. The outer surface shall be completely covered with a natural skin. The cross-sectional diameter and installation shall be in accordance with the manufacturer's recommendations for the size of pipe being placed.
1057.10 Silicone Expansion Joint Sealant. The sealant for expansion joints shall be in accordance with Sec
717.30 The silicone joint sealant shall be a rapid cure, self-leveling, cold applied, single or two-component
silicone sealant. The sealant shall demonstrate resilience, flexibility and resistance to moisture and puncture upon curing. The sealant shall demonstrate excellent adhesion to Portland cement concrete, polymer concrete and steel over a range of temperatures from –30 to 130 F, while maintaining a watertight seal. The sealant shall not contain any solvents or diluents that cause shrinkage or expansion during curing. Acid-cure sealants shall not be used. The date of manufacture or “use by” date shall be provided with each lot of sealant or primer. Material 12 months old or older from the date of manufacture or past the “use by” date shall not be used. The engineer reserves the right to test representative samples from material proposed for use. If a backer rod is required, it shall be closed-cell material, as recommended by the sealant manufacturer. The manufacturer shall certify that the sealant meets or exceeds the following test requirements before installation begins: Physical Properties: Requirement Each component as supplied: Specific Gravity (ASTM D 1475) Extrusion Rate (ASTM C 1183) Durometer Hardness, Shore (ASTM D 2240) "00" (0 C and 25 C ± 1 C [77 ± 3 F]) Ozone and U.V. Resistance (ASTM C 793)1.2 - 1.4 200 - 550 g/minute 30 - 60 No chalking, cracking or bond loss after 5000 hrs. After Mixing: Flow Tack-Free Time (ASTM C 679)Self-Leveling 60 minutes maximum Upon Complete Cure: (ASTM D 5329a) Joint Elongation (Adhesion to concrete/ steel/polymer concrete) Joint Modulus (at 100% elongation)600% minimum 3-12 psi aModified; Sample cured two days at 77 ± 2 F and 50 ± 5 percent relative humidity.
1057.11 Silicone Joint Sealant for Saw Cut and Formed Joints. The sealant for sawed and formed joint shall
be in accordance with Sec 717.40. The silicone joint sealant shall be a cold applied, single component, chemically curing gray sealant with 100 percent elongation and 50 percent compressive joint movement capability. If a backer rod is required, it shall be closed-cell material, as recommended by the sealant manufacturer. The sealant shall be type NS (Non-Sag) and the physical properties shall be in accordance with ASTM D 5893 and the following: Physical Properties Requirement Color Gray Tack free time 35 – 75 minutes Cure time7 days @ 75 F – 90 F and 45 – 55 % relative humidity 6951057.12 Documentation. All material specified in this section shall include certification showing representative test results of the material and certify that the material supplied is in accordance with these specifications. 696SECTION 1058 POLYETHYLENE SHEETING 1058.1 Scope. This specification covers polyethylene sheeting for use in highway construction. 1058.2 Polyethylene Sheeting for Curing. Polyethylene sheeting for curing Portland cement concrete shall be white and shall be in accordance with ASTM C 171. 1058.3 Polyethylene Sheeting as a Bond Breaker. Polyethylene sheeting for use as a bond breaker between a bridge approach slab and a granular base shall be in accordance with ASTM E 1745 Performance Class A. 1058.4 Certification and Acceptance. The contractor shall furnish a manufacturer's certification that the material supplied is in accordance with these requirements. 697SECTION 1059 PROTECTIVE COATING MATERIAL SECTION 1059.10 PROTECTIVE COATING–CONCRETE BENTS AND PIERS (URETHANE).
1059.10.1 Scope. This specification covers modified urethane or polyurethane elastomeric coating to be used as
shown on the plans. This material will typically be applied under expansion devices for protection from deleterious agents in areas where aesthetics is not a high priority.
1059.10.2 General Requirements. The material shall be suitable for outdoor exposure and shall be resistant to
deterioration by ultraviolet light. Additives for ultraviolet stabilization shall not be added after the original manufacturing process. The material shall be suitable for application to concrete surfaces. Surface preparation shall be in accordance with the manufacturer’s recommendations. The material shall be suitable for application to obtain a thickness of 40 mils, dry film without runs or sags when applied to a vertical concrete surface. The material shall have a minimum shelf life, in unopened containers, of at least six months from the date of delivery.
1059.10.3 Cured Material. The cured material shall be in accordance with the following:
Protective Coating – Concrete Bents and Piers (Urethane) Property Requirement Shore A Hardness, ASTM D 2240 (Material shall be cured in 40 mil thick film for 7 days at 75 ± 2 F at 50% relative humidity. Test specimen shall be composed of plied pieces, to a minimum 1/4-inch thickness).15, minimum Tensile Strength, ASTM D 412 (Method and time of cure may be modified as recommended by the manufacturer).45 psi, minimum Elongation, ASTM D 412 (Method and time of cure may be modified as recommended by the manufacturer).200 percent, minimum Water Vapor Permeability, ASTM D 1653 or ASTM E 96, Method BW 40 mil film thickness.0.8 perms, maximum
1059.10.4 Packaging. All two-component materials shall be prepackaged to exact mixing quantities.
1059.10.5 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall
submit a representative one-gallon sample to Construction and Materials. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Urethane Protective Coating Agents for Concrete Bents and Piers. The sample shall be identified by brand name, manufacturer's name and address, and shall be accompanied by the following:
a.Manufacturer's complete material data showing typical test results for the properties specified, generic name of the major components of the material, mixing instructions, surface preparation and application instructions and intended use.
b.Test results after 1000 hours of exposure in an accelerated weathering device, in accordance with ASTM D 822, Procedure B. The film thickness of test specimens shall be 40 mils and shall show no cracking, flaking or blistering after exposure. Slight discoloration will be permitted.
c.In lieu of the accelerated weathering test results required in Sec 1059.10.5(b), the manufacturer may submit a use history showing satisfactory performance for three years in at least two exposed applications. Name, address and telephone number of the users shall be included in the use history.
1059.10.6 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material
supplied is in accordance with all requirements specified and that the material furnished is of the same composition as originally qualified. The engineer reserves the right to sample the material at destination if deemed necessary. SECTION 1059.20 PROTECTIVE COATING – CONCRETE BENTS AND PIERS (EPOXY). 6981059.20.1 Scope. This specification covers two-component modified polyamide converted epoxy to be used as shown on the plans. This material will typically be applied under expansion devices where aesthetics is a high priority.
1059.20.2 Material. The material shall be suitable for application to obtain a minimum coating thickness of 6
mils, dry film without runs or sags when applied to a vertical concrete surface. Pot life and method and time of cure shall be in accordance with the manufacturer's recommendation. The material shall be suitable for outdoor exposure and shall be resistant to deterioration by ultraviolet light. Additives for ultraviolet stabilization shall not be added after the original manufacturing process. The material shall have a minimum shelf life, in unopened containers, of at least six months from the date of delivery.
1059.20.2 1 Color. The color shall be clear or concrete gray.
1059.20.2 2 Finish. The finish shall be high gloss.
1059.20.3 Packaging. Two-component material shall be prepackaged to exact mixing quantities.
1059.20.4 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall
submit a representative one-gallon sample to Construction and Materials. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Epoxy Protective Coating Agents for Concrete Bents and Piers. The sample shall be identified by brand name, manufacturer's name and address, and accompanied by the following information:
a.Manufacturer's complete material data showing typical test results for the properties specified, generic name of the major components of the material, mixing instructions, surface preparation and application instructions and intended use.
b.Test results after 1000 hours of exposure in an accelerated weathering device shall be provided. The tests shall be conducted in accordance with ASTM D 822 or ASTM G 154 using test cycle No. 2 defined in ASTM D 822, except that during the six hour period of darkness, the relative humidity of the air shall be 95 ± 4%. If ASTM G 154 QUV exposure testing is used, Type A lamps shall be used.
1059.20.4 1 For either test, specific operating conditions shall be summarized and provided with the test results.
The film thickness on test specimens shall be 6 mils and shall show no cracking, flaking or blistering after exposure. Only slight discoloration will be permitted.
1059.20.4 2 In lieu of the accelerated weathering test results required in Sec 1059.20.4 (b), the manufacturer
may submit a use history showing satisfactory performance for three years in at least two exposed applications. Name, address and telephone number of the users shall be included in the use history.
1059.20.5 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material
supplied is in accordance with all requirements specified and that the material furnished is of the same composition as originally qualified. The engineer reserves the right to sample the material at destination if deemed necessary. SECTION 1059.30 CONCRETE AND MASONRY PROTECTION SYSTEM.
1059.30.1 Scope. This specification covers clear penetrating siloxane or silane based sealer for use as shown on
the plans.
1059.30.2 Physical Properties. The sealer shall be breathable and non-yellowing and shall be in accordance
with the following requirements: Concrete and Masonry Protection System Specification Itema Sealer Type Vertical ApplicationHorizontal Application Solids Content, percent by weight, min. 6.7 20 Reduction in Water Absorption, percent, min. 80 85 699Reduction in Chloride Intrusion, percent, min. 82 85 Water Vapor Transmission, percent, min. 110 aTested in accordance with NCHRP 244 Series tests.
1059.30.3 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall
submit a representative one-quart sample to Construction and Materials. The sample shall be identified as to brand name, designation as to horizontal or vertical application, manufacturer's name and address, and shall be accompanied by the manufacturer’s data and application sheets, and test results in accordance with Sec
1059.30.2 The manufacturer shall submit certification that the material complies with all requirements of this
specification. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Concrete and Masonry Protection Systems.
1059.30.4 Field Approval. Prior to application of the sealer, including bulk purchase and delivery of products,
the contractor shall prepare a minimum 12 x 12 inch application sample on each of the specified concrete or masonry products for the purpose of demonstrating the final effect, visual and physical/chemical, of the planned installation. The contractor shall proceed with work only after the engineer’s acceptance of the test application for color and compatibility with the substrate.
1059.30.5 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material
supplied is in accordance with all requirements specified and that the material furnished is of the same composition as originally approved. The engineer reserves the right to sample the material at destination if deemed necessary. SECTION 1059.40 SACRIFICIAL GRAFFITI PROTECTION SYSTEM.
1059.40.1 Scope. This specification covers a sacrificial graffiti protection system for application to all surfaces
as shown on the plans.
1059.40.2 Physical Properties. The sacrificial graffiti protection system shall be in accordance with the
following physical properties and shall be chemically compatible with any other coatings to be used. The material shall be suitable for application to obtain a wet-film thickness of 4 to 6 mils without runs or sags when applied to a vertical surface. Sacrificial Graffiti Protection System Item Requirement Melting Point, F, ASTM F 766 165 ±5 Solids Content, min., percent by weight, ASTM D 283426 Volatile Organic Content (VOC), lb/gal, max, ASTM D 3960 0.58
1059.40.3 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall
submit a representative one-gallon sample to Construction and Materials. The manufacturer shall submit documentation to Construction and Materials stating brand name, manufacturer's name and address and accompanied by the manufacturer’s data and application sheets. The manufacturer shall submit certification, including specific test results, that the material complies with all requirements of this specification. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Sacrificial Graffiti Protection Systems.
1059.40.4 Field Approval. Prior to application of the sacrificial graffiti protection system, including bulk
purchase and delivery of products, the contractor shall prepare a minimum 12 x 12 inch application sample on each of the specified concrete or masonry products for the purpose of demonstrating the compatibility of the planned installation. If the sacrificial graffiti protection system is to be applied over previous coatings, the test specimen shall have already received these previous coatings. The contractor shall proceed with work only after the engineer’s acceptance of the test application for appearance and compatibility.
1059.40.5 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material
supplied is in accordance with all requirements specified and that the material furnished is of the same 700composition as originally approved. The engineer reserves the right to sample the material at destination if deemed necessary. SECTION 1059.50 TEMPORARY COATING – CONCRETE BENTS AND PIERS (WEATHERING STEEL).
1059.50.1 Scope. This specification covers a system for protection against absorptive staining from unpainted,
corrosion-resistant steel during initial weathering as shown on plans.
1059.50.2 Physical Properties. The temporary coating shall be in accordance with the following physical
properties and shall be compatible with any other coatings to be used. The material shall be suitable for application to obtain a wet-film thickness of 4 to 6 mils without runs or sags when applied to a vertical surface. Temporary Coating – Concrete Bents and Piers (Weathering Steel) Item Requirement Melting Point, F , ASTM F 766 165 ±5 Solids Content, min., percent by weight, ASTM D 2834 26 Volatile Organic Content (VOC), lb/gal, max, ASTM D 3960 0.58
1059.50.3 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall
submit a representative one-gallon sample to Construction and Materials. The manufacturer shall submit documentation to Construction and Materials stating brand name, manufacturer's name and address, and accompanied by the manufacturer’s data and application sheets. The manufacturer shall submit certification, including specific test results, that the material complies with all requirements of this specification. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Rust Staining Protection Systems.
1059.50.4 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material
supplied is in accordance with all requirements specified and that the material furnished is of the same composition as originally approved. The engineer reserves the right to sample the material at destination if deemed necessary. 701SECTION 1060 ELECTRICAL CONDUIT 1060.1 Scope. This specification covers electrical conduit to be used as specified or as shown on the plans. 1060.2 Acceptance. All material in this section will be accepted based on certification indicating the material is in accordance with this specification and any testing as required by the engineer. 1060.3 Material. 1060.3.1 Rigid Metallic Conduit and Tubing. Except for rigid aluminum conduit, rigid metallic conduit shall be galvanized on both the inside and the outside surfaces. The weight of zinc coating shall be no less than 0.5 ounce per square foot of coated surface, as determined in accordance with AASHTO T 65. The interior or exterior surface, or both, may be given a coating of suitable material to facilitate installation of wires and cables and to permit the conduit to be readily distinguished from pipe used for purposes other than electrical. 1060.3.1.1 Rigid Steel Conduit, Zinc Coated. Rigid steel conduit, zinc coated, (GRC) shall be in accordance with ANSI C80.1, except as noted herein. 1060.3.1.2 Intermediate Metal Conduit. Intermediate metal conduit (IMC) shall be in accordance with ANSI C80.6, except as noted herein. 1060.3.1.3 Rigid Aluminum Conduit. Rigid aluminum conduit (RAC) shall be in accordance with ANSI C80.5. 1060.3.1.4 Electrical Metallic Tubing, Zinc Coated. Electrical metallic tubing (EMT), zinc coated, shall be in accordance with ANSI C80.3 except as noted herein. 1060.3.1.5 Fittings for Rigid Metal Conduit and Electrical Metallic Tubing. Fittings shall be in accordance with ANSI C80.4. 1060.3.1.6 Fittings for Intermediate Metal Conduit. Fittings shall be in accordance with UL 1242, except the coating shall meet the same requirements as the conduit with which the fittings are used. 1060.3.1.7 Inspection. Conduit, tubing and fittings will be inspected for compliance with specifications. Test specimens for determination of weight of coating will be at least 2 inches long, cut no less than 6 inches from the end of the length of conduit or tubing selected for testing. If the prescribed two additional samples for retests are taken, and either sample does not comply, the lot represented will be rejected. 1060.3.2 Rigid Non-Metallic Conduit. Rigid non-metallic conduit shall be either polyvinyl chloride (PVC) or high-density polyethylene (HDPE). 1060.3.2.1 Polyvinyl Chloride Conduit. PVC conduit, bends, couplings and fittings shall be in accordance with UL 651. 1060.3.2.2 High Density Polyethylene Conduit. HDPE conduit shall be in accordance with ASTM D 3035 SDR11. 1060.3.2.3 Fittings for Polyvinyl Conduit. Fittings for PVC conduit shall be in accordance with UL 514. Cement used for the fittings shall be in accordance with the conduit manufacturer’s recommendations. 1060.3.2.4 Fittings for High Density Polyethylene Conduit. Fittings for HDPE conduit shall be in accordance with ASTM D 2683. Epoxy used for the fittings shall be in accordance with the conduit manufacturer’s recommendations. 1060.3.2.5 Inspection and Testing. Material will be inspected for compliance with the specifications, and samples for testing will be taken at either the project location or warehouse, as determined by the engineer. 1060.4 Certification. The contractor shall furnish a manufacturer's certification that the material supplied is in accordance with all requirements. If requested by the engineer, the contractor shall also furnish typical test 702results representative of the material. 703SECTION 1061 ELECTRICAL CONDUCTORS 1061.1 General. This specification covers electrical conductors and associated material for use on highway construction projects. Contractor furnished equipment that will become the property of the Commission shall be of new stock unless stated otherwise in the contract documents. Electrical conductors and associated equipment shall be in accordance with applicable requirements of ICEA, IMSA, NEMA, EIA, NEC, NFPA and regulations of the National Board of Fire Underwriters and shall meet the approval of the engineer. 1061.2 Conductors. Except as noted, all conductors shall be soft drawn, Class B or C stranded copper wire in accordance with NEMA WC70/ICEA A-95-658. Solid conductors may be used only for grounding where connected to a ground rod. 1061.3 High Voltage Power Cable. The voltage rating for high voltage power cable supplying primary electrical power shall be 5 KV for primary voltages less than 5,000 volts, and 15 KV for voltages of 5,000 volts and greater. The specific type of cable shall be as recommended and approved by the utility company or municipality supplying power. 1061.4 Low Voltage Power Cable. Low voltage power cable shall be 600-volt, single conductor cable and thermoplastic or thermosetting cross-linked polyethylene insulated. All cable shall be plainly marked on the outside with the manufacturer's name and identification in accordance with industry practice. Insulation type shall be THHN/THWN-2 orXHHW-2. Average thickness of insulation shall be no less than specified in the following table, with a minimum thickness of 90 percent thereof. Size (AWG or kcmil)Thickness, Mils THHN/THWN-2) 14-12 15 10 20 8-6 30 4-2 40 1-4/0 50 250-500 60 501-1000 70 Size (AWG or kcmil)Thickness, Mils THHN/XHHW-2) 14-10 30 8-2 45 1-4/0 55 213-500 65 501-1000 80 1061.5 Cable-Conduit. Cable-conduit shall consist of one to four low voltage power cables with an insulated sized electrical neutral and a bare safety ground, factory installed in black polyethylene conduit intended for direct burial. The conduit shall be plainly marked on the outside with manufacturer's name and identification in accordance with industry practice and shall be in accordance with ASTM D 3485. Cable-conduit shall be accompanied by the manufacturer's certification stating the conduit is in accordance with the requirements of this specification. 1061.6 Pole and Bracket Cable. Pole and bracket cable located in the lighting or signal pole that supplies electrical power to highway lighting shall consist of two single conductors. Wire size shall be No. 10 AWG in accordance with the requirements of low voltage power cable. Insulation type shall be THHN/THWN-2 or XHHW-2. Average insulation shall be in accordance with Sec 1061.4. 1061.7 Multi-Conductor Cable. Multi-conductor cable for traffic signals shall be No. 16 AWG, rated at 600 volts. The cable shall be in accordance with IMSA Specification No. 19-1 or No. 20-1. 7041061.8 Induction Loop Detector Cable. Induction loop detector cable shall be single-conductor No. 14 AWG wire, with Type XHHW insulation, marked as such, rated at 600 volts. The cable shall be in accordance with IMSA Specification No. 51-7. 1061.9 Loop Detector Lead-In Cable. Lead-in cable used between the loop detector and the controller shall be two-conductor, twisted, shielded No. 14 AWG wire rated at 600 volts. The cable shall be in accordance with IMSA Specification No. 50-2.
1061.10 Certification. All cables and conductors shall be accompanied by certification from the supplier
indicating: (1) the supplier is familiar with the requirements of these specifications and, (2) cable furnished was from a lot manufactured by (manufacturer's name) whose test results are in accordance with these specifications. 705SECTION 1062 PULL AND JUNCTION BOXES 1062.1 Scope. This specification covers pull and junction boxes intended for use on highway lighting and traffic signal projects. 1062.2 Pull Boxes. Pull boxes may be cast-in-place concrete, precast concrete, preformed polymer concrete or preformed fiberglass reinforced polymer concrete. Pull box dimensions shall be as shown on the plans. Each pull box shall be equipped with cable hooks as shown on the plans. Cable hooks shall be galvanized steel or brass with a minimum diameter of 3/8 inch and a minimum length of 5 inches. 1062.2.1 Cast-in-place concrete pull boxes shall be constructed of Class B or B-1 concrete, or a commercial mixture in accordance with Sec 501. Material, proportioning, mixing, slump and transporting of concrete shall be in accordance with Sec 501. Placing, finishing and curing shall be in accordance with Sec 703. Pull boxes shall be cast in a neat and workmanlike manner. Forms will be required for the inside surfaces of the pull box walls; and if the excavation is irregular, forms will also be required for the outside surfaces of the walls. An outside form shall be installed across all trenches leading into the pull box excavation. The ends of all conduits through the walls shall fit tightly against the form. 1062.2.2 Precast concrete pull boxes shall be constructed of Class B or B-1 concrete, or a commercial mixture in accordance with of Sec 501. Material, proportioning, mixing, slump and transporting of concrete shall be in accordance with Sec 501. Concrete for precast pull boxes shall be placed, finished and cured in accordance with Sec 703. 1062.2.3 Preformed pull boxes shall withstand a wheel load of 20,000 pounds. Pull box walls may be either flared or vertical. Metal conduit, if used in preformed pull boxes, shall be electrically bonded to one another inside each pull box. 1062.3 Pull Box Covers. Each pull box shall be equipped with a bolt down cover. The threaded hole that receives the cover lock-down bolt shall be open at the bottom to allow the cleanout of sand, dirt and other debris. Lock-down bolts shall be stainless steel or brass with a penta-head. Frames and covers for cast-in-place and precast concrete pull boxes shall be cast iron in accordance with AASHTO M 105, Class 30, and shall be of the dimensions and weights shown on the plans. Preformed pull box covers shall be polymer concrete and shall have a minimum wheel load rating of 20,000 pounds. A lift opening shall be provided on all covers. Covers for pull boxes to be used for highway lighting or sign lighting shall be embossed with "STATE LIGHTING". Covers for pull boxes to be used for traffic signals, or a combination of traffic signals and 120 volt intersection lighting, shall be embossed with "STATE SIGNALS". Covers for pull boxes to be used for fiber optics shall be embossed with “STATE FIBER OPTICS”. 1062.4 Junction Boxes. Junction boxes shall be flanged and designed for flush mounting if encased in concrete, or designed for surface mounting if external mounting is specified. Junction boxes shall be drilled or tapped for all conduit connections. Junction boxes shall be installed such that covers are removable. Junction boxes shall be stainless steel, fiberglass or PVC watertight NEMA 4 or NEMA 4X enclosures. PVC junction boxes shall have a minimum wall thickness of 1/4 inch. Junction boxes shall be in accordance with the following sizes unless otherwise specified: Junction Box Placement in ConcreteEntering Conduit Size(s)Junction Box Size, H x D x L (Inches) 8 ½” Slab 2" 12 x 4 x 12 Concrete Barrier Type D or H or Abutment Wing2" 12 x 10 x 123" 4" Three - 2" Two - 3" 2" plus 3" 7061062.4.1 PVC and metal conduit shall be joined to junction boxes to make a rigid and waterproof connection. If metal conduit is used, an insulated bushing shall be provided at the end of the metal conduit on the inside of the junction box to prevent scuffing of the cable insulation. 1062.4.2 The junction box cover shall be made watertight with a suitable gasket and secured with stainless steel or cadmium plated screws or bolts. 1062.5 Certification and Acceptance. The contractor shall furnish a manufacturer's certification that the material supplied, excepting material made from cast-in-place concrete, is in accordance with these specifications. 707SECTION 1063 TEMPORARY TRAFFIC CONTROL DEVICES 1063.1 Scope. This specification covers material to be used for temporary traffic control devices. 1063.2 General Requirements. All temporary traffic control devices shall be manufactured as shown on the plans and as specified, in accordance with MUTCD requirements and shall be NCHRP 350 or MASH 2016 compliant. FHWA Category 1 temporary traffic control devices are not required to be crash tested unless modified. Non MASH 2016 FHWA Category 2 temporary traffic control devices and appurtenances manufactured prior to January 1, 2023 may be used until January 1, 2026. Non MASH 2016 FHWA Category 3 temporary traffic control devices and appurtenances manufactured prior to January 1, 2023 may be used until January 1, 2030. All FHWA Category 2 and Category 3 temporary traffic control devices and appurtenances manufactured after January 1, 2023 shall meet MASH 2016 Test Level 3 crash test requirements. Type F three- loop temporary concrete barrier is required to meet NCHRP 350 requirements regardless of manufacturing date and may be used until January 1, 2030. MASH 2016 FHWA Category 4 temporary traffic control devices should be used when available. Nominal dimensions will be permitted for dimensional lumber where applicable. All temporary traffic control devices shall exhibit good workmanship and shall be free of objectionable marks or defects that affect appearance or serviceability. The brand name or model number shall be permanently identified on each traffic control device. 1063.3 Channelizers. All trim-lines and drum-like channelizers shall be manufactured from a non-metallic material, pigmented and molded of a Highway Orange color throughout and stabilized against fading by ultraviolet or other light rays by the incorporation of adequate inhibitors. All reflective sheeting for channelizers shall be in accordance with Sec 1042.2.7.3. 1063.3.1 Temporary Tubular Delineators. Temporary tubular delineators shall be a nominal height of 28 inches and manufactured from a non-metallic material, pigmented and molded of a Highway Orange color throughout and stabilized against fading by ultraviolet or other light rays by incorporation of adequate inhibitors. All reflective sheeting for temporary tubular delineators shall be in accordance with Sec 1042.2.7.5. 1063.4 Signs. 1063.4.1 Rigid Signs. 1063.4.1.1 Sign Substrate. All signs shall be fabricated of substrate designed to provide satisfactory structural rigidity. 1063.4.1.2 Sign Sheeting. All signs shall have a retroreflectorized background. Retroreflective sheeting shall be in accordance with Sec 1042.2.7.2. Sheeting shall be applied to the sign substrate in accordance with the manufacturer’s recommendations and the surface shall be free of air bubbles, wrinkles or other blemishes as determined by the engineer. 1063.4.2 Roll-up Signs. 1063.4.2.1 Sign Substrate. Sign and overlay blanks shall consist of either white, yellow, fluorescent orange and/or pink microprismatic retroreflective sheeting sealed to a heavy-duty coated fabric or vinyl material. The sheeting shall have a minimum coefficient of retroreflection, expressed as candelas per footcandle per square foot, as shown below, when measured in accordance with ASTM E 810 and shall meet the minimum color requirements in accordance with MGS-04-01L specification. The color specifications shall be in accordance with ASTM D 4956. Material shall be submitted by the manufacturer to NTPEP for a minimum exposure time of one year. Results shall be published by NTPEP and available for MoDOT review. For all NTPEP test decks, weathered material shall be within the color specification limits. Heat and impact resistance of the sheeting shall be in accordance with the latest version of ASTM D 4956. 1063.4.2.2 Overlays. Overlays, when used, shall be mechanically fastened to the face of the sign in a manner that will ensure the overlay remains securely attached. Fasteners shall not detract from the appearance of the sign when the overlay is not in use. Velcro fasteners will not be permitted. 1063.4.2.3 Bracing. Each sign shall have a horizontal and vertical cross brace and at least one anti-kiting device located near the center of the sign. Cross braces of sufficient cross-section shall be fastened to each other at the 708midpoints and the ends securely held to the back of the sign by mechanical means. The design shall ensure that the sign remains taut and retains the sign’s intended shape when exposed to normal field conditions. 1063.4.3 Legend and Borders. Legends and borders of all signs shall be vinyl or silk-screened. Vinyl shall be cut by die or a computer-driven cutter. Stencil ink used shall be in accordance with the sheeting manufacturer’s recommendations. Free-hand legend and borders will not be permitted. 1063.4.4 Sign Layout and Design. Sign layout and design shall be as shown on the plans or as directed by the engineer. 1063.4.5 Flag Assembly. Flag assemblies, when specified, shall consist of a flag bracket and two flags. Flags shall be 18 in x 18 in fluorescent orange, vinyl and be securely attached on one side to a blank suitable for displaying the flag as shown on the plans. The flag shall not be of mesh material. The blank shall be securely attached to the flag bracket, be of sufficient cross-section to display the flag in wind speeds up to 50 mph and be of sufficient length to hold the flags approximately six inches from the sign. 1063.4.6 Advance Warning Rails. Advanced warning rails shall be supplied as a system of three rails as shown on the plans. The rail system may be post mounted or mounted on portable structures. When used on post mounted signs, the advance warning rails shall consists of substrate of high-density polyethylene plastic. The rail wall thickness shall be 1/4 in. with white and orange reflective sheeting in accordance with Sec 1042.2.7.4, and shall be applied as shown on the plans. 1063.5 Sequential Flashing Warning Lights. Sequential flashing warning lights shall meet the following requirements:
a.Number of lens directional faces: 1.
b.Flashing rate per minute: 55 to 75.
c.Hours of operation: 24 hours per day. 1063.6 Flashing Arrow Panels. All lamps shall have a nominal 5-inch, 360-degree tunnel visor. A lamp on the back side of the flashing arrow panel shall be continuously energized during operation of the flashing arrow panel. Lamps shall be visible at an angle of 15 degrees to the left and right of center and 4 degrees above and below center during “on” time. The flashing arrow panel shall contain a device to align the arrow panel to oncoming traffic. Arrow panels shall be capable of displaying the flashing arrow, flashing double arrow and four corner flashing caution modes. Solar-powered flashing arrow panels shall be capable of operating in the flashing arrow mode for 20 consecutive days and shall be provided with a device to indicate the remaining charge in batteries. 1063.6.1 Trailer-Mounted Flashing Arrow Panels. Trailer-mounted flashing arrow panels shall be MUTCD, Type C. Trailer-mounted flashing arrow panels shall be solar powered. 1063.6.2 Truck-Mounted Flashing Arrow Panels. Truck-mounted flashing arrow panels shall be MUTCD, Type B. 1063.7 Changeable Message Sign. Each portable Changeable Message Sign (CMS) shall consist of a message board, solar power supply, control systems and mounting and transporting equipment. The unit shall be assembled to form a complete self-contained CMS that can be delivered to the job site and placed into immediate operation. The sign unit shall be capable of operating at an ambient air temperature of -20 to 120 degrees F. and shall not be affected by two-way radio transmissions other than those required to control the CMS. A CMS shall be permanently mounted on a trailer, truck bed, or truck cab per manufacturer’s recommendations. The CMS must be securely mounted on the support vehicle such that it should remain attached during an impact to the vehicle. If it is mounted on a trailer, the trailer must be capable of being leveled and plumbed. CMS trailers should be delineated on a permanent basis by affixing retroreflective material, per Sec 1042.2.7 in a continuous line on the face of the trailer as to be seen by oncoming road users. 7091063.7.1 Message Board. The CMS shall be equipped with a power source and battery back-up to provide continuous operation when failure of the primary power source occurs. Either message board shall be capable to provide three lines of eight individual changeable characters per line. Each character shall be yellow in display on a black background and be a minimum of 18-inches in height. CMS used on roadways with speed limits of 55 mph or higher should be visible from ½ mile under both day and night conditions. The message should be designed to be legible from a minimum of 600 ft. for nighttime conditions and 800 ft. for normal daylight conditions. When environmental conditions that reduce visibility and legibility are present, or when the legibility distances stated in the previous sentences in this paragraph cannot be practically achieved, messages composed of fewer units of information should be used and consideration should be given to limiting the message to a single phase. 1063.7.1.1 The CMS shall have a control system to allow the message to be changed from the CMS location. The control system shall include a display screen upon which messages can be reviewed before being displayed on the sign and a variable display rate that allows the operator to match the information display to the speed of the approaching traffic. For on-site operation, the CMS shall have a removable waterproof keyboard with display panel that allows the operator to generate an unlimited number of additional messages in addition to the preprogrammed stored messages. The keyboard must be equipped with a security lockout feature to prevent unauthorized use of the controller. 1063.7.2 Changeable Message Sign with Communication Interface. The CMS with communication interface shall have a digital cellular transceiver capable of receiving a message in the location deployed from a remote location and forwarding the message to the CMS controller to change the displayed message. 1063.7.3 Solar Power Supply. The CMS shall be equipped with a power source and battery back-up to provide continuous operation when failure of the primary power source occurs. 1063.8 Portable Traffic Signals. Each portable traffic signal (PTS) system shall consist of two trailer-mounted PTS units, a controller assembly and communication link. Each PTS unit shall consist of signal heads and indications, a solar power supply, vehicle detection and mounting and transporting equipment. All components shall be capable of operating in a temperature range of -20 to 120 F. 1063.8.1 Controller Assembly. The controller assembly shall be a minimum two-phase, solid-state traffic signal controller with a conflict monitor capable of operating the signals in accordance with MUTCD requirements and NEMA Standard TS1. The controller shall operate as a fully-actuated unit and shall have the capability of being manually operated to display simultaneous red on both phases. The controller shall be capable of red rest during non-actuated periods. Upon detection of a conflict, the system shall change to a solid red clearance interval followed by flashing red. 1063.8.2 Communication Link. A continuous communications link between the PTS units shall be provided. If a break in communications between the PTS units occurs, the system shall change to a solid red clearance interval followed by flashing red. Upon restoration of communications, the system shall change to a solid red clearance interval followed by normal operations. 1063.8.3 Signal Heads and Indications. Each unit shall consist of two polycarbonate signal heads, including backplates and visors. One signal head shall be mounted on the mast arm assembly and the other on the vertical upright. The signal head mounted on the mast arm shall provide a minimum lateral clearance of 9.5 feet from the center of the outer signal head to the edge of the trailer and a minimum vertical clearance of 16 feet from the bottom of the backplate to the roadway surface. The signal head mounted on the vertical upright shall provide a minimum clearance of 8 feet from the bottom of the backplate to the roadway surface. All signal indications shall be 12 inches in diameter. Traffic signal heads and indications shall be in accordance with the vehicle traffic control signal head requirements of ITE and NEMA Standard TS1 and TS2. 1063.8.4 Solar Power Supply. The power supply shall use a battery bank with sufficient capacity to operate the PTS for 20 consecutive days with no sun. All terminals and connections shall be clearly labeled. 1063.8.5 Vehicle Detection. Detection shall be provided by one of the non-intrusive vehicular detection methods specified in Sec 902 or temporary loop detectors with the capability of providing coverage for a 6-foot x 30-foot area. Temporary loops shall be preformed at the factory. The temporary loops shall have self-adhesive rubberized asphalt backing, which shall bond to the pavement. 7101063.8.6 Support. A factory trained service representative shall be available at the delivery location to provide technical assistance and training, including the installation and operation of software. No additional payment will be made for travel expenses. 1063.9 Portable Signal Flagging Device. Each portable signal flagging device (PSFD) system shall consist of four portable cart-mounted units. Each PSFD unit shall provide a vertical upright with one signal head, vehicle detection, radio controller, and self-contained power supply capable of operating the unit for 16 continuous hours. All components shall be capable of operating in a temperature range of –20 to 120 F. 1063.9.1 Signal Heads and Indications. The signal head shall consist of three (red ball, amber ball, green ball) 12-inch LED signal indications. All signal heads shall be mounted on the vertical uprights with a minimum clearance of 7 feet when the upright is fully extended. 1063.9.2 Vehicle Detection. Detection shall be provided by one of the non-intrusive vehicular detection methods specified in Sec 902 with the capability of providing coverage for a 6-foot x 30-foot area. 1063.9.3 System Operation. The system shall be able to operate in a fixed-time, traffic-actuated, and manual- control mode. The system shall be MUTCD compliant with a controller and conflict monitor and include a wireless radio communication package and wireless remote.
1063.10 Radar Speed Advisory System. Each radar speed advisory system shall consist of a radar unit, speed
display, speed limit display, solar power supply and mounting and transporting equipment.
1063.10.1 Radar Unit. The radar unit shall include necessary cables for connection to the digital display and
power supply, shall be capable of instantaneously displaying and locking readings and shall meet the following minimum requirements: Radar Unit Requirements Speed range15 to 99 mph Accuracy ±1 mph Internal test32 mph check
1063.10.2 Speed Display. The speed display shall be a minimum of 12 inches high and shall be capable of
displaying the radar unit output from 0 to 99 mph.
1063.10.3 Speed Limit Display. The speed limit display shall indicate the work zone speed limit by means of a
36 x 48-inch speed limit sign. The speed limit sign may be comprised of a rigid or roll-up sign or a rigid sign with a variable speed display. The variable speed display shall be a minimum of 12 inches high and shall be capable of displaying two digits.
1063.10.4 Solar Power Supply. The power supply shall be capable of operating the radar unit, speed display
and speed limit display, if applicable, for a minimum of eight hours per day.
1063.11 Truck or Trailer Mounted Attenuators. Each TMA shall have a standard trailer lighting system,
including brake lights, taillights, turn signal lights and Federal Motor Carrier Safety Administration identification bar lights. In the operating position, the rear facing of the TMA shall be marked with alternating 8-inch yellow and 8-inch black retroreflective sheeting forming an inverted “V” at the center and slope downward at an angle of 45 degrees toward each side of the unit or a checkered board pattern consisting of 12- inch square red and 12-inch square white retroreflective sheeting. The TMA may be marked with the same operating pattern or red and white DOT conspicuity tape to simulate the looks of a standard van body trailer when traveling. The TMA shall have the same standard trailer lighting system noted above when the unit is in the transport position.
1063.12 Certification. The contractor shall furnish a manufacturer's certification for all material governed by
this specification. The certification shall indicate full compliance with each applicable specification. 71 1SECTION 1064 TEMPORARY TRAFFIC BARRIER 1064.1 Scope. This specification covers temporary traffic barrier for use in highway construction. 1064.2 Type F Temporary Concrete Barrier. 1064.2.1 Acceptance. 1064.2.1.1 Three-Loop Concrete Barrier. The manufacturer shall provide certification to the contractor that the barrier is in accordance with the contract documents. 1064.2.1.2 Two-Loop Concrete Barrier. Use of two-loop temporary Type F concrete barrier shall not be allowed after January 1, 2023. 1064.2.2 Material. 1064.2.2.1 All material, in the manufacturing of three-loop type F temporary concrete barrier, shall be in accordance with the following specifications: Item Specification Reinforcing Steel for ConcreteAASHTO M 31, Grade 60 Connection Rod A36 Steel Anchor Bolts ASTM A307 Connection Rod Assembly AASHTO M 183 Retainer Bolt and Nut SAE Grade 8 Asphalt Pin A36 Steel Thrie Beam Nested 12 Gage or 10 Gage Thrie Beam Bolts ASTM A307 1064.2.2.1.1 All reinforcing steel shall be deformed bar. Loop steel shall be 0.75-inch smooth steel bars with a minimum yield of 60 ksi, shall have a tensile strength of no less than 1.25 times the yield strength, but a minimum of 80 ksi, a minimum 14 percent elongation in 8 inches, and passing a 180-degree bend test using a 3.5 times diameter pin bend diameter. The loops shall be installed within 0.125 inch of the plan dimensions. 1064.2.2.1.2 The manufacturer shall retain, at a minimum, all compressive strength test results, entrained air content records, and reinforcing steel certification for at least five years. 1064.2.3 Manufacture. 1064.2.3.1 Welding of loop steel shall be limited to the minimum surface welding necessary to maintain the position required for placement. 1064.2.3.2 Visual cracks in the loop steel will be cause for rejection. 1064.2.3.3 Concrete shall be air-entrained with 28-day compressive strength of 5,000 psi. Concrete shall be continuously cured until 5,000 psi is attained. Fine and coarse aggregate shall be in accordance with Sec 1005, except that gradation requirements and percent passing the No. 200 sieve will not apply. Temporary concrete traffic barrier shall be manufactured in accordance with industry standard practices for pre-cast construction. 1064.2.3.4 All temporary concrete traffic barrier units shall be permanently marked with the name and location of the manufacturer, and the month and year of manufacture in a location visible after installation. Paint or other liquid marking will not be permitted. 1064.2.3.5 The surface of temporary concrete traffic barrier shall be smooth and non-deformed and substantially free of honeycomb, surface spalls and surface defects. Barrier units shall be straight and square on the ends and 712shall meet the following tolerances: DimensionTolerance Length + 3/4 inch Width + 1/4 inch Height + 1/4 inch 1064.3 Alternative Temporary Traffic Barrier. 1064.3.1 Approval. Prior to approval and use, the contractor shall submit to MoDOT, the manufacturer’s name, the product brand name or model number, a copy of the MASH 2016 or NCHRP 350 test results, shop drawings and any other information requested by the engineer. 1064.3.2 Acceptance. Acceptance of the material will be based on the manufacturer’s certification and upon satisfactory field performance. 713SECTION 1065 DELINEATORS 1065.1 Scope. This specification covers delineators for use in highway construction. 1065.2 Delineator Body. The delineator body shall be flat sheet aluminum in accordance with Sec 1042.2.1 and meet dimensions as shown on the plans. 1065.3 Permanent Tubular Delineators. Permanent tubular delineators shall be a nominal height of 36 inches and manufactured from a non-metallic material, pigmented and molded to match the color of the closest pavement or curb marking, and stabilized against fading by ultraviolet or other light rays by incorporation of adequate inhibitors. 1065.4 Temporary Traffic Barrier Delineators. Temporary tabs shall be manufactured from a thermoplastic material and meet dimensions as shown on the plans. 1065.5 Retroreflective Sheeting. Retroreflective sheeting shall be permanently affixed to the body of the delineator and follow guidelines in accordance with Sec 1042.2.7.5 for application of sheeting. Manufacturer’s certification shall be provided for delineator sheeting. 714SECTION 1066 MORTARS AND GROUT 1066.1 Scope. This specification covers mortars and grout for use in pipe joints, rubble and brick masonry. 1066.2 Mortars and Grout. Mortars and grout shall be mixed in small quantities as needed and shall not be retempered or used after setting has begun. Type I Portland cement shall be accordance with Sec 1019. Sand shall be clean and shall be in accordance with Sec 1005, except the minus No. 200 sieve requirement will not apply. Water shall be in accordance with Sec 1070. 1066.2.1 Mortar For Pipe Joints. Mortar shall consist of one part Type I Portland cement and two parts sand, by volume, mixed with sufficient water to form a plastic mortar. 1066.2.2 Mortar for Grout. Mortar used for grout shall consist of one part Type I Portland cement and three parts sand, by volume, mixed with sufficient water to form a grout of proper consistency. 1066.2.3 Mortar For Rubble and Brick Masonry. The mortar shall be composed of one part Portland cement plus 10 percent, by volume, of hydrated lime and of two parts sand by volume. Hydrated lime shall be in accordance with ASTM C 207, Type N. After the dry material has been thoroughly mixed, water shall be added, and the mixture shall be turned and chopped by hand or mechanical methods until a stiff mortar results. Mortar shall be mixed no more than 30 minutes prior to use. Mortar for pointing shall be mixed in the proportions of one part Portland cement to one part sand by volume. 1066.2.4 Expansive Mortar. 1066.2.4.1 Aluminum Powder Expansive Mortar. The mortar shall consist of one part Type I Portland cement and three parts sand, by volume, mixed with sufficient water to form a stiff plastic mortar. Unpolished aluminum powder at the rate of 4 grams per sack of cement shall be thoroughly dry mixed with the cement before incorporation with other ingredients. 1066.2.4.2 Other Expansive Mortars. Upon approval from the engineer, other expansive mortars may be used. The expansive mortars shall contain no more than 0.02 percent chlorides by weight and, when subjected to a pull-out test, shall equal or exceed the results of tests conducted using the material specified in Sec 1066.2.4.1. 715SECTION 1067 TRUNCATED DOMES 1067.1 Scope. This specification covers truncated domes used for sidewalk curb cuts and pedestrian island cut- throughs. 1067.2 Domes. Domes shall have a base diameter of 0.9 to 1.4 inches. The top diameter shall be 50 to 65 percent of the base diameter. The dome height shall be 0.2 inches. Dome center-to-center spacing shall be 1.6 to 2.4 inches with a minimum base-to-base spacing of 0.65 inches. Stamped concrete will not be accepted. 1067.3 Panels. Truncated dome surfaces shall extend a minimum of 24 inches in the direction of sidewalk travel and the full width of the curb ramp (exclusive of flares), the landing, or blended transition. The panels shall be made of a durable material. The panels shall carry a manufacturer warranty covering all defects for a five-year period from the time of installation. 1067.4 Acceptance. All material shall be obtained from a source identified on the Qualified List (QL) designated for this specification. 716SECTION 1068 TRENCH DRAINS 1068.1 Scope. This specification covers trench drains used in median and shoulder drainage systems. 1068.2 Acceptance. All material shall be obtained from a source identified on the Qualified List (QL) designated for this specification. 1068.3 Materials. 1068.3.1 Drain grates shall meet AASHTO M 306 requirements for proof-load testing. 1068.3.2 The drain grate inflow area shall be a minimum of 0.27 ft2/lf. Drain grate retaining devices shall not obstruct hydraulic flow in the channel. 1068.3.3 The drain grate retaining device shall withstand, without maintenance, repetitive cyclic vertical loads of 500 pounds. 1068.3.4 The drain grate retainers shall withstand a pullout resistance of 250 pounds per foot after completing a 1,000-hour ASTM B117 salt spray test. 1068.4 Drain grates shall be bicycle safe. 1068.5 The use and location of the trench drain shall be as shown on the plans. 717SECTION 1070 WATER 1070.1 Scope. This specification covers water for use in mixing and curing concrete, and for use in mortar and grout. 1070.2 Requirements. Water for use in mixing and curing concrete, and in mortar and grout, shall be reasonably clean and shall be free from injurious quantities of deleterious substances such as oil, acid, alkali, salt or organic matter. Potable water may be accepted without being tested. Requirements for testing water for mixing or curing purposes may be waived if in the judgment of the engineer, the water is considered satisfactory for the purpose. 1070.3 Testing. As required by the engineer, and if laboratory testing shows that the pH of the water is less than 4.5 or more than 9.5, or that the water contains deleterious substances, the following requirements shall also be met. Autoclaved bars, made with the water and a cement that shows satisfactory soundness when mixed with distilled water, shall show an expansion not to exceed 0.5 percent. The compressive strength at seven days of a mortar consisting of one part cement and 2.75 parts of natural silica sand and the water being tested shall show a reduction of no more than 10 percent of the compressive strength developed by 1:2.75 mortar containing the same cement and sand and mixed with distilled water. 718SECTION 1071 ASPHALT RELEASE AGENTS, FIBER ADDITIVES AND LIQUID ANTI-STRIP ADDITIVES 1071.1 Scope. This specification covers asphalt release agents for use in coating truck beds and bituminous mixture additives. 1071.2 Acceptance. All material under this specification shall be obtained from a source identified on the Pre- Acceptance List designated for this specification. All material will be inspected and accepted in accordance with Sec 106. 1071.3 Asphalt Release Agent. The asphalt release agent shall not be detrimental to bituminous mixtures and shall not dissolve asphalt binder when applied to the truck bed. 1071.3.1 Physical Properties. The following physical properties shall be determined. 1071.3.1.1 Unit Weight. The weight per gallon shall be determined in accordance with AASHTO T 59, Weight per Gallon of Emulsified Asphalt. 1071.3.1.2 Solids. The percent solids shall be determined in accordance with ASTM D 1644, Method A. 1071.3.1.3 Acidity or Alkalinity Level (pH). The pH of the undiluted agent shall be determined by appropriate methods. 1071.3.1.4 Asphalt Miscibility. When tested in accordance with MoDOT Test Method TM 63, the asphalt release agent shall show no evidence of dissolving the asphalt binder. 1071.3.2 Dilution. Dilution by diesel or other petroleum products will not be permitted. 1071.3.3 Documentation. The manufacturer shall submit a certification and guarantee to Construction and Materials prior to initial approval showing the brand name and designation, the composition or description of the release agent, and the manner in which the material will be identified on the containers. The manufacturer shall certify that the material is in accordance with this specification and shall list typical values of current tests for the properties listed in Sec 1071.3.1. The certified test report shall show the manufacturer's name, brand name of material, lot and date tested. The manufacturer shall also submit a one-quart sample accompanied by an MSDS for the material. In addition, the manufacturer shall furnish information for any dilution requirements, including the minimum dilution rate and special application requirements. 1071.3.4 Packaging and Marking. The containers in which release agents are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Special applicators and dilution rates shall be designated on the container. Bulk shipments shall be accompanied by a delivery ticket showing this information. 1071.4 Bituminous Mixture Fiber Additives. Fibers for stone matrix asphalt mixture may be either cellulose or mineral fiber, and shall be in accordance with AASHTO M 325 for mineral fibers when tested in accordance with MoDOT Test Method TM 60. 1071.4.1 Documentation. The manufacturer shall submit a certification and guarantee to Construction and Materials prior to initial approval, showing the brand name and designation, the composition or description of the fibers, and the manner in which the material will be identified on the containers. The manufacturer shall certify that the material is in accordance with this specification and shall list typical values of current tests for the properties listed in AASHTO MP8. The certified test report shall show the manufacturer's name, brand name of material, lot and date tested. The manufacturer shall submit at least a 5-pound sample accompanied by an MSDS for the material. 1071.4.2 Packaging and Marking. The containers in which fibers are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Bulk shipments shall be accompanied by a delivery ticket showing this information. 7191071.5 Liquid Anti-Strip Additives. Liquid anti-strip additives shall not be detrimental to the bituminous mixture. 1071.5.1 Physical Properties. Amine-type liquid anti-strip additives that are physically mixed with the asphalt binder will be classified as Type I. Latex-type liquid anti-strip additives that are applied to the aggregate will be classified as Type II. The following physical properties shall be determined for each type. 1071.5.1.1 Type I Liquid Anti-Strip Additives. Test Test Method Specific Gravity @ 77 F AASHTO T 228 Brookfield Viscosity 77 F using an RVT viscometer. The report shall include the corresponding test temperature, speed, spindle and model of instrument.ASTM D2196 Pensky-Martens Closed Cup Flash Point or Cleveland Open Cup Flash PointASTM D93 AASHTO T 48 Infrared Spectrum (neat material) Appropriate Method 1071.5.1.2 Type II Liquid Anti-Strip Additives. Test Test Method Weight Per Gallon @ 77 F ASTM D1475 Brookfield Viscosity 77 F using an RVT viscometer. The report shall include the corresponding test temperature, speed, spindle and model of instrument.ASTM D2196 pH Appropriate Method Percent Solids ASTM D1644 Method A Infrared Spectrum (latex portion) Appropriate Method 1071.5.2 Heat Stability. The additive shall be stable and shall not separate under all manufacturer listed storage and use temperatures. When Type I or Type II additives are blended with the proposed bituminous material to be used at the anticipated application rate, the blended material shall still meet all bituminous material specifications and shall be heat stable. Heat stability shall be established by comparing AASHTO T 283 specimens made by preparing three conditioned specimens using aged, blended material that has been held at 325 F for 96 hours and three conditioned specimens using fresh blended material. The average tensile strength of conditioned specimens using aged material shall be compared with conditioned specimens made with fresh blended material. If the average conditioned strength of the mixture with aged material is less than 90 percent of the mixture with fresh blended material, the anti-strip additive will not be permitted for use. This requirement will also apply if tested on any specific mix design using the approved anti-strip additive. 1071.5.3 Unconditioned Strength. The anti-strip additive shall not significantly lower the unconditioned strength of AASHTO T 283 specimens. This shall be determined by preparing an additional six unconditioned specimens, three with and three without the liquid anti-strip additive. The average tensile strengths of unconditioned specimens shall be compared with specimens with and without the liquid anti-strip additive. If the average unconditioned strength of the mixture with the additive is less than 90 percent of the mixture without the additive, the anti-strip additive will not be permitted for use in that bituminous mixture. 1071.5.4 Documentation. The manufacturer shall submit a certification and guarantee to Construction and Materials prior to initial approval showing the brand name and designation, the composition or description of the anti-strip liquid, and the manner in which the material will be identified on the containers. The manufacturer shall certify that the material is in accordance with this specification and shall list typical values of current tests for the properties listed in Sec 1071.5.1. A copy of the bituminous mix design used to test for heat stability and unconditioned strength shall be included with the test results. The certified test report shall show the manufacturer's name, brand name of material, lot and date tested. The manufacturer shall submit at least a one- gallon sample accompanied by an MSDS for the material. 7201071.5.5 Packaging and Marking. The containers in which anti-strip liquids are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Bulk shipments shall be accompanied by a delivery ticket showing this information. 721SECTION 1073 JOINT MATERIAL FOR STRUCTURES 1073.1 Scope. This specification covers material for performed compression seals and strip seals with lubricant- adhesive for sealing joints, and expanded or extruded polystyrene material for use as bedding material under prestressed panels and in the corrugation areas of stay-in-place forms used on bridge decks. 1073.2 Acceptance. All material under this specification shall be obtained from a source identified on the PAL designated for this specification. All material will be inspected and accepted in accordance with Sec 106. 1073.3 Preformed Compression Seal. Preformed compression seals shall be in accordance with ASTM D 3542 and with the following additional requirements. 1073.3.1 The movement range of the seal as defined in ASTM D 3542 shall be as shown in the contract documents, and the height of seal shall be no less than the nominal width. The seal shall be delivered in containers marked with the manufacturer’s name, size of the seal, lot number and date of manufacture. 1073.3.2 The lubricant adhesive applied for installation shall be in accordance with the seal manufacturer and in accordance with Sec 717. The lubricant adhesive shall be delivered in containers marked with the manufacturer's name, lot number, date of manufacture and instructions for storage and use. 1073.4 Strip Seal. Strip seals shall be in accordance with ASTM D 5973 and the following additional requirements. 1073.4.1 The gland lugs of the seal that fasten into the steel extrusion shall be of a type that exerts pressure to the contact surfaces. Glands with snap or arrowhead-type lugs will not be permitted. The seal shall be delivered in containers marked with the manufacturer’s name, size of the seal, lot number and date of manufacture. 1073.4.2 The lubricant adhesive applied for bonding the gland to the steel extrusion shall be as recommended by the seal manufacturer and in accordance with Sec 717. The lubricant-adhesive shall be delivered in containers marked with the manufacturer's name, lot number, date of manufacture and instructions for storage and use. 1073.5 Expanded or Extruded Polystyrene Material. 1073.5.1 Bedding Material for Prestressed Panels. The expanded or extruded polystyrene material shall be in accordance with the following: Property Test Requirement Compression StrengthASTM D 162160 psi, min. Water Absorption ASTM D 28422% by volume, max. Oxygen Index ASTM D 286324 minimum 1073.5.2 Material for Corrugation Areas of Stay-In-Place Forms. Expanded polystyrene material shall be in accordance with the following: Property Test Requirement Compression StrengthASTM D 162110 psi, min. Water Absorption ASTM D 28422% by volume, max. 1073.5.3 Adhesive for Expanded or Extruded Polystyrene Materials. Adhesive for use with expanded or extruded polystyrene material shall be in accordance with the polystyrene manufacturer’s recommendations. 1073.6 Open Cell Foam Joint System. All components of the system shall be supplied by one manufacturer. The joint system shall be comprised of the following components.
a.Cellular polyurethane foam impregnated with 100% hydrophobic polymer, water based emulsion and factory coated, on the roadway surface, with highway-grade, fuel resistant silicone. 722(b) Field-applied epoxy adhesive primer.
c.Field-applied silicone sealant bands that seal the gap between the edge of the bridge and the silicone topping on the joint. This silicone will also be used for locking field splices in the joint together. 1073.6.1 General Movement Requirements. The seal shall have a working range of 50% in tension and 50% in compression. Changes in plane and direction shall be executed using factory fabricated watertight transition assemblies conforming to the plans and specifications. 1073.6.2 Seal Properties. The seal shall be able to meet the following properties: Property Requirement Temperature Service Range, ASTM C 711-40° F to 185° F Bleeding None at 180° F @ 50% compression for 3 hrs. UV Resistance, ASTM G 155 No Changes at 2000 hrs. Polymer impregnation agent Free of any waxes or asphalts 1073.6.3 Adhesive Properties. The epoxy adhesive shall be a 100% solids, two component moisture sensitive modified epoxy adhesive which meets ASTM C 881. 1073.6.4 Sealant Properties. The silicone sealant shall be a one part, cold applied chemically curing silicone joint sealant which meets ASTM D 5893. 1073.7 Preformed Silicone or EPDM Joints. All components, materials and equipment required for the installation shall be obtained through an approved supplier of the system. All components of each respective joint system shall come from the same manufacturer and cannot be substitutes for others. 1073.7.1 Joint Properties. The joint material shall meet or exceed the following physical requirements: Property SpecificationRequirement Durometer (Shore A) ASTM D 224055 ±5 min. Tensile Strength ASTM D 412550 psi min. Elongation ASTM D 412350% min. Tear Strength (Die B) ASTM D 624100 ppi min. Compression Set At 350° F 22 hrs.ASTM D 39530% max. Operating Temperature Range -60° F to 350° F Specific Gravity 1.51 ±0.10 1073.7.1.1 The joint seal shall be pre-qualified by undergoing and passing a cyclic loading test. Any rips, tears or bond failure will be cause for rejection. Manufacturer shall provide documentation to verify testing meeting these minimum requirements. Cyclic Loading Test Property Requirement Test Sample Length 2 feet min. Joint Skew 45° Number of Cycles 200 min. Joint Opening 2 inches Movement min. to max. opening Temperature -20° F 1073.7.2 Epoxy Primer. Epoxy primer shall be used to ensure the appropriate bond of the joint sealing system and to protect the surfaces of the joint after installation of the seal. The epoxy primer shall meet the following physical requirements: 723Epoxy Primer Property SpecificationRequirement Viscosity (centipoises)ASTM D 2196 44 Solids ASTM D 4209 41 Specific Gravity ASTM D 1217 0.92 Flashpoint ASTM D 56 48 VOC ASTM D 3960 520 1073.7.3 Locking Adhesive. The adhesive material shall cure quickly and shall be as recommended by the manufacturer. The material shall adhere to concrete, elastomeric concrete, polymer concrete and steel and shall meet the following physical requirements: Locking Adhesive Property Specification Requirement Sag/Flow ASTM C 639 3/16 inch max. Hardness ASTM C 661 20-30 Tack Free Time ASTM C 679 30 minute max. Cure Through to ¼ inch ThicknessAt 75° F/50% Relative Humidity24 hours max. Skin Over Time (Tooling Time)At 75° F/50% Relative Humidity5 minute max. Resistance to U.V. ASTM C 793No cracking, Ozone Chalking or Degradation Flashpoint ASTM D 412 200 psi min. VOC ASTM D 412 450% min. 1073.8 Documentation. Prior to approval and use of this material, the manufacturer shall submit to Construction and Materials a certified test report showing specific test results in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested and date of manufacture. In addition, the manufacturer shall submit a sample of the seal or polystyrene material and a one-pint sample of the adhesive for laboratory testing, accompanied by a technical data sheet and an MSDS. With approval by the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on the appropriate pre-acceptance list. Pre-acceptance lists are available through Construction and Materials or MoDOT’s web site. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed, and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified. 724SECTION 1075 CENTRIFUGALLY-CAST FIBERGLASS-REINFORCED POLYMER MORTAR PIPE 1075.1 Scope. This specification covers centrifugally-cast fiberglass-reinforced polymer mortar pipe to be used in pipejacking and microtunneling for horizontal boring applications under roadways. 1075.2 Acceptance. Acceptance of the material will be based on the manufacturer’s certification and upon the results of any tests required by the engineer. 1075.3 Manufacture. 1075.3.1 Pipe shall be manufactured from polyester resin systems with a proven history of acceptable performance for the particular application. The historical data shall have been acquired from a composite material of similar construction and composition as the proposed product. 1075.3.2 Pipe shall be manufactured from reinforcing glass fibers of commercial grade E-glass filaments with binder and sizing compatible with impregnating resins. 1075.3.3 Pipe shall be manufactured from silica sand, with a minimum of 98 percent silica, and a maximum moisture content of 0.2 percent. 1075.3.4 When used, resin additives, such as curing agents, pigments, dyes fillers, thixotropic agents, etc., shall not detrimentally affect the performance of the product. 1075.4 Documentation. The manufacturer shall provide certification to the contractor that the material provided is in accordance with ASTM D 3262 and that pipe joints meet the performance requirements of ASTM D 4161. The certification shall state the manufacturer’s name and shall have attached typical results of tests on the material and pipe joints. 1075.5 Construction Inspection. Pipe will be inspected for defects prior to installation. Damaged pipe will be rejected. Any pipe that appears cracked near the joint will be rejected. 725SECTION 1080 STRUCTURAL STEEL FABRICATION 1080.1 Scope. This specification covers the fabrication and inspection of bridges and structures made of structural steel and miscellaneous metals. 1080.2 Material. Except as amended by Sec 1080.2.4, all material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item Section/Specification Shear Connectors 1037 Paint for Structural Steel 1045 Coating of Structural Steel 1081 Structural Carbon SteelAASHTO M 270, Grade 36 ASTM A709, Grade 36 Structural Low Alloy SteelAASHTO M 270, Grade 50 ASTM A709, Grade 50 AASHTO M 270, Grade 50W ASTM A709, Grade 50W Quenched and Tempered Alloy SteelAASHTO M 270, Grade HPS 50W ASTM A709, Grade HPS 50W AASHTO M 270, Grade HPS 70W ASTM A709, Grade HPS 70W ASTM A709, Grade 100/100W Carbon Steel Bolts and Nuts ASTM A307 High Strength Bolts, Nuts and WashersASTM F3125 Grade A 325 Type 1 ASTM F3125 Grade A325 Type 3 ASTM F3125 Grade A490 Type 1 (Plain only) ASTM F3125 Grade A490 Type 3 ASTM F436 ASTM A563 AASHTO M 292 Cold Finished Carbon Steel ShaftingAASHTO M 169 Carbon Steel Forgings AASHTO M 102 Class F Alloy Steel Forgings AASHTO M 102 Class G Gray Iron Castings AASHTO M 105 Class 50 Malleable Iron Castings ASTM A47 Carbon Steel Castings AASHTO M 103 Grade 485-275 Galvanized CoatingsAASHTO M 111 AASHTO M 232 Class C ASTM B695 Class 55 Lead for Bearing Pads ASTM B29 Identification of Metals ASTM A6 1080.2.1 Galvanized Bolts. Bolts, nuts and washers specified to be galvanized shall be galvanized in accordance with the requirements of AASHTO M 232 (ASTM A153), Class C or shall be mechanically galvanized in accordance with ASTM B695, Class 55. Except for anchor bolts, galvanizing thickness shall not exceed 6 mils. Fasteners installed prior to the completion of shop blast cleaning will not require galvanizing. The thickness of the zinc coating for galvanized bolts shall be measured on the wrench flats and top of the bolt head. For mechanically galvanized bolts, the significant surfaces as referenced in ASTM B695 shall be the entire bolt surface, excluding the underside of the surface of the head and the shank surface between the threaded portion and the underside of the head. The thickness of the zinc coating on the galvanized nuts shall be measured on the wrench flats. For mechanically galvanized nuts, the significant surfaces shall be all surfaces of the nut excluding the threads. The thickness of the zinc coating on galvanized washers shall be measured on both sides. The significant surfaces on mechanically galvanized washers shall be all surfaces of the washer. 7261080.2.2 Fit Up Bolts. Fit up and shipping bolts shall be coated to prevent corrosion where a finish coat will not be applied. Shipping bolts for uncoated weathering steel will not require coating. 1080.2.3 Falsework. Falsework material will be subject to the engineer's approval. All falsework material shall be in good condition such that the material performs as designed. Falsework piling shall be capable of withstanding driving to a depth sufficient to develop adequate bearing. 1080.2.4 Certified Mill Test Reports. For structural steel, the contractor shall submit a copy of the certified mill test report giving the chemical analysis and results of physical tests on the material furnished. The mill test report shall state the location of the mill where the molten metal was produced. Two copies of the mill test report will be required for material used in railroad structures. If steel is produced outside the United States, the contractor shall submit a certified test report from a MoDOT approved U. S. laboratory showing specific results of chemical analysis and physical tests for each heat furnished and stating that the material meets the specification requirements. Mill tests and laboratory reports shall be submitted for approval before any request is made for shop or field inspection. In addition, the engineer may take samples for chemical analysis and physical tests from the fabricated steel delivered to the project site. Any time or cost effects caused by obtaining and analyzing samples from delivered steel shall be anticipated by the contractor as part of the quality assurance process and no compensation or additional time will be allowed for costs or delays associated with this activity. Unless otherwise specified, the supplementary requirements of AASHTO M 270 for Charpy V-notch impact tests in temperature zone 2 shall be mandatory where the contract documents indicate notch toughness is required for fracture critical or non-fracture critical components. Mill test reports shall include the results of Charpy V-notch testing and impact serial numbers for fracture critical components. 1080.2.5 High Strength Fastener Assemblies. In addition to the requirements of Sec 712.2, high strength bolts, nuts and washers shall meet the following requirements. The contractor shall furnish a manufacturer's certification showing results of tests performed. Identification in accordance with the appropriate AASHTO/ASTM specifications shall be maintained by container markings which shall match identifying numbers on the certifications and be traceable to the certified mill test reports. High strength fastener assemblies shall be galvanized unless specifically indicated otherwise by the contract documents. When high strength bolts are used with weathering steel, the fasteners shall be Type 3, including fasteners located in areas of the structure to be partially coated, expansion device supports, slab drain brackets and similar items. High strength fasteners in partially coated areas of weathering steel and slab drain baskets attached to weathering steel shall be coated in accordance with Sec 1080.4.5.1. ASTM F3125 Grade A490 bolts shall be installed plain (also referred to as uncoated or black), tensioned and then cleaned and coated with the coating system as specified on the plans. The cleaning and the zinc coating shall not be applied by any process, which can cause hydrogen embrittlement. All certification testing requirements and mill test reports referenced in the following sections shall be in accordance with Sec 106. 1080.2.5.1 Bolts. All bolts shall be in accordance with ASTM F3125 Grade A325 except when ASTM F3125 Grade A490 bolts are specified on the plans. If the contractor elects to use load indicator bolts, only a hex head will be permitted. The type of head used shall be consistent throughout the entire structure, unless otherwise approved by the engineer. 1080.2.5.1.1 Proof Load Tests. Proof load tests in accordance with ASTM F606 Method 1 shall be performed. Minimum test frequency shall be in accordance with ASTM F3125 Grade A325. 1080.2.5.1.2 Wedge Tests. Wedge tests on full size bolts, in accordance with ASTM F606, paragraph 3.5 shall be performed. If bolts are to be galvanized, tests shall be performed after galvanizing. Minimum test frequency shall be in accordance with ASTM F3125 Grade A325. Weathering steel nuts shall be grade C3 or DH3. 1080.2.5.2 Nuts. All nuts shall be in accordance with AASHTO M 292 as applicable or ASTM A563, except as follows. 1080.2.5.2.1 Nut Grades. 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. Nuts that are to be galvanized shall be heat treated grade 2H, DH or DH3. Weathering steel nuts shall be grade C3 or DH3. 1080.2.5.2.2 Overtapping. Nuts to be galvanized shall be tapped oversize the minimum amount required for proper 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 be in accordance with the mechanical requirements and the rotational-capacity 727test requirements of ASTM A563. The overtapping requirements of ASTM A563 will apply, except these limits shall be considered maximum values instead of the minimum, as currently shown. 1080.2.5.2.3 Nut Lubrication. All galvanized nuts, including ASTM A194 nuts, shall meet the supplementary requirements of ASTM A563. Galvanized nuts shall be lubricated with a lubricant containing a dye of any color that contrasts with the color of the galvanizing. 1080.2.5.2.4 Proof Load Tests. Proof load tests in accordance with ASTM F606 shall be performed. Minimum test frequency shall be in accordance with ASTM A563 or AASHTO M 292. If nuts are to be galvanized, tests shall be performed after lubricating. 1080.2.5.3 Washers. All washers shall be in accordance with ASTM F436. Hardness testing shall be performed on galvanized washers. The coating shall be removed prior to taking hardness measurements. Washers for weathering steel shall be Type 3. 1080.2.5.4 Rotational-Capacity Tests. Rotational-capacity tests shall be performed on all bolt, nut and washer assemblies by the manufacturer or distributor prior to shipping. Washers shall be part of the test, regardless if they are required as part of the installation procedure or not. Tests shall be conducted after galvanizing when galvanizing is required. 1080.2.5.4.1 Test Methods. Except as modified herein, the rotational-capacity test shall be performed in accordance with ASTM F3125 Grade A325. 1080.2.5.4.2 Test Lots. Each combination of bolt production lot, nut lot and washer lot shall be tested as an assembly. Where washers are not required as part of the installation procedures, washers need not be included in the lot identification. A rotational-capacity lot number shall be assigned to each combination of lots tested. The minimum frequency of testing shall be two assemblies per rotational-capacity lot. 1080.2.5.4.3 Testing Device. The bolt, nut and washer assembly shall be assembled in a Skidmore-Wilhelm Calibrator or an acceptable equivalent device. 1080.2.5.4.4 Minimum Rotation. The minimum rotation, from a snug tight condition, 10 percent of the specified proof load, shall be as follows: Minimum Bolt Rotation Bolt LengthRotation ASTM F3125 Grade A325ASTM F3125 Grade A490 ≤ 4 Diameters 240° (2/3 turn)240° (2/3 turn) > 4 Diameters and ≤ 8 Diameters360° (1 turn) 300° (5/6 turn) > 8 Diameters 420° (1 1/6 turn)360° (1 turn) 1080.2.5.4.5 Required Tension. The tension reached at the above rotation shall be equal to or greater than 1.15 times the required installation tension. The installation tension and the tension for the turn test for ASTM F3125 Grade A325 and ASTM F3125 Grade A490 bolts shall be as follows: Required Bolt Tensions Diameter, in.1/25/83/47/81.001-1/81-1/41-3/81-1/2 ASTM F3125 Grade A325 Req. Installation Tension, kips121928395164 81 97118 Turn Test Tension, kips142232455974 94112136 ASTM F3125 Grade A490 728Req. Installation Tension, kips152435496480102121148 Turn Test Tension, kips172840567492117139170 1080.2.5.4.6 Torque. After the required installation tension has been exceeded, one reading of tension and torque shall be taken and recorded. The torque value shall be as follows: Torque ≤ 0.25 PD Where: Torque = measured torque, foot-pounds P = measured bolt tension, pounds D = bolt diameter, feet 1080.2.5.4.7 Short Bolts. Bolts that are too short to test in a Skidmore-Wilhelm Calibrator may be tested in a steel joint. The maximum torque requirement shall be computed using a value of P equal to the turn test tension shown in Sec 1080.2.5.4.5. 1080.2.5.5 Reporting. The results of all tests, including zinc coating thickness, required herein and in the applicable AASHTO/ASTM specifications and the location and date of the tests performance, shall be recorded on the appropriate document. The tests need not be witnessed by an inspection agency. The manufacturer or distributor performing the tests shall certify the results are accurate. 1080.2.5.6 Documentation for High Strength Fastener Assemblies. 1080.2.5.6.1 Mill Test Reports. A Mill Test Report (MTR) shall be furnished for all mill steel used in the manufacture of the bolts, nuts or washers. The MTR shall indicate the location where the material was melted and manufactured. 1080.2.5.6.2 Manufacturer Certified Test Reports. The manufacturer of the bolts, nuts and washers shall furnish a Manufacturer Certified Test Report (MCTR) for each item furnished including the following information:
a.The lot number of each of the items tested.
b.The rotational-capacity lot number as required in Sec 1080.2.5.4.2.
c.The results of the tests required in Sec 1080.2.5.5.
d.The pertinent information required in Sec 1080.2.5.4.2.
e.A statement that MCTR for the items are in conformance to this specification and the applicable AASHTO/ASTM specifications. The location where the bolt assembly components were manufactured. Rotational capacity testing if completed by the manufacturer. 1080.2.5.6.3 Distributor Certified Test Reports. The Distributor Certified Test Report (DCTR) shall include MCTR for the various bolt assembly components. The rotational-capacity test may be performed by a distributor in lieu of a manufacturer and shall be reported on the DCTR. The DCTR shall indicate the following if not included in the MCTR:
a.The results of the tests required in Sec 1080.2.5.5. 729(b) The pertinent information required in Sec 1080.2.5.4.2.
c.The rotational-capacity lot number as required in Sec 1080.2.5.4.3.
d.A statement that the MCTR are in accordance with this specification and the applicable AASHTO/ASTM specifications.
e.Certification of galvanizing from the galvanizing supplier shall be in accordance with Sec 1080.2.1. 1080.2.5.7 Shipping of High Strength Fastener Assemblies. Bolts, nuts and washers, where required, from each rotational-capacity lot shall be shipped in the same container in proportionate quantities for use. 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 shipping container shall be permanently marked by the manufacturer or distributor with the rotational-capacity lot number such that identification will be possible at any stage prior to installation. The appropriate MTR, MCTR or DCTR shall be supplied in accordance with the contract documents. 1080.2.6 Machine Bolts. Machine bolted field connections shall be made with machine bolts having American Standard Regular Heads and Nuts of hexagonal shape and shall be in accordance with ANSI B 18.2.1 and B 18.2.2. Threads shall extend slightly beyond the nut to permit burring. One plain washer in accordance with ANSI B 18.22.1 shall be used at all slotted holes. 1080.2.7 Cast Steel. For cast steel, the foundry shall furnish a certified copy of foundry reports giving the chemical analysis and results of physical tests on the material from each heat. These reports shall be submitted for approval of material being furnished before any required machine work is done on the castings. 1080.2.8 Cast Iron. For gray iron castings, the foundry shall furnish one finished tension test specimen in accordance with AASHTO M 105 from each heat. The required machine work shall not proceed until material being furnished has been approved. If cast steel is furnished in lieu of gray iron, the minimum tensile strength shall be 50,000 psi. 1080.2.9 Identification of Metals. The steel shall be stamped or stenciled and color striped with paint at the mill. Heat numbers shall be steel stamped or stenciled with paint at the mill. Separate markings and color codes shall be in accordance with ASTM A6. The characteristic color stripes shall be placed on each part cut from the mill piece. For steels not covered by ASTM A6, the fabricator shall furnish the engineer the color coding in writing before fabrication begins. Heat numbers shall be painted on all principal pieces and these pieces shall be so noted on the shop drawings. Principal pieces for this requirement shall include all beams, flanges, webs, splice plates, cover plates, bearings, bearing stiffener plates, load bearing members of end diaphragms, pin plates, hanger plates and others as may be directed by the engineer. Principal pieces shall include individual plates of all truss members, truss gusset plates, splice plates and floorbeam connection angles. The color code and heat number markings shall be placed on the material such that the markings are visible throughout the work of fabrication. Loss of identification on pieces or items will be cause for rejection of the pieces or items. 1080.2.9.1 Fracture Critical Members. Principal pieces requiring identification shall also include components of fracture critical members. Traceability of both heat numbers and impact serial numbers shall be maintained for fracture critical members and attachments. 1080.2.9.2 Direction of Rolling. Unless otherwise indicated in the contract documents, steel plates for main members and splice plates for flanges and main tension members shall be cut and fabricated such that the primary direction of rolling is parallel to the direction of the principal tensile or compressive stresses. The direction of rolling shall be maintained for all principal pieces during fabrication. 1080.2.10 Steel Stamping. Any metal die stamping of match marks and erection marks in structural steel members shall be limited to a position in the end 1 1/2 inches of flange plates and flange splice plates, the middle third of web plates and the outside edge of the middle third of web splice plates. Metal die stamping at other locations or for other purposes may be approved by the engineer provided low stress dies are used. Low stress dies will be defined as those manufactured to produce impressions that are rounded at the bottom rather than sharp edged. Metal die stamping on pin plates and hanger plates will not be permitted. 1080.3 Fabrication and Inspection. 7301080.3.1 Quality Assurance Inspection. The engineer will be responsible for QA inspection to assure the quality of the fabricated material. QA inspection by the engineer will not relieve the contractor of the responsibility to provide fabricated structural steel items in accordance with the contract documents. Sufficient QC, as necessary to assure work being performed conforms to the contract documents, shall be the responsibility of the contractor and fabricator. Following adequate notification that QC inspections and testing by the fabricator have been performed, QA inspection will be at the option of the engineer. Regardless of the location and degree of QA inspection, material and workmanship not meeting specified performance criteria or conforming to the contract documents or recognized good practice may be rejected at any time prior to final acceptance of the work. 1080.3.1.1 Locations of Inspection. QA inspection of fabricated material will ordinarily be made in the shop for fabricating shops within the 48 contiguous States and for shops outside the U. S., but within 1,000 miles of Jefferson City, MO. High strength bolts, nuts and washers shall be presented for sampling at the fabrication shop performing the primary fabrication or at a location agreed to by Construction and Materials. In some cases, QA inspection in the fabrication shop may be waived and inspection made when the fabricated material is delivered to the project site. All costs of QA inspection at fabricating shops located both outside the 48 contiguous States and more than 1,000 miles from Jefferson City, shall be at the contractor’s expense. In such cases, the contractor will be charged with transportation costs and expenses of QA inspectors for trips made from Jefferson City to locations to which the inspectors must travel for shop inspection work. These transportation costs and expenses of QA inspectors will be deducted by the Commission from monies due the contractor. 1080.3.1.2 Notification of Inspection. The Bridge Division shall be electronically notified at least four working days prior to the beginning of the shop fabrication so a QA inspector may be present if so desired and to allow the QA inspector to make travel arrangements. If the fabricator notifies and requests inspection and the QA inspector arrives at the location of inspection to find the material is not ready for inspection as indicated in the request, any travel costs incurred by MoDOT for additional inspection shall be paid by the contractor. 1080.3.1.3 Access for Inspection. The engineer shall have full access to all parts of the shop or project site where material is being fabricated or assembled and shall be provided with every reasonable facility for determining the character of material and workmanship. 1080.3.1.4 Field Inspection. No increased time or compensation will be allowed for additional work, delays or additional costs as a result of QA inspection at the project site, including required repairs, including where samples were removed, refabrication, securing samples for chemical analysis and physical tests. 1080.3.1.5 Office Space. A suitable office area shall be provided for exclusive use by the engineer. The office may be enclosed or semi-enclosed as available at the location of QA inspection, but shall be suitable for use as determined by the engineer. The floor space shall be at least 120 square feet unless otherwise approved by the engineer, weatherproof, secure, insulated and lighted. The office space shall be adequately ventilated, heated and air conditioned. Electric outlets with 110-120 volt, 60 Hz current and a telephone with outside line, inter-plant and dial-up computer capabilities shall be provided. Office furniture consisting of a desk, a minimum of 30 x 60 inches with drawers, a swivel desk chair with arms and a storage/filing cabinet with lock hardware and key shall be provided. All office furniture will be subject to approval by the engineer. Should any furniture become unsatisfactory, the furniture shall be promptly repaired or replaced to the satisfaction of the engineer. Accessible parking shall be provided near the office any time the shop is in operation on MoDOT projects. No direct payment will be made for furnishing and maintaining an acceptable office area for QA inspection. 1080.3.1.6 Certifications. All structural steel fabricators performing work for the following listed components of steel structures shall be certified prior to the start of fabrication under the appropriate category of the AISC Certification Program for Steel Bridge Fabricators or the AISC Certification Program for Bridge and Highway Metal Component Manufacturers as follows:
a.Fabricators of unspliced rolled beams and temporary bridges shall be certified to the Simple Bridge (SBr) requirements.
b.Fabricators of straight or curved (radius over 500 feet) rolled beams with field or shop splices, built-up welded constant depth straight or curved (radius over 500 feet) I-shape plate girders, built-up welded variable depth straight or curved (radius over 1000 feet) I-shaped plate girders, and trusses with a total length less than 200 feet or substantially pre-assembled and shipped in no more than three sub- assemblies shall be certified to the Intermediate Bridge (IBr) requirements. 731(c) Fabricators of bridges beyond the listed structures of 1080.3.1.6(a) or 1080.3.1.6(b) shall be certified to the Advanced Bridge (ABr) requirements.
d.Fabricators of fracture-critical members indicated in the contract plans shall also meet the requirements for fracture-critical certification in addition to the other bridge certifications.
e.Fabricators of overhead sign trusses, steel bearings, POT bearings, finger plate expansion devices, and flat plate expansion devices shall be certified to the Bridge and Highway Metal Component Manufacturers requirements unless the fabricator is certified to one of the Steel Bridge Fabricator levels (SBr, IBr, or ABr).
f.AISC certification will not be required for manufacturers of simple laminated or elastomeric bearing pad assemblies or PTFE bearing pad assemblies.
g.Fabricators that apply steel painted coatings in the fabrication shop shall be certified to the AISC Applicators of Complex Coatings Endorsement (SPE), SSPC QP3 – Shop Painting Certification Program, or NIICAP AS-1 Shop Accreditation. 1080.3.2 Shop Drawings. Shop drawings for structural steel and miscellaneous metals shall be required and shall be prepared in strict accordance with the design details shown on the plans. If details are lacking, the details shall be supplied and shall conform to the design plans and specifications. All drawings shall be clear and complete and shall be thoroughly checked before submittal. Shop drawings shall be completely titled in accordance with the contract plans and shall pertain to only a single structure. One set of the shop drawings for railroad structures and other structures shall be submitted electronically to the Bridge Division for approval. The prints submitted shall be legible and shall have distinct details of sufficient contrast. Prints that do not have the desired clarity and contrast will be returned for corrective action. One set of prints will be returned marked reviewed or approved subject to noted corrections. The contractor shall promptly make necessary corrections and resubmit for final approval. When shop drawings are approved, the contractor shall furnish as many additional prints as requested. Reproductions on cloth or film of the original shop drawings shall be required for railroad structures and shall be delivered to the engineer prior to completion of the work. The approval of shop drawings will cover only the general design features and in no case shall this approval be considered to cover errors or omissions in shop details. The contractor shall be responsible for the accuracy of the shop drawings, the fabrication of material and the fit of all connections. All changes in the fabrication and erection work caused by errors in shop drawings and any changes in fabrication necessary for satisfactory results shall be at the contractor’s expense. After shop drawings have been approved, no changes in dimensions or substitutions of sections shall be made without written approval from the engineer. Shop drawings shall be revised to show any authorized changes and the required number of prints shall be furnished to the engineer. 1080.3.2.1 Non-Domestic Shop Drawings. Shop drawings from fabricators located outside the 48 contiguous States, whether marked approved or approved subject to the corrections noted, will be returned to the contractor and the contractor shall be responsible for transmitting the drawings to the fabricator for further handling. Should such fabricator also be the contractor, all prints will be returned to the office located on the project. 1080.3.2.2 Weld Procedures. All welding procedures to be used shall be prepared by the manufacturer, contractor or fabricator as a written procedure specification. For new welding procedures, one copy shall be electronically submitted for approval prior to submitting shop drawings. Approved weld procedures will be kept on file by Bridge and may be considered for use on multiple projects. Any changes to the parameters of an approved welding procedure shall require submittal for approval. The shop drawings submitted for approval shall indicate the welding procedure to be used for each joint. 1080.3.2.3 Verification of Work. By submission of shop drawings, the contractor represents to the Commission that all material, field measurements, construction requirements, performance criteria and similar data have been verified. The contractor further represents that the shop drawings have been coordinated and verified with the details of the work to be performed by other fabricators and entities on the project. No allowance for additional costs or delays will be made to the contractor for incorrect fabrication as a result of failure to coordinate or perform these verifications. 1080.3.3 Fabrication. Fabrication of all parts of the structure shall be carefully done in strict accordance with the approved shop drawings. 7321080.3.3.1 Straightening. Straightening of any deformed structural material shall be performed by non- injurious methods prior to being worked in the shop. Sharp kinks and bends will be cause for rejection. 1080.3.3.2 Holes. Holes for connections of main members shall be subpunched or subdrilled and reamed while assembled in the shop or may be drilled from the solid with main members and each splice plate fully assembled in their final erected positions. Holes for floor beams and framed stringer connections shall be drilled or reamed to a steel template of sufficient thickness to center the drill accurately and all members to be secured through the same group of holes shall be drilled or reamed from the same template. Holes may be punched full size in secondary members such as lateral, longitudinal and sway bracing, lacing bars, stay plates and diaphragms. Stacking of web splice plates during drilling or reaming operations on straight girders will be permitted. 1080.3.3.3 Reaming and Finishing of Holes. Reaming or drilling full size from the solid shall be done while the truss, girder, continuous I-beam or other component as noted, is assembled, either in an upright position or on its side, properly adjusted for camber and sweep and after the connecting parts have been firmly fastened together. A minimum of one full span, from bearing to bearing, shall be fully assembled before reaming or drilling full size begins. Connecting parts assembled in the shop for the purpose of reaming or drilling holes for field or shop connections shall not be interchanged or reversed and shall be matchmarked. A diagram showing such marks shall be detailed on the shop drawings. Burrs resulting from reaming, drilling or punching shall be removed. All connections shall be disassembled after drilling or reaming to make these holes accessible for deburring. Required cleaning and painting shall be done after disassembly. Reamed, drilled or punched holes shall be round and perpendicular to the member. Any hole out of round more than 1/16 inch will be cause for rejection of the plate. Eighty-five percent of the holes in any group shall not show an offset greater than 1/32 inch between adjacent thicknesses of metal after reaming or drilling. All holes shall be drilled or reamed and aligned such that a bolt of the specified diameter will enter the hole and the head and nut will seat on the metal before tensioning. 1080.3.3.4 Applicable Codes. All welding, oxygen cutting, shearing and clipping and dimensional tolerances shall be in accordance with the ANSI/AASHTO/AWS D1.5: 2002, Bridge Welding Code. Tubular steel structures shall be governed by the current edition of the AWS D1.1, Structural Welding Code - Steel, in effect at the time of the contract, unless specified otherwise. Aluminum structures shall be governed by the current edition of the AWS D1.2, Structural Welding Code - Aluminum, except as amended by Sec 903, unless otherwise indicated. 1080.3.3.5 Modifications to the Bridge Welding Code. The following modifications to the ANSI/AASHTO/AWS D1.5 2002, Bridge Welding Code (AWS), shall apply: 1080.3.3.5.1 AWS Sec 1.3 Paragraph 1.3.4 - Paragraph 1.3.4 shall be replaced with the following: The gas metal arc welding process shall not be used on any structural components of bridges. Approved gas metal arc processes may be used for incidental, non-structural components as may be specifically approved by the engineer. Tack welding with an approved gas metal arc process will be permitted for joints that will subsequently be welded using an approved submerged arc automatic welding process. 1080.3.3.5.2 AWS Sec 1.3 Paragraph 1.3.7 - A new Paragraph 1.3.7 shall be added as follows: All primary shop welds shall be made by approved submerged arc automatic welding processes. The automatic welding process shall be one in which the wire or electrode feed, speed of travel and guidance are all mechanically controlled. Noncompliance with this requirement will be cause for rejection of the welded material unless prior approval is granted by the engineer for welding the specified joints by the use of other processes. The automatic welding process requirement for primary shop welds shall be shown on the shop drawings for each joint. Primary shop welds will be defined as flange and web butt welded splices in I-beams, box members and plate girders, plate girder or box flange to web fillet welds and cover plate to flange fillet welds. 1080.3.3.5.3 AWS Sec 2.8 Paragraph 2.8.1.1 - Paragraph 2.8.1.1 shall be replaced with the following: The minimum fillet weld size, except for fillet welds used to reinforce groove welds, shall be as shown in the following table or as calculated using procedures established to prevent cracking in accordance with Paragraph 4.2.2. In both cases, the minimum size will apply if the size is sufficient to satisfy design requirements. 733Material Thickness of Thicker Part Joined, in.Minimum Size of Fillet Welda, in. To 3/4 1/4b Over 3/4 to 2 ½ 5/16b Over 2 ½ 1/2 aExcept that the weld size need not exceed the thickness of the thinner part joined. bSingle pass welds must be used. 1080.3.3.5.4. AWS Sec 3.2 Paragraph 3.2.2.2 (4) - A new Paragraph 3.2.2.2 (4) shall be added as follows: Quenched and tempered steel plate may be thermally cut provided sufficient preheating is applied according to the steel producer's written recommendations. Procedures for thermal cutting of quenched and tempered steel plate, along with the steel producer's written report, shall be submitted to the engineer for approval prior to the start of such work. 1080.3.3.5.5 AWS Sec 3.2 Paragraph 3.2.3.4 - Paragraph 3.2.3.4 shall be replaced with the following: The corrective procedures described in Table 3.1 shall not apply to discontinuities in rolled base-metal surfaces. Such discontinuities may be corrected by the fabricator in accordance with ASTM A6, except that repair by welding will be permitted only when approved by the engineer. Approval will be limited to areas where there will be less than the maximum design stress in the finished structure. When surface imperfections in alloy, low alloy and carbon steel plates are repaired by grinding, the surfaces shall have edges faired to the plate surface with a maximum slope of 1 in 10. 1080.3.3.5.6 AWS Sec 3.2 Paragraph 3.2.11 - A new paragraph 3.2.11 shall be added as follows: Edges of principal pieces as identified in Sec 1080.2.9 shall not be produced by mechanical shearing. For other than principal pieces, sheared edges of plates not to be welded that are more than 5/8 inch thick and carrying calculated stress shall be planed to a depth of 1/4 inch. 1080.3.3.5.7 AWS Sec 3.3.8 - Sec 3.3.8 shall be replaced with the following: Temporary welds shall be subject to the same WPS requirements as final welds. Temporary welds shall be removed unless otherwise permitted by the engineer and the surface shall be made flush with the original surface. Unless previously approved in writing by the engineer, there shall be no temporary welds for fabrication, transportation, erection or other purposes on main members except at locations more than 1/6 the depth of the web from the flanges of beams and girders. There shall be no temporary welds in tension zones of members of quenched and tempered steels. Temporary welds at other locations shall be shown on shop drawings and shall be made with approved consumables. Removal of temporary welds shall conform to Paragraphs 3.3.7.3 and 3.3.7.4. 1080.3.3.5.8 AWS Sec 3.4 Paragraph 3.4.6 - Paragraph 3.4.6 shall be replaced with the following: All shop splices in each component part of a cover-plated beam or built-up member shall be made and all required nondestructive testing completed and approved by the engineer before the component part is welded to other component parts of the member. Long members or member sections may be made by shop-splicing subsections, each made in accordance with this subsection (See 2.17.6). All shop splices shall be made using full penetration welds that fully develop the capacity of the original member. Additional shop splices required due to length limits of available material may be used if detailed on the shop drawings and placed at locations approved by the engineer. No additional payment will be made for any additional shop splices placed in the members at the option of the contractor, including shop splices that may be required as a result of material limitations. 1080.3.3.5.9 AWS Sec 3.5 Paragraph 3.5.1.8.1 - A new Paragraph 3.5.1.8.1 shall be added as follows: The maximum permissible variation from specified width for rolled or burned flange plates shall be -1/8 inch to +3/8 inch. 1080.3.3.5.10 AWS Sec 3.5 Paragraph 3.5.1.9 - Paragraph 3.5.1.9 shall be replaced with the following: 734The bearing ends of bearing stiffeners shall be flush and square with the web and shall have at least 75 percent of this area in contact with the inner surface of the flanges. The remaining 25 percent of the area of the bearing stiffener shall be within 0.010 inch of the inner surface of the flanges. When bearing against a steel base or seat, all steel components shall fit within 0.010 inch for 75 percent of the projected area of web and stiffeners and not more than 1/32 inch for the remaining 25 percent of the projected area. Girders without stiffeners shall bear on the projected area of the web on the outer flange surface within 0.010 inch. The included angle between web and flange shall not exceed 90 degrees in the bearing length. The top surface of a flange or shelf plate supporting a steel bearing rocker shall be considered a flat surface with a tolerance of 0.003 inch per inch in any direction over the projected area of the rocker. The top surface of a flange or shelf plate in direct contact with elastomeric bearings shall not deviate from a true plane surface by more than 1/16 inch. 1080.3.3.5.11 AWS Sec 3.5 Paragraph 3.5.1.16 - A new Paragraph 3.5.1.16 shall be added as follows: Permissible variation in length of assembled beams or girders between the centerline of bearing devices shall not exceed plus or minus 1/4 inch for any one span or plus or minus 1/2 inch for any two or more spans within the assembled unit. The actual centerline of any bearing device shall lie within the thickness of the bearing stiffener. 1080.3.3.5.12 AWS Sec 3.7 Paragraph 3.7.2.5 - A new Paragraph 3.7.2.5 shall be added as follows: If, after three repairs to the same area of a weld requiring radiographic or ultrasonic quality, there is any part of the original defect remaining or there is a new rejectable indication, the total joint shall be cut apart, all deposited weld metal removed, joint preparation made and the total joint rewelded. 1080.3.3.5.13 AWS Sec 3.7 Paragraph 3.7.2.6 - A new Paragraph 3.7.2.6 shall be added as follows: The gas metal arc welding process shall not be used for the repair of welds except when repairing welds made with the GMAW process. 1080.3.3.5.14 AWS Sec 5.21 Paragraph 5.21.6.2 - A new Paragraph 5.21.6.2 shall be added as follows: Any cost involved in qualifying welders, welding operators and tackers, including all material costs, finishing of test specimens, the physical testing of finished specimens and any radiography required shall be borne by the contractor. Required radiography and physical testing of finished specimens shall be performed at test facilities approved by the engineer. 1080.3.3.5.15 AWS Sec 6.1 Paragraph 6.1.6 - A new Paragraph 6.1.6 shall be added as follows: The contractor shall submit to Bridge Division (Fabrication@modot.mo.gov) the following documentation for each individual performing nondestructive testing (NDT); their certifications, current eye exam, and the NDT company written practice, including the Level III individual certification used for the written practice. 1080.3.3.5.16 AWS Sec 6.6 Paragraph 6.6.5 - Paragraph 6.6.5 shall be replaced with the following: If the engineer subsequently requests nondestructive testing, not specified in the original contract agreement, the contractor shall perform any requested testing or shall permit any requested testing to be performed. Handling, surface preparation, repair welds and any nondestructive testing requested by the engineer, as a result of weld repair, shall be at the contractor’s expense. Payment for any non-destructive testing that does not indicate the need for repair to the tested weld will be in accordance with Sec 109.4. 1080.3.3.5.17 AWS Sec 6.7 Paragraphs 6.7.1, 6.7.1.1 and 6.7.1.2 - Paragraphs 6.7.1, 6.7.1.1 and 6.7.1.2 shall be replaced with the following: Radiographic inspection (RT) shall be required for areas of both shop and field butt welds as specified herein with RT acceptance or rejection criteria based on 2002 AWS D1.5 Table 6.8, Tension Welds.
a.One hundred (100) percent inspection shall be required for flanges of rolled beams and girders 735(b) One hundred (100) percent of transverse butt welds in webs for a distance of no less than one-sixth of the web depth from each flange
c.Twenty-five (25) percent of the remainder of the web depth
d.At least one-third of the length of all longitudinal web splices shall be radiographed at even intervals throughout the length of the splice. When a rejectable defect is found by radiography in any partially tested joint, either initially or in a later additional radiograph, tests shall be conducted on either side of and adjacent to the rejectable test area. If a rejectable defect is found in any additional areas, then 100 percent of vertical web splices and an additional 10 percent of total weld length in longitudinal web splices shall be tested. The location of these additional test areas shall be as directed by the engineer. All complete joint penetration groove welds in T- and corner joints shall be 100 percent tested by ultrasonic testing (UT) with UT acceptance or rejection criteria based on 2002 AWS D1.5 Table 6.3, Tension Stress, except as follows: L shaped plate connection brackets on expansion devices with complete joint penetration welds at the corner, are not required to be ultrasonically tested. On fabricating expansion joints only (does not apply to finger, flat and modular expansion devices), 25 percent of each joint subject to compression or shear, or, at the contractor’s option, 25 percent of the total joints subject to compression or shear. When the latter is selected, the tested joints shall be distributed throughout the work and shall total at least 25 percent of the compression or shear weld length.
a.If unacceptable discontinuities are found in spot testing, the entire length shall be tested.
b.If unacceptable discontinuities are found in 20 percent or more of the compression or shear joints in that "lot'', all compression and shear joints in that "lot" shall be tested for their full length. A "lot'' is defined as those tension or compression/shear joints, or both, which were welded in accordance with the same approved WPS and non-destructively tested-as a group.
c.Ultrasonic testing acceptance or rejection criteria will be in accordance with 2002 AWS D1.5 Table 6.4 Compressive Stress.
d.Shop complete joint penetration splicing of flat bar, beam, or support angle under the expansion joint is only by approval and shown on the shop drawings, this type of splicing will require 25 percent ultrasonic testing as stated. 1080.3.3.5.18 AWS Sec 6.10 Paragraph 6.10.3.4 - A new Paragraph 6.10.3.4 shall be added as follows: Edge blocks shall be used when radiographing butt welds greater than 1/2 inch in thickness. The edge blocks shall have a length sufficient to extend beyond each side of the weld centerline for a minimum distance of 2 inches and shall have a thickness equal to the thickness of the weld, plus or minus 1/16 inch. The minimum width of the edge blocks shall be no less than 1 inch. The edge blocks shall be centered on the weld with a snug fit against the plate being radiographed, allowing no more than 1/16 inch gap. Edge blocks shall be made of radiographically clean steel and the surface shall have a finish of ANSI 125μin. or smoother (refer to ANSI/AWS D1.1-98 Structural Welding Code - Steel, Sec 6.17, Paragraph 6.17.13 and Figure 6.15). 1080.3.3.5.19 AWS Sec 6.10 Paragraph 6.10.11.2 - Paragraph 6.10.11.2 shall be replaced with the following: If the greatest and least thickness of a weld connecting parts of different thickness cannot be rendered with adequate contrast on a single film with a single exposure, a dual film or dual exposure technique shall be used to obtain suitable density for both the greatest and the least thickness of the weld. 1080.3.3.5.20 AWS Sec 6.12 Paragraph 6.12.4 - A new Paragraph 6.12.4 shall be added as follows: After completion of all radiographic inspection, the contractor shall submit to the engineer one set of drawing details showing the location and identification numbers of all radiographs taken. 1080.3.3.5.21 AWS Sec 6.26 Paragraph 6.26.2.1 - Paragraph 6.26.2.1 shall be replaced with the following: For any welds, the greatest dimension of any porosity or fusion type discontinuity that is 7361/16 inch or larger in greatest dimension shall not exceed the size, B, indicated in Figure 6.8 for the effective throat or weld size involved. The distance from any porosity or fusion type discontinuity described above to another such discontinuity, to an edge or to the toe or root of any intersecting flange-to-web weld shall not be less than the minimum clearance allowed, C, indicated in Figure 6.8 for the size of discontinuity under examination. 1080.3.3.5.22 AWS Sec 6.26 Paragraph 6.26.2.2 and Figure 6.9 - Delete paragraph 6.26.2.2 and Figure 6.9. 1080.3.3.5.23 AWS Sec 6.26 Paragraph 6.26.3.1 - Paragraph 6.26.3.1 shall be replaced with the following: Welds subjected to ultrasonic testing in addition to visual inspection shall conform to the requirements of Table 6.3. 1080.3.3.6 Calibrated Tapes. When the contract involves fabrication of a bridge with a bearing-to-bearing span of 100 feet or more, certifications and identifying numbers of calibrated measuring tapes or numbered tapes matched to a calibrated master shall be kept on file for review by the engineer. Certification of the measuring tape to be used or certification of the master from which the tape was matched shall be traceable to the U. S. National Bureau of Standards. Certification of tapes for shop use shall be renewed at least every two years. 1080.3.3.7 Connection Angles. Connection angles for floor beams and stringers shall be flush and shall be correct as to position and length of member. If milling is required, no more than 1/16 inch shall be removed from the thickness of the angles. 1080.3.3.8 Longitudinal Stiffeners. Longitudinal girder web stiffeners shall be a single length if possible. If more than a single length is necessary, such lengths shall be joined by a full penetration butt weld. The location of these butt welds shall be shown on the shop drawings for each joint and shall be subject to approval by the engineer. Runoff plates in accordance with AWS Section 3.12 shall be used. The welds shall be radiographically tested and accepted in accordance with AWS Sec 6.10 prior to being attached to the web. 1080.3.3.9 Pins. Pins shall be furnished true to size and shall be straight, smooth and free from flaws. Pins shall be provided with hexagonal chamfered nuts. The screw ends shall be sufficiently long to permit burring the threads when members are connected. Pilot and driving nuts shall be furnished for each size of pins where required. Threads for all pins and bolts shall conform with the ANSI B1.1 Free Fit - Class 2 Series except that when recessed nuts are specified, pin ends requiring a threaded diameter of 1 3/8 inches or more shall have six threads per inch. If standard nuts are specified for this size pin, a minimum of four threads to the inch shall be used. 1080.3.3.10 Pin Holes. Pin holes shall be bored true to size, smooth and straight, at right angles to the axis of the member and parallel with each other. The boring shall be done after the member is assembled and welded. The center-to-center distance of pin holes shall be correct within 1/32 inch for an individual component or member. The diameter of pin holes shall not exceed that of the pin by more than 1/50 inch for pins 4 inches or less in diameter or no more than 1/32 inch for pins larger than 4 inches in diameter. 1080.3.3.11 Casting. Castings shall be free from inclusions of foreign material, casting faults, injurious blow holes or other defects which render the castings unsuitable for the service intended. Castings shall be properly filleted at re-entrant angles. No tolerance will be allowed below the dimensions shown on the plans for thicknesses over an appreciable area of the casting. A reasonable oversize will not be cause for rejection. 1080.3.3.12 Bent Plates. Bent plates shall be cold bent and taken from the stock plates such that the bend line will be at right angles to the direction of rolling. The radius of bends, measured to the concave face of the metal, shall be in accordance with the requirements as shown in the table below, in which "T" is the thickness of the plate. If a shorter radius is required, the plates shall be hot bent. Hot bent plates shall be bent at right angles to the direction of rolling. Before hot or cold bending, the corners of the plate shall be rounded to a radius of 1/16 inch throughout that portion of the plate at which the bending is to occur. Angle Through Which Plate is BentMinimum Radius 61 degrees to 90 degrees 1.0 T Over 90 degrees to 120 degrees 1.5 T Over 120 degrees to 150 degrees 2.0 T 7371080.3.3.13 Surface Finish. Bearing plates of rolled steel not requiring a surface finish shall be straightened to a plane surface. The surfaces of plates of rolled steel or cast material which are to be in contact shall be finished as shown on the plans and the final finish shall be prepared in a manner to give at least 50 percent contact as indicated by standard machinist's blue test. Rockers and pedestals made from rolled steel shall be finished after welding. If a flat surface is shown on the plans, the tolerance shall be 0.003 inch per inch in any direction. Flat surfaces in full contact shall be finished at right angles to each other. Bearing plates shall be assembled in sets. The surface finish of bearing and base plates and other bearing surfaces that are to come in contact with each other or with concrete shall meet the following surface roughness requirements as defined in ANSI B 46.1, Surface Roughness, Waviness and Lay, Part I: Surface Roughness Requirements Micro-inches, Max. Steel Slabs 2,000 Heavy Plates in Contact in Shoes to be Welded1,000 Milled Ends of Compression Members, Stiffeners and Fillers500 Bridge Rollers and Rockers 250 Pins and Pin Holes 125 Sliding Bearings 125 1080.3.3.14 Horizontally Curved Rolled Beams and Plate Girders. If the plans show rolled beams or welded plate girders to be finished to a horizontal curvature, fabrication shall be as follows:
a.Rolled beams shall be curved by the heat curving procedure.
b.Welded plate girders may be fabricated by cutting the flanges to the specified curvature before the girders are attached to the webs or, if not prohibited by the contract, may be curved by the heat curving procedure.
c.If the heat curving procedure is used, the procedure shall comply with the following requirements:
1.Material. Heat curving of rolled beams and welded plate girders shall be limited to AASHTO M 270 Grade 36, AASHTO M 270 Grade 50, AASHTO M 270 Grade 50W and AASHTO M 270 Grade HPS 70W.
2.Type of Heating. Beams and girders may be curved by either continuous or V-type heating.
3.Temperature. The heat curving operation shall be conducted such that the temperature of the steel never exceeds 1,100 F as measured by temperature-indicating crayons or other suitable means applied before heating. The heating of the steel to a temperature greater than 1,200 F will be considered destructive heating and will be conclusive cause for rejection of the steel. Quenching with water or water and air, will not be permitted. Cooling with dry compressed air will be permitted after the steel has cooled to 600 F.
4.Position for Heating. The girder may be heat curved with the web in either a vertical or a horizontal position, unless noted on the contract plans. When curved in the vertical position, the girder shall be braced or supported in such a manner that the tendency of the girder to deflect laterally during the heat curving process will not cause the girder to overturn. When curved in the horizontal position, the girder shall be supported near the ends and at intermediate points, if required, to obtain a uniform curvature. When the girder is positioned horizontally for heating, intermediate safety catch blocks shall be maintained at the mid- length of the girder within 2 inches of the flanges at all times during the heating process.
5.Sequence of Operations. Heat curving shall be completed before the girder is painted. The contractor shall submit a curving procedure addressing the attachment of stiffeners, connection plates and cover plates for review prior to commencement of the heat curving process. 7381080.3.3.15 Shop Assembly. 1080.3.3.15.1 If required by the contract, the structural steel for bridges shall be completely shop assembled for inspection, supported only at points of bearing. Long bridges required to be entirely shop assembled may be divided into units for assembly with each unit extending from expansion device to expansion device. 1080.3.3.15.2 Beams and girders of all other bridges shall be assembled for inspection in line assemblies with a minimum length assembled of one complete span, from bearing to bearing. 1080.3.3.15.3 During shop assembly, connecting parts shall be firmly fastened together and held in alignment with a minimum of four drift pins and four make-up bolts per flange splice plate, web splice plate or similar connecting part, until assembly inspection is complete. 1080.3.3.15.4 All trusses, plate girders and continuous I-beams shall be assembled to permit inspection of all parts. QA inspection of the assembly will be at the option of the engineer. 1080.3.3.16 Shop Measurement of Curvature and Camber. Horizontal curvature and vertical camber will not be measured for QA inspection in the shop until all welding (except shear connectors), drilling and heat curving operations have been completed and the flanges have cooled to a uniform temperature. For bridges not requiring complete shop assembly, the vertical camber will be checked with the girder in a horizontal position and the horizontal curvature will be checked with the girder in either a horizontal or vertical position. The shop drawings shall show the required offsets for both curvature and camber at approximately 10-foot intervals, measured along the girder. The permissible variation in specified sweep for horizontally curved beams and girders, measured in inches, but not to exceed 1/2 inch, shall be as follows: 1/8 inch x 0.1 x (number of feet from end bearing) 1080.3.4 Shear Connector Studs. Shear connector studs may be attached to the beams or girders either in the fabricating shop or in the field. All applicable requirements of the Occupational Safety and Health Administration (OSHA) shall be met. If the shear connector studs are to be attached in the field, the contractor shall notify the engineer no less than one week before the contractor begins welding shear connectors to the beams or girders so the engineer may inspect for approval the proposed welding procedure and equipment. Only welding procedures, equipment and operators meeting the requirements of Secs 1080.3.3.4, 1080.3.3.5 and 712 shall be used. Areas to which shear connectors are to be attached shall be cleaned of all foreign material, such as oil, grease or paint by a suitable method. Where a shop coat of inorganic zinc primer has been applied, removal shall be limited to the minimum area necessary to apply the studs. After completion of the welding operations, the primed area shall be touched up with a suitable inorganic zinc primer or epoxy mastic paint (non-aluminum). Where galvanized steel beams or girders are specified, galvanizing material shall be omitted or removed one inch clear of weld locations. The method used to omit or remove the galvanizing material shall be masking, grinding or other methods approved by the engineer. After completion of the welding operations, the ungalvanized areas of the beam or girders shall be coated with epoxy mastic paint (non-aluminum). 1080.3.5 Shipping. Fabricated material shall not be shipped before a "Fabrication Inspection Shipment Release" is issued by MoDOT’s fabrication inspector to the fabricator and engineer by email. The fabricator shall email this release to the contractor prior to shipping fabricated parts. All parts shall be loaded and protected to prevent damage in transit. Pins, nuts, bolts and other small parts shall be boxed or crated. 1080.4 Weathering Steel. 1080.4.1 Description. This section contains provisions that shall modify, supplement and expand the requirements of the contract plans and other provisions of Sec 1080 when the use of weathering steel is specified for structures. Weathering steel will be defined as structural steel specified under AASHTO M 270 Grades 50W, HPS 50W and HPS 70W that is intended to be primarily used in a bare, uncoated application for the structure. 1080.4.2 High Performance Steels. 1080.4.2.1 Material Requirements. All high performance steel shall be in accordance with the latest edition of AASHTO M 270 and supplements. As an option, HPS 50W and HPS 70W thermomechanical-controlled- 739processing (TMCP) steel plates available from the manufacturer in limited thicknesses may be directly substituted for the quenched and tempered product. 1080.4.2.2 Fabrication Requirements. All fabrication shall be in accordance with the latest edition of the AASHTO Guide Specifications for Highway Bridge Fabrication with HPS70W Steel, an addendum to be used in conjunction with ANSI / AASHTO / AWS D1.5: 2002, except as modified by this section. Only fabricators meeting the requirements of the AISC Certification Program for Steel Bridge Fabricator Advanced Bridge (ABr) classification or approved equal may be used to fabricate HPS 50W and HPS 70W steel. Whenever magnetic particle testing is conducted, only the yoke technique will be permitted as described in Sec 6.7.6.2 of AWS D1.5: 2002, modified to test using alternating current only. 1080.4.2.3 Welding Requirements for HPS. All welding for high performance steel shall be in accordance with AASHTO / ANSI / AWS D1.5: 2002 Bridge Welding Code except as modified herein and by the latest edition of the AASHTO Guide Specifications for Highway Bridge Fabrication with HPS70W Steel. Only submerged arc and shielded metal arc welding processes shall be permitted when welding Grade HPS 70W steel. The matching submerged arc consumables using the ESAB electrode and Lincoln flux combinations, recommended in Appendix A of the guide specification shall not be allowed. Filler metals used for single pass fillet welds or for complete joint penetration groove welds connecting Grade HPS 70W plate to ASTM A709 Grade HPS 50W or Grade 50W may conform to the matching or undermatching requirements from AWS D1.5: 2002 as indicated in the guide specification. Moisture resistant coating shall be required for all shielded metal arc welding. The contractor may request approval of alternate consumables in lieu of the filler metals listed in the guide specification for submerged arc welding in accordance with AWS D1.5 Table 4.1. The request for approval shall include documentation of successful welding and shall include diffusible hydrogen tests indicating the levels of diffusible hydrogen to meet the requirements of the guide specifications. Grade HPS 50W may be welded under the same requirements as ASTM A709 Grade 50W. 1080.4.3 Cleaning. Except for the areas of the structure to be partially coated as described in Sec 1080.4.4, all surfaces of the structural steel shall be blast cleaned in the fabrication shop to meet the requirements of the Steel Structures Painting Council (SSPC) SSPC-SP6 and may be left uncoated. Faying surfaces of connections to be shop bolted shall be blast cleaned prior to permanent assembly of the connections. After blast cleaning, the steel shall be kept clean of all foreign material. If the steel becomes contaminated, the steel shall be cleaned with a method approved by the engineer. Girders contaminated with concrete or grout splatters shall be washed off before the material is allowed to dry. 1080.4.4 Partial Coating. Weathering steel partial coating shall be in accordance with Sec 1081.10.3.4.3. 1080.4.5 High Strength Fastener Assemblies. All high strength fastener assemblies shall be in accordance with Sec 1080.2.5. 1080.4.5.1 Coated Connections. Weathering grade fasteners in contact with coated structural steel items or located in areas of the structure to be partially coated shall be initially prepared and coated in the field with a gray epoxy mastic (non-aluminum) after the erection of the structure in accordance with the same procedure specified in Sec 1081. The epoxy-primed fasteners shall be subsequently coated with the system field coats specified for the structure in areas to be partially coated. 1080.4.5.2 Cleaning. Prior to field bolting connections of high strength fasteners, the faying surfaces shall be cleaned of loose rust by abrasive blast, power hand tools or other approved methods. Tightly adhering rust will not be required to be removed. 1080.4.6 Welding. All welds shall utilize welding processes and electrodes as required that will provide corrosion resistance and weathering characteristics for the welds comparable to the base metal, in accordance with the Section 4 of AWS D1.5: 2002 or as modified in Sec 1080.4.2.3. 1080.4.7 Bearings. Steel bearings, plate steel for elastomeric and PTFE bearings, structural steel for POT bearings, sole plates, masonry plates and associated items shall be in accordance with ASTM A709 Grade 50W. The exposed surfaces of all bearings for weathering steel structures under expansion joints shall be shop primed and field coated with the complete system specified for the structure in accordance with Sec 1080.4.4 and 1081. 1080.4.8 Protection of Concrete Masonry. All substructure concrete shall be protected from the effects of rust staining during construction in accordance with Sec 711. 7401080.4.9 Storage of Weathering Steel. Weathering steel shall be stored under conditions that will prevent unsightly, uneven weathering and excessive corrosion. If uneven weathering occurs, the contractor shall reclean the steel to the satisfaction of the engineer. If cleaning does not produce satisfactory uniformity in appearance or if in the judgment of the engineer, excessive corrosion or chemical contamination has occurred, the contractor shall replace the material at the contractor’s expense. As a minimum, the following conditions shall be avoided and the contractor shall take additional precautions as deemed necessary:
a.Storage in transit, open cars or trucks for an extended period of time.
b.Standing water on material in storage or entrapment of moisture.
c.Contact with chemically treated lumber used for blocking or other types of foreign matter.
d.Exposure to chlorides or other chemical contamination. 1080.5 High Strength Bolt Installation. Shop installed high strength bolts shall be in accordance with Sec 712. 1080.6 Coating of Structural Steel. Shop coating of structural steel shall meet the requirements of Sec 1081. 741SECTION 1081 COATING OF STRUCTURAL STEEL
1081.10 Protective Paint Systems.
1081.10.1 Scope. This specification covers coating new and existing bridges and structures made of structural
steel and miscellaneous metal with protective paint systems.
1081.10.2 Systems of Coatings. The required system and color or choice of systems and color will be specified
on the plans. Each coat of the specified system shall be applied to all structural steel, unless the contract specifically delineates otherwise. The system and color of coating to be shop-applied shall be shown on the shop drawings. All coatings shall comply with local VOC (Volatile Organic Compound) regulations where the paint is applied. The system and color shall not vary for any portion of the entire structure, including material for field repairs and shall be compatible products of a single manufacturer. The contractor shall coordinate the various items of work to ensure compliance with the requirements of this section. Approved material specifications and dry film thickness for the coating systems shall be as indicated in the following table: Paint Systems for Structural Steel System G (High Solids, Zinc-Epoxy-Polyurethane) Coating Section Dry Film Thickness, mils Inorganic Zinc Prime Coat or Organic Zinc Prime Coat 1045.3 or 1045.103.0 min. to 6.0 max. or 3.0 min. to 6.0 max. Epoxy Intermediate Coat 1045.43.0 min. to 5.0 max. Polyurethane Finish Coat, Gray or Brown 1045.52.0 min. to 4.0 max. System H (High Solids, Zinc-Waterborne Acrylic Intermediate-Waterborne Acrylic Finish) Coating Section Dry Film Thickness, mils Inorganic Zinc Prime Coat or Organic Zinc Prime Coat 1045.3 or 1045.103.0 min. to 6.0 max. or 3.0 min. to 6.0 max. Waterborne Acrylic, Intermediate Coat 1045.62.0 min. to 4.0 max. Waterborne Acrylic, Finish Coat, Gray or Brown 1045.62.0 min. to 4.0 max. System I (High Solids, Zinc-Polysiloxane) Coating Section Dry Film Thickness, mils Inorganic Zinc Prime Coat or Organic Zinc Prime Coat 1045.3 or 1045.103.0 min. to 6.0 max. or 3.0 min. to 6.0 max. Polysiloxane Finish Coat 1045.73.0 min. to 6.0 max. Aluminum & Gray Epoxy-Mastic Primer Coating Section Dry Film Thickness mils Aluminum Epoxy-Mastic Primer 1045.85.0 min. Gray Epoxy-Mastic Primer 1045.95.0 min
1081.10.3 Protective Coating of Structural Steel.
1081.10.3 1 Scope. This specification covers the preparation of previously uncoated structural steel surfaces,
furnishing and applying specified coatings, protection and drying of coatings, furnishing protection from coating spatter and disfigurement, and final cleanup.
1081.10.3 2 Certification. Contractors performing coating operations for new structural steel shall be certified
prior to the start of coating operations under the following SSPC Certified Contractor QP program or NACE International Institute Contractor Accreditation Program (NIICAP) as follows:
a.For field application of intermediate and finish coats, the contractor shall be certified to the SSPC QP1 – Field Application or NIICAP AS-1 Field Application. 742(b) For shop application of any coats by the steel fabricator, the fabricator shall be certified in accordance with Sec 1080.3.1.6 (g).
c.For field application of gray epoxy mastic primers to new steel and contact surfaces between the new steel and existing steel, no SSPC QP certification or NIICAP accreditation will be required.
1081.10.3 3 Surface Preparation.
1081.10.3 3.1 Cleaning. Oil, grease and other contaminants shall be removed in accordance with procedures
from Steel Structures Painting Council specification SSPC-SP1 prior to blast cleaning. Where high strength bolts are installed prior to blast cleaning or finish coat, the lubricant on high strength bolt assemblies shall also be removed in accordance with SSPC-SP1.
1081.10.3 3.1.1 Inorganic Zinc. Surfaces to be prime coated shall be blast cleaned with abrasives in accordance
with SSPC-SP10, producing a height of profile 1.5 mils minimum and 3.0 mils maximum for all systems. The appearance of the final blast cleaned surface shall be in accordance with SSPC-Vis1, Photograph A SP-10, B SP-10, C SP-10, or D SP-10. Conformance with the corresponding SP-5 photographs will also be acceptable. The blast profile shall be assessed with replica tape per ASTM D4417, Method C. The contractor shall make available to the engineer access to all SSPC specifications referenced for cleaning and coating operations.
1081.10.3 3.1.2 Organic Zinc. Surfaces to be prime coated shall be blast cleaned with abrasives in accordance
with SSPC-SP6, producing a height of profile 1.0 mils minimum and 3.0 mils maximum for all systems. The appearance of the final blast cleaned surface shall be in accordance with SSPC-Vis1, Photograph A SP-6, B SP- 6, C SP-6, or D SP-6. Conformance with the corresponding SP-5 and SP-10 photographs will also be acceptable. The blast profile shall be assessed with replica tape per ASTM D4417, Method C. The contractor shall make available to the engineer access to all SSPC specifications referenced for cleaning and coating operations.
1081.10.3 3.2 Preparation for Coating. After blast cleaning, all surfaces shall be cleaned to remove any trace
of blast products, dust or dirt from the surface and from all pockets and corners. Sharp fins resulting from the blast cleaning operation shall be removed with an approved method that will maintain the minimum anchor profile for the prime coat. The blast-cleaned surfaces shall be given the specified prime coat as soon as practical, but within 24 hours after blast cleaning. If blast cleaned surfaces rust before coating is accomplished, the surface shall be reblasted by the contractor at the contractor's expense. All rusted, damaged or uncoated areas, including ungalvanized nuts, bolts and washers to be prime coated in the field, shall be blast cleaned to the same degree as specified above for the applicable coating system. Care shall be exercised to ensure the blasted steel remains free of grease and oil during handling.
1081.10.3 3.3 Recleaning. When there is contamination of any blast-cleaned surface to be coated, the material
shall be recleaned to the requirements of SSPC-SP10 for inorganic zinc and SSPC-SP6 for organic zinc.
1081.10.3 4 Limits of Coating Application. Unless otherwise indicated on the plans, the application of the
intermediate and finish coats for Systems G and H, and the application of the finish coat for System I, hereinafter referred to as field coats, shall be applied to the structure within the following limits.
1081.10.3 4.1 Bridges over Roadways. This section will not apply to bridges over railroads.
1081.10.3 4.1.1 The intermediate field coat for beam and girder spans shall be applied to the surfaces of all
structural steel, except that areas of steel to be in contact with concrete shall not receive the intermediate coat. The intermediate coat shall also be applied to the bearings, except where bearings will be encased in concrete. The finish coating for beam and girder spans shall include the facia girder or beams. The limits of the facia girders or beams shall include the bottom of the top exterior flanges, top of the bottom exterior flanges, the exterior web area, the exterior face of the top and bottom flange and the bottom of the bottom flange. Areas of steel to be in contact with concrete shall not receive the finish coat. The finish coat shall also be applied to the exterior bearings, except where bearings will be encased in concrete.
1081.10.3 4.1.2 The surfaces of all structural steel located under expansion joints of beam and girder spans shall
be field coated for a distance of 1 1/2 times the girder depth, but no less than 10 feet from the centerline of the joint. Within this limit, the items to be field coated shall include all surfaces of beams, girders, bearings, diaphragms, stiffeners and miscellaneous structural steel items. Areas of steel to be in contact with concrete 743shall not receive the field coats. The limits of the field coatings shall be masked to provide crisp, straight lines and to prevent overspray on adjacent areas.
1081.10.3 4.1.3 For all truss or steel box girder spans, the above limits will not apply and all structural steel for
these span types shall be field coated, except the areas of steel to be in contact with concrete.
1081.10.3 4.1.4 Straps for steel stay-in-place forms shall be removed in areas where field coating shall be
required in accordance with this Specification. Flame cutting will not be permitted. The contractor shall take care not to damage the structure or the shop coating during strap removal. Any damage to the shop coating as a result of the contractor's operations shall be repaired by the contractor in accordance with this Specification. Any damage to the rest of the structure shall be repaired as approved by the Engineer.
1081.10.3 4.1.5 When System I is specified on the plans for beam and girder spans, a System G intermediate
coat shall be applied similarly in accordance with Sec 1081.10.3.4.1.1 intermediate field coating requirements except that an intermediate coat will not be required to be applied to the beams and girders where the System I finish coat is to be applied. The contractor shall have the option to substitute the System I finish coat in place of a System G intermediate coat.
1081.10.3 4.2 Bridges Over Streams or Railroads.
1081.10.3 4.2.1 The field coating for beam and girder spans shall include the facia girders or beams. The limits
of the facia girders or beams shall include the bottom of the top exterior flanges, top of bottom exterior flanges, the exterior web area, the exterior face of the top and bottom flange and the bottom of the bottom flange. Areas of steel to be in contact with concrete shall not receive the field coats. The field coatings shall also be applied to the exterior bearings, except where bearings will be encased in concrete. The interior beams or girders shall only have the prime coat applied with no other field coating required.
1081.10.3 4.2.2 The surfaces of all structural steel located under expansion joints of beam and girder spans shall
be field coated for a distance of 1 1/2 times the girder depth, but no less than 10 feet from the centerline of the joint. Within this limit, the items to be field coated shall include all surfaces of beams, girders, bearings, diaphragms, stiffeners and miscellaneous structural steel items. Areas of steel to be in contact with concrete shall not receive the field coats. The limits of the field coatings shall be masked to provide crisp, straight lines and to prevent overspray on adjacent areas.
1081.10.3 4.2.3 For all truss or steel box girder spans, the above limits will not apply and all structural steel for
these span types shall be field coated, except the areas of steel to be in contact with concrete.
1081.10.3 4.2.4 Straps for steel stay-in-place forms shall be removed in areas where field coating shall be
required in accordance with this Specification. Flame cutting will not be permitted. The contractor shall take care not to damage the structure or the shop coating during strap removal. Any damage to the shop coating as a result of the contractor's operations shall be repaired by the contractor in accordance with this Specification. Any damage to the rest of the structure shall be repaired as approved by the Engineer.
1081.10.3 4.3 Weathering Steel Bridges.
1081.10.3 4.3.1. The surfaces of all structural steel located under expansion joints, but not in contact with
concrete, shall be coated with complete specified paint system within a distance of 1 1/2 times the girder depth, but no less than 10 feet, from the centerline of all deck joints. Within this limit, items to be coated shall include all surfaces of beams, girders, diaphragms, stiffeners, bearings and miscellaneous structural steel items. The prime coat for the specified paint system shall be applied to the structural steel within the above limits in the fabrication shop. The intermediate and finish coats shall be applied in the field in accordance with Sec
1081.10.3 3. The color of the finish coat shall be brown.
1081.10.3 4.3.2. Portions of the structural steel embedded in or in contact with concrete, including but not
limited to the top flanges of girders, shall be coated with no less than 2.0 mils of the prime coat for the specified paint system and this coating shall extend a minimum of 12 inches beyond any vertical concrete face. Shear connectors need not be coated or protected from overspray.
1081.10.3 4.3.3 Required work shall include blast cleaning for all areas to receive the specified prime coat to
SSPC-SP-10 (Near White Blast Cleaning) in accordance with Sec 1081.10.3.3, except that areas to be primed 744that will be embedded in concrete may be prepared to no less than SSPC-SP-6. The limits of the areas to be shop and field coated shall be masked to provide crisp, straight lines to prevent overspray on adjacent areas.
1081.10.3 4.3.4 The galvanized surfaces of drain support brackets shall be prepared according to the coating
manufacturer's recommendation and field coated with a gray epoxy mastic primer (nonaluminum) within a distance of 6 inches from the point of connection to the weathering steel structure.
1081.10.3 5 Coating Thickness Measurement. The dry film thickness of the coatings will be measured by
magnetic-type gauges in accordance with Steel Structures Painting Council, specification SSPC-PA2. At the option of the engineer, the adhesion of the prime coat will be measured in accordance with ASTM D3359, Test Method A. When the adhesion is tested, each test result shall equal or exceed scale 3A. Locations for adhesion tests shall be randomly selected. Test locations shall be in areas of least visibility in the completed structure and shall be touched up in an approved manner after completion of the test. When satisfactory test results are not obtained, additional adhesion tests shall be taken to determine the area of insufficient adhesion. For these areas, the surface shall be prepared in accordance with Sec 1081.10.3.3.1 and the area recoated in accordance with these specifications. If additional prime coat is required to provide the specified minimum thickness, the prime coat shall be applied as soon as possible, but within 24 hours of the initial application.
1081.10.3 6 Coating Material Storage. All coating material shall be stored in accordance with the coating
manufacturer’s recommendations. Exposure to storage temperatures outside the range recommended in the manufacturer's specifications will be considered cause for rejection of the coating material.
1081.10.3 7 Weather Conditions.
1081.10.3 7.1 Temperature Limitations. The prime coat shall be applied in accordance with the
manufacturer’s recommendations, except that the minimum air and steel temperature shall be no less than 34 F. Finish and intermediate coats applied over the prime coat shall be applied in accordance with the manufacturer's recommendations, which shall be furnished to the engineer. The minimums and maximums or additional requirements established by the coating manufacturer’s written specifications for recommended air or metal temperature or relative humidity will apply if those requirements are more restrictive than those specified in the contract documents.
1081.10.3 7.2 Moisture Limitations. Coatings shall not be applied in rain, snow, fog or mist, or when the steel
surface temperature is less than 5 F above the dew point. The dew point shall be determined in accordance with MoDOT Test Method TM 38. Coatings shall not be applied to wet, damp, frosted or ice-coated surfaces.
1081.10.3 7.3 Application in Protected Areas. When coatings are applied in a protected area to eliminate the
weather conditions, the coated steel shall remain in the protected area until the coatings are cured.
1081.10.3 7.4 Damaged Coatings. Any uncured coatings exposed to freezing, excess humidity, rain, snow,
condensation or curing temperatures outside the range recommended by the manufacturer will be considered damaged. Damaged coatings shall be permitted to dry, then shall be removed and the surface blast cleaned and recoated at the contractor’s expense.
1081.10.3 8 Thinning. Thinners will be permitted as recommended by the manufacturer's recommendations,
provided VOC limits are not exceeded.
1081.10.3 9 Application. Coatings shall be applied in accordance with the Steel Structures Painting Council
specification SSPC-PA1, unless otherwise specified by the product manufacturer. Stripe coating, as defined by SSPC-PA1 shall be required for all applied coating layers. The manufacturer's written specifications for application, upon request, shall be submitted to the engineer for review prior to application.
1081.10.3 9.1 Application Repairs. If deficiencies in the quality of work or material result in rejection, the
contractor shall submit a repair proposal for approval by the engineer.
1081.10.3 9.2 Curing of Coatings. Curing time for recoating shall be within the limits of the manufacturer's
recommendations. Application of the finish coat over the intermediate coat shall be accomplished within the recoat time for proper adhesion established by the manufacturer's recommendations. 7451081.10.3.10 Shop Coating. All surfaces of fabricated structural steel, including areas that will be inaccessible after assembly, contact surfaces of high strength bolted connections and all surfaces to be in contact with concrete in the completed structure shall be coated in the shop with the prime coat. The primer shall be of the type and thickness specified, except as modified by Secs 1081.10.3.10.1 and 1081.10.3.10.2. Structural steel sway bracing for the substructure may be prepared and coated in the field.
1081.10.3 10.1 Contact Surfaces. Contact surfaces of high strength bolted field splice and diaphragm
connections shall be prime coated to produce a dry film thickness no less than 1.5 mils or more than 2.5 mils. The limits of the coating thickness for these surfaces shall be shown on the shop drawings. The maximum limit of 2.5 mils may be increased provided acceptable test results in accordance with the Testing Method to Determine the Slip Coefficient for Coatings Used in Bolted Joints (AISC Specification for Structural Joints Using ASTM A 325 or A 490 Bolts, Appendix A) are submitted and approved by the engineer. Revised shop drawings will not be required upon acceptance of the test results. The tests shall meet the requirements for the slip coefficient and creep resistance for Class B coatings and shall be performed by a nationally recognized independent testing laboratory. Any change in the formulation of the coating will require retesting, except when thinned within the limits of manufacturer's recommendations. At the contractor's option, the contact surfaces of connections for all non-slab bearing diaphragms on non-curved girders may be prime coated with a dry film thickness of no less than 3.0 mils or more than 6.0 mils, unless noted otherwise on the plans.
1081.10.3 10.2 Inaccessible Surfaces. Surfaces that will not be in contact, but that will be inaccessible after
assembly, shall be prime coated to produce a dry film thickness of no less than 3.0 mils and no more than 6.0 mils. Dry film thickness on surfaces that will be in contact with concrete may be reduced to 2.0 mils provided thorough and complete coverage is obtained. Although shear connectors need not be coated, protection of the connectors from overspray when coating other parts of the beam or girder will not be necessary. Coating thickness measurements will not be made on shear connections.
1081.10.3 10.3 Touch-up of Galvanized Bolts. The galvanized coating of nuts, bolts and washers damaged
during shop installation shall be shop repaired in accordance with Secs 1081.10.3.11.1 and 1081.10.3.11.1.1.
1081.10.3 10.4 Inspection Prior to Coating. No coatings shall be applied before shop inspection of fabrication
has been completed. Surfaces of steel within 2 inches of edges to be field welded shall not be coated in the shop.
1081.10.3 10.5 Erection Match Marks. Erection match marks shall not be visible in the completed structure.
1081.10.3 11 Field Coating. Intermediate and finish coats for the specified coating system shall be applied in
the field. The contractor shall be responsible for final cleanup and field touch-up of any shop applied coating, including surface preparation and coating of field connections, welds or bolts, areas masked in the shop and all damaged or defective coating and rusted areas. Surface preparation for field touch-ups shall be performed in accordance with Sec 1081.10.3.3, unless otherwise approved by the engineer. The touch-up field coat shall consist of the same coating used for the shop-applied coat. Contact surfaces of high strength bolted connections shall be protected from the intermediate and finish coats. Damage to the coating of galvanized bolts, nuts and washers where bare steel is exposed shall be repaired in accordance with these specifications or, the connection may be prepared as specified in Sec 1081.10.3.3, followed by a touch-up field coat application of the required coating system.
1081.10.3 11.1 Field Touch-up of Galvanized Bolts. The galvanized coating of nuts, bolts and washers
damaged during installation shall be repaired. Lubricants shall be removed in accordance with SSPC-SP1. Rust shall be removed in accordance with SSPC-SP-2 or SSPC-SP-3. Touch-ups shall consist of the application of an approved gray epoxy mastic. The touch-up material shall be compatible with and from the same manufacturer as the coating system to be used for the structure. Prior to field coating operations, the contractor shall submit information on the specific products to be used, including compatibility data and applicable recoating times, to the engineer for review. Subsequent coatings shall be applied within the recoat time recommended by the manufacturer.
1081.10.3 11.1.1 Touch-up Color. For areas of the structure that will not receive a field coat, the color of the
touch-up material for bolts specified in Sec 1081.10.3.11.1 shall be similar to galvanized metal.
1081.10.3 11.1.2 Previously Repaired Material. If repairs to the galvanized coating of shop-installed nuts,
bolts and washers have previously been performed in accordance with Sec 1081.10.3.10.3 or if epoxy mastics are otherwise shop-applied to structural steel, the contractor shall be responsible for any special field preparation 746required for proper adhesion of subsequent field coats to the epoxy coating. Prior to field coating operations, the contractor shall submit the manufacturer's recommendations to the engineer.
1081.10.3 11.1.3 Masking. Previously coated or adjacent areas shall be masked or otherwise protected from
material used to touch-up the galvanized coating of fasteners.
1081.10.3 11.2 Sequence of Work. Field coatings, except for touch-up and coating of inaccessible surfaces,
shall not be applied until the concrete deck has been placed, the forms removed and all concrete spatter, foreign material and contaminants are removed from existing coatings, unless otherwise approved by the engineer. Prior to submittal of alternative application methods, the contractor shall present methods to be used to prevent damage to the intermediate and final field coatings. The sequence of work shall be arranged to provide ample time for each coat to cure before the next coat is applied. The intermediate field coats shall be free of all oil, grease, dust or dirt prior to application of the next coat. Intermediate or prime coats that have been exposed to chlorides used in snow removal operations shall be cleaned by power washing as defined in Sec 1081.10.5.4.2.2 prior to application of the subsequent intermediate or final coats. In no case shall a coat be applied until the previous coat has been approved by the engineer. Excessive rust streaks or coatings on concrete masonry shall be removed by sandblasting or by other approved methods without damage to the masonry.
1081.10.3 11.3 Work Under Stage Construction Contracts. If complete field coating is not included in the
contract for erection of structural steel, the touch-up coating of newly erected work and the coating of surfaces that will be inaccessible after erection shall be included as part of the work to be performed under the contract for erection. Field coating under any contract that does not include the erection shall include cleaning, preparation of any previously applied coatings, repairs and spot application of coatings required at the time the work is performed. Prior to field coating structural steel that was erected under a previous contract, the contractor shall submit the manufacturer's recommendations to the engineer, outlining requirements for cleaning and preparation of all existing coatings. The manufacturer’s recommendations shall include requirements for preparation of epoxy mastics previously applied for touch-up or other purposes.
1081.10.3 11.4 Partial Applications. If partial applications of the field finish coats to a structure as provided in
Sec 1081.10.3.4 is required or permitted, the contractor shall perform field touch-up coating to areas of the structural steel outside the limits to receive the intermediate and finish coats. Touch-up shall be in accordance with in Sec 1081.10.3.11 and at the contractor’s expense.
1081.10.3 12 Identification. The contractor shall, at the completion of the coating application, stencil in black
paint on the structure the number of the bridge, the word "COATED", the system used and the month and year the coating was completed. The letters shall be capitals approximately 3 inches high. The legend shall be stenciled on the outside face of an outside stringer or girder near each end of the bridge as directed by the engineer.
1081.10.3 13 Property and Traffic Protection. The contractor shall protect pedestrian, vehicular, railroad and
other traffic, persons and property, upon, beneath and in the vicinity of the structure and all portions of the bridge against damage or disfigurement by blast media, blast residue, coatings, coating material, equipment or by any other operations.
1081.10.4 Recoating of Structural Steel (System G , H or I).
1081.10.4 1 Scope. This specification covers the field preparation of structural steel surfaces to be recoated,
furnishing and applying specified coatings, protection and drying of coatings, furnishing protection from coating spatter and disfigurement, and final cleanup.
1081.10.4 2 Certification. Contractors performing coating operations for field applied recoating shall be
certified prior to the start of the coating operations under the appropriate category of the AMPP QP program as follows:
a.For coating operations where there is no presence of lead, heavy metals, or other hazardous materials, the contractor shall be certified to the AMPP QP1 – Field Application.
b.For coating operations where lead, heavy metals, or other hazardous materials are present, the contractor shall be certified to the AMPP QP2 – Field Removal of Hazardous Coatings. 7471081.10.4.3 Systems of Protective Coatings. All structural steel shall be recoated by the contractor in the field using one of the complete systems, including prime coats, in accordance with Sec 1081.10.2, unless noted otherwise. Recoating of structural steel, including surface preparation, weather conditions, application, touch-up and protection, shall be in accordance with all requirements of Sec 1081.10.3 unless in conflict with Sec 216, which shall control.
1081.10.4 4 Surface Preparation. Cleaning and coating of structural steel shall proceed in areas or sections as
approved by the engineer, usually consisting of one or more complete spans. The cleaning and application of the coatings for each specified section shall be entirely completed and accepted by the engineer prior to proceeding with additional cleaning or coating. Surface preparation shall be in accordance with Sec 1081.10.3.3. All existing coatings and paint shall be removed by blast cleaning unless specifically indicated otherwise in the contract.
1081.10.4 4.1 Approved Blast Media. Only silica sand and steel abrasive shall be allowed for use as approved
blast media for paint removal. A safety data sheet (SDS) for the blast media selected for use shall be submitted for approval at the pre-construction conference held with the contractor. The SDS shall be maintained on site by the contractor and shall be available for review upon request. All paint removed with approved blast media shall be sent to the Doe Run lead smelter for recycling and is not considered a solid or hazardous waste in accordance with 40 CFR 261.2(e)(1)(ii). Surface preparation areas cleaned with unapproved blast media shall be at the contractor’s expense. The collected residue shall consist of media no larger than one inch and removed paint chips.
1081.10.4 4.2 Environmental Regulations. The paint removal operation shall comply with all local, state and
federal regulations, including but not limited to, the EPA, OSHA Standards 29 CFR 1910 and 1926.62, and the Missouri Code of State Regulations, including 10 CSR 10 Air Conservation Commission, 10 CSR 20 Clean Water Commission, 10 CSR 25 Hazardous Waste Commission, and 10 CSR 80 Solid Waste Management. The contractor shall have all necessary licenses and certifications as required by the Missouri Department of Health including necessary licenses and certification for lead abatement/removal workers prior to commencement of the cleaning operation. If hazardous waste will be generated at the site, the contractor shall notify the engineer and Environmental Section in Design Division and comply with all applicable hazardous waste generator requirements.
1081.10.4 4.3 Containment and Collection of Blast Residue. A containment system, or enclosure, is required
to prevent the release of blast media residue and other debris generated during surface preparation activities from entering the environment. Enclosures are typically made up of combinations of cover panels, scaffolds, supports, screens, and tarps. The complexity of any given enclosure will vary depending on the method of paint removal being employed and the degree of surface preparation that is specified. For a simple scraping operation ground-covering tarps may be sufficient while for a blasting operation, the enclosure could be a designed structure with a negative pressure ventilation system. The contractor shall collect all blast residue (paint residue/blast media) from the cleaning operations for recycling. All blast media and residue shall be contained or collected; should an accidental release occur, the contractor shall complete all necessary cleanup efforts as directed by the Engineer. Blast residue shall be managed as a recyclable material. Container management shall be in accordance with Sec 1081.10.4.4.3.3. Analytical testing required for the disposal of blast residues shall be the responsibility of the contractor.
1081.10.4 4.3.1 Waste Solvent Management. All waste solvent generated from painting operations shall be
containerized, sampled, and submitted for analytical testing to enable a hazardous waste determination.
1081.10.4 4.3.2 Hazardous Waste Notification. The contractor shall submit a “Notification of Regulated Waste
Activity” form to MDNR Hazardous Waste Program to obtain the EPA identification number. Requests shall be submitted as soon as hazardous waste is determined or at least 30 days prior to shipping hazardous waste. The cost of obtaining the EPA identification number will be considered as part of the surface preparation cost and the engineer will subtract the cost from the contract. Hazardous waste shall not be shipped offsite until the EPA identification number has been received. The contractor will file the quarterly and annual hazardous waste reports in accordance with 10 CSR 25-5.262(2)(D)1 and will deactivate the EPA identification number upon contract completion. The contractor shall submit copies of all hazardous waste manifests and quarterly/annual reports to MoDOT’s Environmental Section.
1081.10.4 4.3.3 Container Management.
7481081.10.4.4.3.3.1 The blast residue from cleaning operations shall be stored in contractor furnished, watertight 55-gallon steel drum containers stacked on wooden pallets with labels facing outward. The containers shall be free of structural defects and all other materials including but not limited to construction debris, solvents, flammables, aluminum, magnesium, aerosol cans, rags and any ferrous or non-ferrous metals larger than one cubic inch. The containers shall have removable lids complete with a bolt ring, bolt and nut. Containers shall remain closed at all times, except when necessary to add blast residue. Material other than the blast residue from the cleaning operations shall not be placed in the containers. At the end of each day’s work, the containers shall be stored outside the 100-year floodplain in a secure area as approved by the engineer. Containers of approved blast residue destined for recycling, shall be marked with a “Blast Residue” label provided by the Engineer or Environmental Section in the Design Division and marked with the following information:
a.Blast Residue.
b.Marked with one of the following:
1.Contains Heavy Metals/Lead Compounds.
2.Contains Non-Lead Compounds.
c.Generator: MoDOT.
d.Bridge Site Number.
e.Date Container was Filled.
1081.10.4 4.3.3.2 Containers of hazardous waste shall be packaged, marked and labeled according to hazardous
waste regulations 10 CSR 25-5.262(2)(C)1. Containers of hazardous waste shall be stored separate from containers of non-hazardous waste and approved blast media destined for recycling. The contractor shall maintain an inventory of the quantity of the containers stored at the site and the quantity delivered to an approved facility. All containers shall be delivered to the approved facility within 30 days upon completion of the surface preparation. Copies of container inventories, all test results, shipping papers, hazardous waste manifest signed by the receiving facility, solid waste disposal request, recycling certificates and any other disposal documentation shall be submitted to the engineer with a copy to the Environmental Section in the Design Division within 30 days upon delivery to the approved facility.
1081.10.4 4.3.4 Shipment of Residue. Approved blast media containing paint residue shall be shipped with a
bill of lading to the Doe Run smelter for recycling. The contractor shall obtain appropriate shipping papers (bill of lading), if required, from the Engineer or Environmental Section in the Design Division. These shipping forms shall be completed prior to shipment. The Doe Run smelter will reject any shipment received without the proper shipping papers. The contractor shall notify the Doe Run smelter at least 2 days prior to shipment to ensure the receiving facility will be able to accept the material.
1081.10.4 4.3.5 Personal Protective Equipment. Clothing, tarps, hoses and other cleaning material containing
blast residue shall be managed as a hazardous waste unless determined non-hazardous. Personal protective equipment being disposed, such as tyvek suits, respirator cartridges, boots, etc. but not tarps, shall be placed into 55-gallon steel drums. Spent tarps shall be placed into DOT approved cardboard boxes and stacked on wooden pallets. Container management shall be in accordance with Sec 1081.10.4.4.3.3.
1081.10.4 4.3.6 Invoices and Payment. The contractor shall dispose of all paint residue/blast media and
personal protective equipment in accordance with all Federal and State regulations at the Doe Run smelter. Spent solvents shall be disposed of at an EPA approved hazardous waste treatment, storage and disposal facility. Transporting and disposal cost shall be the contractor’s responsibility. A copy of the disposal manifest and paid receipt shall be given to the engineer. Failure to provide proper documentation will result in withholding payment. For more information concerning management of blast residue or approved hazardous waste treatment, storage and disposal facilities, contact the Environmental Section in the Design Division.
1081.10.4 5 Joints. All seams and joints that cannot be satisfactorily sealed or coated shall be adequately
caulked with compounds compatible with the coating system being applied. Caulking material shall be in accordance with the coating manufacturer's recommendations and shall meet the approval of the engineer. 749Caulking shall be satisfactorily completed for an entire joint or seam after application of the prime coat and before application of any specified finish or intermediate coats.
1081.10.4 6 Identification. At the completion of recoating, the contractor shall stencil in black paint on the
structure the number of the bridge, the word "RECOATED", the system used and the month and year the coating was completed. The letters shall be capitals approximately 3 inches high. The legend shall be stenciled on the outside face of an outside stringer or girder near each end of the bridge as directed by the engineer.
1081.10.4 7 Property and Traffic Protection. The contractor shall provide protection in accordance with Sec
1081.10.3 13.
1081.10.5 Overcoating of Structural Steel.
1081.10.5 1 Scope. This specification covers the field preparation of structural steel surfaces to be overcoated,
disposal of paint residues and power washing water, furnishing and applying the specified coatings, protection and drying of the coatings, furnishing protection from coating spatter or disfigurement and final cleanup.
1081.10.5 2 Certification. Contractors performing coating operations for field applied overcoating shall be
certified prior to the start of the coating operations under the appropriate category of the AMPP QP program as follows:
a.For coating operations where there is no presence of lead, heavy metals, or other hazardous materials, the contractor shall be certified to the AMPP QP1 – Field Application.
b.For coating operations where lead, heavy metals, or other hazardous materials are present, the contractor shall be certified to the AMPP QP2 – Field Removal of Hazardous Coatings.
1081.10.5 3 System of Protective Coatings. All exposed and accessible surfaces of structural steel and steel
bearings shall be coated with the specified paint system in accordance with Sec. 1081.10.2 unless otherwise noted. The color of the field coat shall be as shown on the plans. Overcoating of structural steel shall be in accordance with all requirements of Sec 1081.10.3 except surface preparation and unless in conflict with Sec 216, which shall control.
1081.10.5 4 Surface Preparation. Surface preparation shall be in accordance with Sec 1081.10.4.4, except that
blast cleaning will not be required.
1081.10.5 4.1 Removal of Existing Paint. The existing steel shall be cleaned by approved methods in
accordance with Sec 1081.10.5.4.2.
1081.10.5 4.1.1 Environmental Regulations. The paint removal operation shall be in accordance with all local,
state and federal regulations, including those defined in Sec 1081.10.4.4.2.
1081.10.5 4.1.2 Water for Power Washing. The water used for power washing shall be clean, potable water,
free from contaminants. During power washing operation, solids shall be contained or removed, but collection of wash water is not required for this activity.
1081.10.5 4.1.3 Collection of Residue. Collection of all paint residue shall be in accordance with the following
requirements. The containers shall remain closed at all times, except when necessary to add additional residue. Material other than the residue from the cleaning operations shall not be placed in the containers. Any testing required for the disposal of the residues shall be the responsibility of the contractor. Copies of the inventory, all testing data, required certifications and shipping manifests shall be provided to the engineer and to the Environmental Section in Design Division in accordance with Sec 1081.10.4.4.3.3.2.
1081.10.5 4.1.4 Testing of Paint Residue. At the conclusion of the power washing operation, the contractor
shall obtain samples of the paint residue in the presence of the engineer. The samples shall be analyzed by an independent testing laboratory for Toxicity Characteristic Leaching Procedure (TCLP) heavy metals. Samples shall be collected and analyzed in accordance with EPA approved methods. Copies of all test reports shall be supplied to the engineer and the Environmental Section in Design Division. Any additional testing required to comply with any federal, state or local regulations shall be provided by the contractor. If TCLP heavy metals 750test results exceed the regulatory limits, the contractor shall handle and dispose of the material in accordance with hazardous waste regulations at an EPA-approved RCRA treatment, storage, or disposal (TSD) facility. If test results indicate levels below the regulatory limits, then the material shall be disposed of as a solid waste at a sanitary landfill.
1081.10.5 4.2 Cleaning of Structural Steel. All exposed steel surfaces shall be mechanically cleaned in
accordance with Sec 1081.10.5.4.2.1 and in accordance with the paint manufacturer’s recommendations prior to application of the coating. Power washing will not be required. However, the contractor may use power wash cleaning if desired during surface preparation. All surfaces cleaned shall be approved by the engineer prior to application of the coating.
1081.10.5 4.2.1 Mechanical Cleaning. Exposed structural steel where mechanical cleaning is required shall be
cleaned in accordance with SSPC-SP2 or SSPC-SP3. Blast cleaning as a substitute cleaning method will be acceptable. Mechanical cleaning will be required for areas of rusted steel, loose, cracked or brittle paint or areas indicated by the engineer. The cleaning shall be performed 2 inches beyond the areas of rust or defective paint in all direction or until tightly adhered paint is obtained with no rust or blisters. Edges between the bare steel and the paint shall be feathered. Collection of the residue removed shall be in accordance with Sec 1081.10.5.4.1.3.
1081.10.5 4.2.2 Power Wash Cleaning. The contractor may clean the steel by a low-pressure power wash to
remove loose paint, dirt and other loose deleterious material. The maximum pressure for the power washing shall be 1,500 psi. Construction of a containment system around the work area is required and shall consist of wooden framed construction, installation of a drip tarps consisting of #100 sieve filter fabric, or other alternative method that effectively filters the water and captures solids, as approved by the Engineer. If necessary, solvent cleaning in accordance with SSPC-SP1 shall be employed to augment the power washing. Collection of the residues from the power washing operation shall be in accordance with Sec 1081.10.5.4.1.2. After the power washing operation, areas that have remaining rust or loose paint shall be recleaned in accordance with Sec
1081.10.5 4.2.1, except that vacuum power tools will be required for power tool cleaning. All surfaces washed
shall be completely free of all foreign matter, surface dry and approved by the engineer prior to application of the coating.
1081.10.5 5 Application. Coating shall be applied in accordance with Sec 1081.10.3 and the manufacturer’s
recommendations. The steel shall be free of all cleaning residues prior to coating. Areas that have been cleaned to bare steel shall be prime coated on the same day as the cleaning. Any areas that rust prior to application of the prime coat shall be recleaned. The prime coat and field coat shall be applied to all steel surfaces with the exception of steel encased in concrete. Any existing paint that curls or lifts after application of the specified system shall be removed, the area recleaned and the coating reapplied.
1081.10.5 6 Identification. At the completion of the final coating application, the contractor shall, stencil in
black paint on the structure the number of the bridge, the words “OVERCOATED – System _” and the month and year the coating was completed. The letters shall be capitals approximately 3 inches high. The legend shall be stenciled on the outside face of an outside girder near each end of the bridge as directed by the engineer.
1081.10.5 7 Property and Traffic Protection. The contractor shall provide protection in accordance with Sec
1081.10.3 13.
1081.10.6 Aluminum & Gray Epoxy-Mastic Primer.
1081.10.6 1 Scope. This specification covers the application of other approved primer coatings for touch-up and
other repair applications.
1081.10.6 2 Surface Preparation. The epoxy-mastic shall be applied over an SSPC-SP2, SSPC-SP3 or SSPC-
SP6 surface preparation, including removal of all rust scale, loose rust, loose mill scale and loose or non- adherent paint. Oil and grease shall be removed in accordance with SSPC-SP1 Solvent Cleaning. Areas adjacent to required areas will not be required to be masked to prevent overspray.
1081.10.6 2.1 Environmental Regulations. The surface preparation operation shall be in accordance with all
local, state and federal regulations, including those defined in Sec 1081.10.4.4.2.
1081.10.6 2.2 Collection of Residue. The collection of residue shall be in accordance with Sec 1081.10.4.4.3
and 1081.10.5.4.1.3. 7511081.10.6.3 Application. Material application methods, air and surface temperatures and relative humidity shall be in accordance with the manufacturer’s written instructions and Sec 1081.10.3. The most restrictive application and environmental requirements for the epoxy-mastic shall be used when applying the primer to the steel.
1081.10.7 Organic Zinc-Rich Primer.
1081.10.7 1 Scope. This specification covers the application of an approved organic zinc-rich primer for
recoating, repair, touch-up and other field applications.
1081.10.7 2 Surface Preparation.
1081.10.7 2.1 Recoating Steel. Surface preparation shall be in accordance with Sec 1081.10.4.4.
1081.10.7 2.2 Touch-up on Inorganic Zinc-Rich Primer. Oil and grease shall be removed in accordance with
SSPC-SP1 Solvent Cleaning. Surface preparation shall be in accordance with SSPC-SP2 or SSPC-SP3, including removal of all loose rust, loose mill scale and loose or nonadherent paint.
1081.10.7 2.3 Touch-up on Existing Galvanized Steel. Oil and grease shall be removed in accordance with
SSPC-SP1 Solvent Cleaning. Surface preparation shall be in accordance with SSPC-SP7, including removal of all rust scale, loose rust and loose mill scale.
1081.10.7 2.4 Environmental Regulations. The surface preparation operation shall be in accordance with all
local, state and federal regulations, including those defined in Sec 1081.10.4.4.2.
1081.10.7 2.5 Containment and Collection of Blast Residue. The collection of residue shall be in accordance
with Sec 1081.10.4.4.3.
1081.10.7 3 Application. Material application methods, air and surface temperatures and relative humidity shall
be in accordance with the manufacturer’s written instructions and Sec 1081.10.3. The most restrictive application and environmental requirements for the organic zinc shall be used when applying the primer to the steel.
1081.20 Galvanizing of Structural Steel.
1081.20.1 Scope. This specification covers galvanizing new and existing bridges and structures made of
structural steel and miscellaneous metals.
1081.20.2 Material. All material shall be in accordance with Division 1000, Material Details, and in
conjunction with: Item Specification Galvanizing ASTM A123 Galvanizing RepairASTM A780
1081.20.3 Galvanized Metal. Structural steel beams or girders, bracing and diaphragms shall be galvanized as
shown on the plans and in accordance with this specification. Galvanizing shall be applied after fabrication. Galvanized material on which the galvanizing has been damaged will be rejected or may, with approval from the engineer, be repaired in the field, fabrication shop, or at the galvanizing facility by the zinc alloy stick method in accordance with this specification. Required field welds and adjacent areas on which galvanizing has been damaged shall be galvanized by this same repair method. The area to be regalvanized shall be thoroughly cleaned, including the removal of slag on welds. Touch-up of galvanizing of sheet material less than 3/16 inch may be completed by the use of an approved aluminum epoxy mastic coating if the material will not be in direct contact with concrete or with an approved non-aluminum epoxy mastic coating if the material will be in direct contact with concrete. Other protective coatings specified in ASTM A780 will not be permitted for galvanized beams, girders, bracing and diaphragms. 7521081.20.4 Acceptance Criteria. All galvanized steel products shall be free from any bare steel, blisters, flux deposits, and dross inclusions. The minimum average coating thickness shall be 3.9 mils and the maximum average coating thickness shall be 25 mils. The finished galvanized product shall be uniform in appearance with no lumps, projections, indentations, globules, runs, sags, or heavy build-up at welded joints. 753SECTION 1091 LIGHTING EQUIPMENT 1091.1 Lighting Poles. 1091.1.1 Pre-Approval. Fabricators shall submit two copies of shop drawings to Traffic. Submittals shall be approved by Traffic in writing prior to fabrication of the lighting poles. Shop drawings shall indicate design details required for pole fabrication, including material grades and thicknesses, welding and orientation of any longitudinal seams. Shop drawings shall provide pole installation and hardware details. Design details for all possible pole combinations shown on the plans may be submitted. Shop drawings stress calculations shall be signed and sealed by a registered professional engineer in the State of Missouri. Upon written approval, pre- approved drawings may be used on any project where the design conditions of the shop drawings are not exceeded. 1091.1.2 Requirements. Lighting poles shall be steel or aluminum in accordance with the contract and shall be of the same material and design throughout the project. Poles shall be of the type shown on the plans. The fabricator may furnish poles with other shapes, gages and dimensions meeting or exceeding those shown on the plans and specifications. The mounting height of the slipfitter above the pavement and the pole design numbers will be specified by numbers following the pole type designation. Clamps shall be provided for connecting bracket arms to poles to obtain the specified mounting height. All poles shall have removable raintight metal pole caps. All handhole covers and pole caps shall be attached to the pole with a chain constructed of the same material as the pole and shall be held in place by screws. The screws shall penetrate through the metal cap or cover and pole securely attaching the cap or cover to the pole. The chain shall be capable of supporting at least six times the weight of the cover or cap and be securely attached to the inside of the pole and of sufficient length to allow removal of the cover or cap for maintenance access. An aluminum or stainless steel identification tag with embossed or engraved letters and numbers shall be provided with all poles as shown on the plans. The tag shall be attached to the pole 6 inches above the top of the handhole or 18 inches above the base plate over the transformer base door. Shims may be used between the pole base or transformer base and the foundation for leveling purposes. Four copies of applicable pre-approved drawings shall be supplied with the poles and shall be provided to the engineer. 1091.1.2.1 Type AT. Each Type AT pole shall be provided with a transformer base in accordance with Sec 901. A grounding conductor shall be attached to the ground lug in each transformer base as shown on the plans. 1091.1.2.2 Type B and MB. Each Type B and MB pole shall have a wiring handhole with a suitable metal cover near the base using a grounding lug inside the pole as shown on the plans. A grounding conductor shall be attached to the ground lug in each pole as shown on the plans. 1091.1.2.3 Steel. Steel lighting poles shall be round or octagonal shaft poles. The shaft section shall be fabricated from basic oxygen or open hearth steel sheet, No. 11 gage, as one continuous shaft or as individual segments no less than 10 feet in length, joined together using electrically welded, intermediate, transverse, full penetration, circumferential joints. Each sheet shall be formed into a tube with one continuous-welded longitudinal seam. After manufacture, the material shall have a minimum yield strength of 48,000 psi, including the weld. Poles shall be manufactured with steel shoe bases or base plates attached to the lower end of the shafts and arranged for bolting to a transformer base or to a foundation. All base plates and shoe bases shall be equipped with four cast steel or cast iron nut covers in accordance with AASHTO M 103 or M 105 or four aluminum nut covers and shall have four galvanized or stainless steel screws for securing covers to the pole. Welding and fabrication of the assemblies shall be in accordance with the ANSI/AWS D1.1 Structural Welding Code-Steel. All poles, shoe bases, base plates and cast steel or cast iron nut covers shall be fully galvanized after fabrication. 1091.1.2.3.1 For shoe base-type poles, each shoe base shall be a one-piece casting in accordance with AASHTO M 103, Grade 65-35 with four anchor bolt holes. Each shoe base shall consist of a collar, flange and gussets, all integrally cast. Ample fillet radii shall be provided at the juncture of these components to reduce the effects of stress concentration. The flange of the base shall be flat and continuous around the outside of the collar. The base shall telescope from the shaft and be secured by two continuous welds. One weld shall be on the inside of the base at the end of the shaft and the other weld shall be on the outside at the top of the base. The shoe base shall be arranged for bolting to a transformer base or to a foundation. 7541091.1.2.3.2 For base plate-type poles, the base plate shall be no less than 13 inches square and no less than 1 1/4 inches thick. 1091.1.2.4 Aluminum. 1091.1.2.4.1 Aluminum lighting poles shall be round shaft poles. Each shaft shall be manufactured as a two- piece pole by the spun drawn method from seamless extruded aluminum tubing, ASTM B 221, Alloy 6063-T6 and shall have a nominal wall thickness for the lower section of 0.250 inch and a nominal wall thickness for the upper section of 0.188 inch. The one-piece shaft for 30-foot mounting height shall have a nominal wall thickness of 0.188 inch, except those with twin-truss type arms shall have a nominal wall thickness of 0.250 inch. Shoe base-type poles shall be manufactured with heavy cast aluminum shoe bases attached to the lower ends of the shafts. Each shoe base shall be a permanent mold casting in accordance with ASTM B 108, Alloy 356.0-T6 and shall be free from cracks, pits and blowholes. The shoe base shall be arranged for bolting to a transformer base or to a foundation. The base shall have four anchor bolt holes, shall be equipped with four cast aluminum bolt covers and shall have four stainless steel fasteners for securing covers to the shoe base. Each shoe base shall consist of a collar, flange and gussets, all integrally cast. Ample fillet radii shall be provided at the juncture of these components to reduce the effects of stress concentration. The flange of the base shall be flat and continuous completely around the outside of the collar. The base shall telescope from the shaft and be secured by two continuous welds. One weld shall be on the inside of the base at the end of the shaft and the other weld shall be on the outside at the top of the base. The base and shaft shall be welded in the T4 temper with filler alloy 4043 and precipitation heat treated, artificially aged, to the T6 temper by an approved method after welding. Welding shall be in accordance with Article 6.9 of AASHTO’s Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals. 1091.1.2.4.2 At the fabricator’s option, the shafts for aluminum lighting poles may be formed from one piece of aluminum sheet, ASTM B 209, Alloy 5086-H34, having one continuous weld. The one-piece shaft for the 30- foot mounting height shall have a 9-inch diameter at the base and a nominal wall thickness of 0.135 inch. Shafts for 35 to 55-foot mounting heights shall have a 13.4-inch diameter at the base and a nominal wall thickness of 0.135 inch for both sections. Each shoe base shall be a permanent mold casting having an integral cast aluminum riser and shall be in accordance with ASTM B 108, Alloy 356.0-T6 and shall be free from cracks, pits and blow holes. The integral riser shall be designed to slip-fit into the pole shaft a sufficient distance to develop the full strength of the pole. The riser shall be bonded to the shaft with a structural epoxy adhesive that shall develop the strength of the pole. The epoxy shall develop a minimum of 1,200 psi in shear when tested in accordance with ASTM D 1002. The shoe base shall have four anchor bolt holes, shall be equipped with four cast aluminum bolt covers and shall have four stainless steel fasteners for securing the covers to the shoe base. Each shoe base shall consist of a collar, flange and gussets, all integrally cast. The flange of the shoe base shall be flat. 1091.2 Transformer Bases. Transformer bases shall be permanent mold castings in accordance with ASTM B 108, Alloy 356.0-T6 and shall be free from cracks, pits and blow holes. The transformer base shall be designed to accommodate and provide access to electrical equipment. The base shall have internal lugs for mounting on a foundation and shall be designed for bolting to the base plate of the lighting pole using flat and lock washers. A grounding lug shall be provided in each base. The access opening shall have a hinged fiberglass or plastic door with a tamper-resistant fastening device. The outside of the door shall be imprinted or adequately labeled with the warning, "DANGER - HIGH VOLTAGE". No direct payment will be made for transformer bases. 1091.3 Circular Steel Pile Foundations. Circular steel pile foundations, the steel connector plate and steel closure plate shall be of the dimensions shown on the plans. The slotted hole may be saw cut or flame cut. All sharp edges shall be ground smooth. The steel connector plate and steel closure plate shall be welded to the steel pile foundation. The foundation assembly shall be fully galvanized after fabrication. Bolts shall project no less than 1/4 inch nor more than 5/8 inch beyond the nut when properly tensioned. Flat and lock washers shall be used for attachment. 1091.4 Steel H-Pile Foundations. Steel H-pile foundations and steel connector plates shall be of the dimensions shown on the plans. The steel connector plates shall be welded to the H-pile foundation. The foundation assembly shall be fully galvanized after fabrication. Bolts shall project no less than 1/4 inch or more than 5/8 inch beyond the nut when properly tensioned. Flat and lock washers shall be used for attachment. 1091.5 Screw Anchor Foundations. Screw anchor foundations and steel connector plates shall be of the dimensions shown on the plans. The slotted hole may be saw cut or flame cut. All sharp edges shall be ground 755smooth. The steel connector plates shall be welded to the screw anchor shaft. The foundation assembly shall be fully galvanized after fabrication. Bolts shall project no less than 1/4 inch nor more than 5/8 inch beyond the nut when properly tensioned. Flat and lock washers shall be used for attachment. 1091.5.1 Fabricators for screw anchor foundations shall submit four copies of shop drawings to Traffic. Shop drawings shall indicate complete design details required for fabrication, including material grades, dimensions, thicknesses and welding. Shop drawings shall provide installation procedures and indicate the maximum torque ratings of the foundations. 1091.5.2 Submittals shall be approved by Traffic in writing prior to fabrication. Upon written approval, pre- approved drawings may be used on any project where the design conditions of the shop drawings are not exceeded. 1091.6 Bracket Arms. Bracket arms shall be similar in design to those shown on the plans, arranged for 2-inch slipfitter luminaire mounting, and shall be attached to the poles as shown on the plans. Bracket arms shall be of the same material as the pole. Bracket arm mounting plates shall match the shape of the pole. A one-inch pipe nipple shall be welded in place in the wire entrance hole on the mounting plate. The welds shall be placed on the side of the plate away from the pole. Flat and lock washers shall be used for attachment. 1091.7 Luminaires. 1091.7.1 Pre-Approval. Manufacturers of LED luminaires shall submit a completed New Product Evaluation Form. Family grouping in accordance with LED Lighting Facts is permitted, provided this is clearly indicated on the submittal form, and clearly communicated via a letter that includes detailed calculations relating the tested product to the submitted product. The luminaire size shall be as specified in the contract. A pipe stop shall be included in the assembly to locate the luminaire properly on the bracket arm. Product cutsheets shall be submitted for luminaire, LED light source, LED driver and surge protection device, if applicable. If dimmable LED driver is specified, provide diagrams illustrating light output and input power as a function of control signal. Instructions for installation and maintenance of LED luminaires shall be provided. Summary of luminaire recycled content and recyclability in accordance with the FTC Green Guides, expressed as a percentage of luminaire weight. IES LM-79 luminaire photometric report shall be produced by a test laboratory that satisfies LED Lighting Facts accreditation requirements. The report shall include, name of test laboratory, report number, date, complete luminaire catalog number, description of luminaire, LED light source, LED driver, and Goniophotometry. IES TM-15 Backlight-Uplight-Glare (BUG) ratings shall be for initial (worst- case) values, i.e., Light Loss Factor (LLF) = 1.0. If luminaires are tilted upward for Energy Star TM-21 calculations, BUG ratings shall correspond to the same angle of tilt. 1091.7.1.1. Lumen maintenance calculations and supporting test data shall be in accordance with LED Lighting Facts guidance, with the exception calculations shall be based on 50,000 cumulative hours of operation and an ambient temperature range of max. 40°C (104°F) to min.-20°C (-4°F). Submit completed ENERGY STAR TM- 21 Calculator as an electronic excel file. Provide computer-generated point-by-point photometric analysis of maintained light levels. Calculation/measurement points shall be per IES RP-8. Separated vehicular lanes, bikeways, and walkways shall be evaluated separately. Calculations shall be for maintained values, i.e. Light Loss Factor (LLF) < 1.0, where LLF = LLD x LDD x LATF. Lamp Lumen Depreciation (LLD) shall be 0.90 or the value calculated in the Energy Star TM-21 calculations, whichever is lower. Luminaire Dirt Depreciation (LDD) shall = 0.90 and Luminaire Ambient Temperature Factor (LATF) shall = 0.96. Mesopic multipliers (i.e., effective luminance factors) shall not be used. All values shall assume photopic visual adaptation. Submit IES LM-63 format electronic file containing luminous intensity data associated with submitted LM-79 report(s) and used for point-by-point calculations. Summary of Joint Electron Devices Engineering Council (JEDEC) or Japan Electronics and Information Technology Industries (JEITA) reliability testing performed for LED packages. Summary of reliability testing performed for LED driver(s). Safety certification and file number indicating compliance with UL 1598. Applicable testing bodies are determined by the US Occupational Safety Health Administration (OSHA) as Nationally Recognized Testing Laboratories (NRTL) and include: CSA (Canadian Standards Association), ETL (Edison Testing Laboratory), and UL (Underwriters Laboratory). Documentation supporting any U.S. origin claims for the product, in accordance with FTC guidance. 1091.7.1.2. Before approval and purchase, vendor shall supply luminaire sample(s) identical to product configuration(s) submitted for inspection. Commission may request IES LM-79 testing of luminaire sample(s) to verify performance is within manufacturer-reported tolerances. Electrically test fully assembled luminaires before shipment from factory. After installation, Commission may perform IES LM-50 field measurements to 756verify performance requirements, giving consideration to manufacturing tolerances and measurement uncertainties as outlined in IES LM-61 and NEMA LSD 63. 1091.7.1.3. Written product warranty shall be of the minimum duration of ten years, and shall cover maintained integrity and functionality of luminaire housing, wiring, connections, LED light source(s) and LED driver(s). Negligible light output from more than 10 percent of the LED packages constitutes luminaire failure. Warranty period shall begin 90 days after date of invoice, or as negotiated by Commission such as in the case of an auditable asset management system. Manufacturer or local sales representative shall provide installation and troubleshooting support via telephone and/or email. 1091.7.2 Requirements. 1091.7.2.1. Roadway. Luminaire shall be designed for ease of component replacement and end-of-life disassembly. Type III medium distribution, semi-cutoff light distribution shall be set in accordance with the manufacturer's recommendations unless otherwise directed by the engineer, or shown on the plans. Transmissive optical components shall be applied in accordance with OEM design guidelines to ensure suitability for the environment (e.g., electromagnetic, thermal, mechanical, chemical). LED light source(s) and driver(s) shall be RoHS compliant. Nominal luminaire input wattage shall account for nominal applied voltage and any reduction in driver efficiency due to sub-optimal driver loading. Luminaire shall accept the voltage or voltage range specified at 50/60 Hz, and shall operate normally for input voltage fluctuations of plus or minus 10 percent. All internal components shall be assembled and pre-wired using modular electrical connections. The following shall be in accordance with corresponding sections of ANSI C136.37, wiring and grounding, terminal blocks for incoming AC lines (electrical mains wires), photocontrol receptacle, latching and hinging, mounting provisions, and ingress protection. 1091.7.2.1.1.Underpass. Luminaires for underpass lighting shall be high-pressure sodium The luminaires shall consist of a pre-wired unit for wall mounting, with raintight cast aluminum housing, cast aluminum door with integral cast guard, heat-resistant glass prismatic refractor, asymmetric aluminum reflector and socket for horizontal lamp position, complete with 150-watt lamp and 240-volt or 480-volt ballast as required. Type IV short distribution, non- cutoff light distribution shall be set in accordance with the manufacturer's recommendations, unless otherwise directed by the engineer or shown on the plans. The door shall have a stainless steel hinge along the bottom, stainless steel latches at the top and non-ferrous metal or stainless steel safety chains. Provisions shall be made for attaching the unit directly to a wall or to an outlet box stud with non- ferrous metal or stainless steel hardware. Ballasts for underpass luminaires shall be in accordance with Sec 901. The ballast power cables shall be individually fused with in-line fuse holders between the line and load, in the junction box or the luminaire housing if no junction box is shown on the plans. The fuse rating shall be three amps unless otherwise shown on the plans. 1091.7.2.2. Painted or finished luminaire surfaces exposed to the environment shall exceed a rating of six per ASTM D1654 after 1000 hours of testing per ASTM B117. Each luminaire shall have aluminum housing with two 2-inch slipfitters or one 4-bolt slipfitter or one 2-inch slipfitter with a longitudinal leveling system. The housing shall have a natural aluminum or gray baked enamel finish. The coating shall exhibit no greater than 30% reduction of gloss per ASTM D523, after 500 hours of QUV testing at ASTM G154 Cycle 6. All metal parts, such as springs on the latches and hinges, U-bolts and screws shall be made from non-ferrous metal or stainless steel. All parts of the luminaire shall be fabricated from corrosion resistant material. 1091.7.2.3. Luminaire shall start and operate in ambient temperature range specified. Maximum rated case temperature of driver and other internal components shall not be exceeded when luminaire is operated in ambient temperature range specified. Wiring inside the luminaire housing shall be protected by suitable heat resistant insulating material. Mechanical design of protruding external surfaces (heat sink fins) shall facilitate hose-down cleaning and discourage debris accumulation. Liquids or other moving parts shall be clearly indicated in submittals, shall be consistent with product testing, and shall be subject to review by Commission. Luminaire designation indicated “ANSI C136.41, 7-pin” on New Product Evaluation Form shall be fully prewired and shall incorporate an ANSI C136.41 compliant receptacle. If a dimmable LED driver is specified, the 0-10V or DALI control wires shall be connected to the receptacle pads as specified in ANSI C136.41; connection of the two remaining pads shall be by Manufacturer, as directed by Commission. 1091.7.2.4. Luminaire shall be listed for wet locations by a U.S. Occupational Safety Health Administration (OSHA) Nationally Recognized Testing Laboratory (NRTL), shall have locality-appropriate governing mark and certification, and shall meet the performance requirements specified in ANSI C136.2 for dielectric withstand, 757using the DC test level and configuration. Luminaire shall meet the performance requirements specified in ANSI C136.2 for electrical immunity, using the combination Enhanced Wave Test Level (10kV/5kA) for whether failure of the electrical immunity system can possibly result in disconnect of power to luminaire. Luminaire shall comply with FCC 47 CFR part 15 interference criteria for Class A (non-residential) digital devices, and shall comply with section 5.2.5 (luminaires rated for outdoor use) of ANSI C82.77 at full input power and across specified voltage range. 1091.7.2.5. Color Rendering Index (CRI) shall be no less than 50. Nominal Correlated Color Temperature (CCT) shall be 3000k with allowable IES LM-79 Chromaticity Values of 2870 to 3220 measured CCT (k) and -0.006 to 0.006 Measured Duv. Luminaire shall have an external label per ANSI C136.15 and shall have an internal label per ANSI C136.22. 1091.7.3 Navigation. All lanterns shall be weatherproof and operate on a 120-volt system. Lanterns shall be of the fresnel lens-type and shall be fabricated from a corrosion-resistant material. Each lantern shall provide an LED or a standard service lamp with at least four standby lamps controlled by a lampchanger mechanism capable of illuminating the standby lamp after each lamp burnout. Mounting brackets and all accessories shall be provided with each lantern. A swing arm and retrieval chain shall be provided for main channel lanterns to hold the fixture in proper operating position. The swing arm and retrieval chain shall be capable of being locked in both the upright and inverted positions. Mounting brackets shall be fully galvanized or stainless steel, and all hardware shall be stainless steel. 1091.8 Control Stations. Control stations shall consist of all equipment and material necessary for the distribution of secondary electrical power as shown on the plans. Control stations will be specified by the secondary voltage. 1091.8.1 Cabinets. Control cabinets shall be of sufficient size to house all equipment as shown on the plans. All equipment such as circuit breakers, switches, contactors, fuses, photoelectric controls and terminal blocks shall be installed on the panel as shown on the plans. Control cabinets shall have a control panel constructed of the same material as the cabinet. Cabinets shall be NEMA 4, dust-tight, watertight and constructed of 0.125-inch minimum reinforced sheet aluminum alloy and be of clean-cut design and appearance. All hinges, catches and other hardware shall be non-ferrous metal or stainless steel. Cabinets shall have a No. 2 Corbin cabinet lock and provisions for locking with a padlock. Two keys for cabinet locks shall be furnished by the contractor. Mounting shall be as shown on the plans. 1091.8.2 Lightning Arrestors. Lightning arrestors shall be of the rated voltage as shown on the plans. 1091.8.3 Photoelectric Controls. Photoelectric controls shall be of the cadmium-sulfide or solid-state type operating on 120 volts or 240 volts, as shown on the plans and shall operate on a line supply of 50 to 60 hertz. The load capacity of the photoelectric cell relays shall be a minimum of 1,000 watts. Photoelectric cells shall operate a lighting system through mercury load relays or contactors as shown on the plans. The photoelectric cell circuitry shall be designed to be normally closed at night. The photoelectric cell shall be configured such that in the event of failure, the lights shall be on. The turn-on range shall be adjustable from 1.0 to 3.0 footcandle. A turn-on setting of 1.0 footcandle and a turn-off setting of 2.0 footcandles shall be made at the factory. The photoelectric cell shall have a time delay to avoid operation due to lightning and transient light. A suitable bracket for mounting the photoelectric cell shall be provided. The photoelectric cell shall be mounted into a three-prong twist lock socket. All top mount photoelectric controls shall face an open sky and side mount photoelectric controls shall face north. Each photoelectric control unit shall include a lightning arrestor. Test switches used with photoelectric controls shall be three-position switches or two single-pole breakers as shown on the plans. Test switches shall be clearly labeled and mounted in the control cabinet. 1091.8.4 Contactors. Contactors shall be NEMA Type 1 enclosed, magnetic-type, two-pole, single phase for 600 volts, 60-hertz service. The operating coil shall be designed for 120-volt or 240-volt operation as shown on the plans. The contactor shall be electrically held, have the minimum rating and shall be housed in the control cabinet as shown on the plans. Mercury load relays shall be two-pole, normally-open, mercury contact, magnetic-type with load capacity as shown on the plans. 1091.8.5 Circuit Breakers. All circuit breakers shall be molded-case thermal-magnetic circuit breakers. The number and trip rating of circuit breakers shall be as shown on the plans. All breakers shall be designed for panel mounting with cable connections on the line and load sides. 7581091.8.5.1 Type A Circuit Breakers. Type A circuit breakers shall have a minimum of 18,000 amps alternating current interrupting rating at 240 volts alternating current and 14,000 amps alternating current interrupting rating at 480 volts alternating current. Breakers shall be full-size and designed to accept wire sizes up to 2/0 AWG. Terminals shall be provided for the wire sizes as shown on the plans. 1091.8.5.2 Type B Circuit Breakers. Type B circuit breakers shall have a minimum of 10,000 amps alternating current interrupting rating at 240 volts alternating current. Type B circuit breakers shall have a nominal size no greater than one inch wide by 4 inches high by 3 inches deep. Terminals shall be configured for the wire sizes as shown on the plans. If the breaker terminals are not designed for the required wire sizes, suitable terminal adapters, connectors or terminal blocks shall be used to convert the wire sizes. 1091.9 Power Supply Assembly. 1091.9.1 Disconnect cabinets shall be NEMA 4, dust-tight and watertight. The operating handle shall have full cover interlock to prevent the door from opening when the breaker is on. The enclosure shall have provisions for padlocking the enclosure and for padlocking the switch in the on or off position. 1091.9.2 Meter boxes shall be NEMA 3R or NEMA 4.
1091.10 Cable Splicing.
1091.10.1 Splice blocks shall be designed for the wire size used, shall have one port per wire and the wires
secured with set screws. The set screw holes shall be protected with removable plugs.
1091.10.2 Resin splice kits shall consist of a protective plastic case designed for the type of connector used,
filled with a resin insulating compound mixed in accordance with the manufacturer's recommendations. 759SECTION 1092 SIGNAL EQUIPMENT 1092.1 Signal Heads. Signal heads shall meet the following requirements:
a.All signal heads shall be weatherproof and black in color in accordance with Sec 1092.1.1. All indications shall be 12 inches unless specified otherwise.
b.All signal indications in conventional signal heads shall be illuminated with LED modules. All LED modules, shall be in accordance with ITE Vehicle Traffic Control Signal Heads: Light Emitting Diode (LED) Circular Signal Supplement dated Jun 27, 2005, shall be Intertek ETL verified and shall be in accordance with the following:
1.The lens of each green indication shall be clear. If a polymeric lens is supplied, a surface coating shall be applied to provide abrasion resistance.
2.The LED modules shall not contain Aluminum Gallium Arsenide (AlGaAs).
3.The LED modules shall provide constant light output under power. Modules with dimming capabilities shall have the option disabled or shall be set on a non-dimming operation.
4.Module shall be labeled with “Manufactured in conformance with the ITE LED Circular Signal Supplement”.
5.Provided with spade adapters.
c.All arrow LED modules shall be in accordance with ITE Vehicle Traffic Control Signal Heads. Light Emitting Diodes (LED) Vehicle Arrow Traffic Signal Supplement dated July 1, 2007, shall be Intertek ETL verified and shall be in accordance with the following.
1.Be omni-directional.
2.The lens of each green arrow indication shall be clear.
3.Module shall be labeled with "Manufactured in conformance with the ITE LED Vehicle Arrow Traffic Signal Supplement".
4.Provided with spade adapters. 1092.1.1 Housing, Door and Visor. All new signal sections shall be clean, smooth and free from imperfections. The connection between signal housings shall be weatherproof. Housings shall be rigidly fastened together by a three- or four-bolt assembly or other connectors approved by the engineer. Doors that will exclude dust and moisture shall be used to ensure a weatherproof unit. A tunnel visor shall be supplied with each signal section and each door shall have provisions for attachment of the tunnel visor. All visors shall be held in place by four stainless steel fastening screws or bolts and shall be capable of being removed without opening the signal head door. Internal bosses or inserts shall be provided, in each housing, for mounting a terminal block and for the attachment of back plates. The top and bottom exterior of the housing shall be flat to ensure perfect alignment of assembled sections. The housing of each section shall be one piece with sides, back, top and bottom integrally molded. The design of the housing shall be such that, with the aid of simple tools and the addition of standard parts, it shall be possible to make any assembly consisting of one or more signal sections and, with the addition of standard bracket assemblies, assemble signal faces into multi-way traffic signal head configurations. The housings shall be polycarbonate. All material used in construction of polycarbonate signal heads shall be of ultraviolet stabilized color-impregnated polycarbonate resin. The housing shall have a minimum thickness of 0.09 inch and shall be ribbed or plated to produce added strength. If signal housings are not ribbed, minimum 0.10-inch aluminum plates shall be furnished and installed inside and outside the section housing at all points of attachment of the pipe bracket. 1092.1.2 Louvers. The degree of cut-off shall be stamped on the louver or printed on a decal on the front of the louver and shall be visible after installation. 7601092.1.2.1 Fixed louvers shall be formed of 0.025-inch sheet aluminum. The top and bottom bends of each fin shall be securely fastened to the inside of the supporting ring. The angles of cut-off from either side of the center axis of the light beam shall be provided by six types of louvers: Type A - 3 degrees, Type B - 7 degrees, Type C - 10 1/2 degrees, Type D - 14 degrees, Type E - 18 1/2 degrees and Type F - 26 1/2 degrees. 1092.1.2.2 Adjustable louver units shall be composed of an acrylonitrile butadiene styrene (ABS) plastic housing and polycarbonate baffles. The unit shall be designed to prevent light leakage between the housing and the visor, and shall have an adjustable view range of 7 to 42 degrees. All plastic material shall be ultraviolet stabilized. All hardware shall be brass or stainless steel. 1092.1.3 Hardware. Hardware shall be 1 1/2-inch galvanized steel or unfinished aluminum, except aluminum pipe brackets and side mount brackets. Aluminum pipe brackets shall have a spun finish. Side mount brackets may be constructed of molded, glass-impregnated polycarbonate no greater than 12 inches in length. Elbows, tees and crosses shall be straight threaded and furnished with a square head set screw at each connection point to ensure rigid mounting. Fittings attached to the signal housing shall incorporate serrations or, by the use of an adapter ring, shall be compatible with the serrations on the signal housing. 1092.1.4 Backplates. Backplates shall be provided on all signal heads as shown on the plans. Backplates shall be black in color and constructed of flat pre-cut or preformed thermoplastic. Flat pre-cut thermoplastic backplates shall have a minimum thickness of 0.250 inch. Preformed thermoplastic backplates shall have rolled out edges and a minimum final thickness of 0.10 inch. When as indicated in the plans, a retroreflective strip shall be placed along the perimeter of the backplate. The retroreflective strip shall be made from yellow sheeting in accordance with Section 1042. The retroreflective strip shall be adhered to the backplate as shown in the plan. 1092.1.5 Optically Limiting Signal Heads. All signal sections shall meet the following:
a.Each signal housing shall be die cast aluminum having a chromate preparatory treatment. The signal housing and lens holder shall be predrilled for backplates and visors. All access openings shall be sealed with weather resistant gaskets. Hinge and latch pins shall be non-ferrous metal or stainless steel. The lens holder and interior of the housing shall be optical black. The housing shall mount to standard 1 1/2-inch fittings as a single section, as a multiple section face or in combination with conventional signals. The signal housing shall be provided with an adjustable connection that permits incremental tilting from zero to 10 degrees above or below the horizontal while maintaining a common vertical axis through the mounting assembly. The housing connection shall permit external adjustment about the mounting axis in 5-degree increments. Attachments such as visors, backplates or adapters shall readily fasten to mounting surfaces without affecting the weatherproof characteristics and light integrity of the signal.
b.The optical system shall consist of an objective lens, optical limiter-diffuser, lamp, lamp fixture and optical masking tape.
1.The objective lens shall be a high-resolution planar incremental lens, hermetically sealed within a flat laminate of weather-resistant acrylic or approved equivalent. The lens shall be symmetrical in outline and if rotated to any 90-degree orientation about the optical axis, shall not displace the primary image.
2.The optical limiter-diffuser shall provide an accessible imaging surface at focus on the optical axis for objects up to 1,200 feet distant and shall permit an effective veiling mask to be applied as determined by the desired visibility zone. The optical limiter-diffuser shall be provided with positive positioning and shall be composed of heat resistant glass.
3.The lamp shall be in accordance with Sec 1092.1, and shall have an integral reflector. The lamp shall be attached to the diffusing element with a collar having a specular inner surface.
4.The lamp fixture shall consist of a separately accessible housing and integral lamp support, an adjustable ceramic socket and a self-aligning, quick release lamp retainer. Electrical connection between section housing and lamp housing shall be accomplished with an interlock assembly that disconnects the lamp holder when the door is opened. 761(5) A signal lamp intensity control shall be supplied in each signal section to provide dimming of the signal lamp as the ambient light intensity drops below approximately 3 footcandles. 1092.1.6 Pedestrian LED Countdown Signal Heads. Pedestrian LED countdown signal heads shall include two LED signal modules, one indicating a “WALKING PERSON” and “UPRAISED HAND” icon and the second a two digit numeric pedestrian change interval countdown display to inform pedestrians of the number of seconds remaining in the pedestrian change interval and any array of LEDs and related power supplies and any required lenses which, when connected to appropriate power, provides a single pedestrian signal indication and a countdown signal in a single housing unit. LED pedestrian signal countdown heads shall be in accordance with ITE specifications and standards for Pedestrian Traffic Control Signal Indicators: Light Emitting Diode (LED) Signal Modules dated August 4, 2010 and the following:
a.Pedestrian LED countdown signal head housings shall be constructed of a black, one-piece, 0.250- inch thick, polycarbonate material as shown on the plans. The housing shall include an integral mounting bracket designed for mounting on the side of the pole on all makes of signal poles with a terminal compartment and minimum 5-position, double-row terminal block.
1.The door, lens and any openings in the housing shall have gaskets or seals to exclude dust and moisture from the inside of the compartment.
2.Lenses shall be constructed of polycarbonate material and reduce glare.
3.Lenses shall be hard coated or otherwise made to comply with the UV material exposure effects of the Society of Automotive Engineers (SAE) J576.
4.Lenses shall be a replaceable part, without the need to replace the complete LED signal housing.
5.Pedestrian LED countdown signal head housing shall be provided with a manufactured, preformed rectangular visor or screen-type louver.
b.Indications on LED signal modules shall be ITE Class 3 for icons and countdown display digits Icon and countdown modules shall be Intertek ETL verified and be in accordance with the following:
1.The LED module lenses shall use transparent film or materials with similar characteristics.
2.Modules, conforming to this specification, shall be labeled with the following statement, “Manufactured in Conformance with the ITE Pedestrian Traffic Control Signal Indicators: Light Emitting Diode (LED) Signal Modules”.
3.Modules with dimming capabilities shall have the option disabled or shall be set on a non-dimming operation.
4.LED signal modules displaying ITE Class 3 icons shall be constructed such that both the “WALKING PERSON” icon and the “UPRAISED HAND” icon are displayed from the same module on the same rectangular surface area. The illumination of one icon shall not result in the illumination of the other icon.
5.Supplied with spade adapters.
c.If the pedestrian change interval is interrupted or shortened as part of the transition into a preemption sequence the countdown pedestrian signal display should be discontinued and go dark upon activation of the preemption transition.
d.The countdown learning cycle shall only be initiated after the initial installation, a return from a power failure greater than 2 seconds, a repeated demand to change programming, or after preemption. During the learning cycle, the countdown display shall remain blank. The learning cycle shall not last more than two complete cycles. 7621092.1.7 Finishing. Mounting brackets and hardware, except the aluminum pipe brackets and polycarbonate side mounted brackets, shall be galvanized steel or unfinished aluminum. Aluminum pipe brackets shall have a spun finish. Painting of the mounting brackets and hardware will not be permitted. 1092.2 Posts and Mast Arms. A grounding lug shall be provided for all units. A grounding conductor shall provide grounding continuity for all metallic, noncurrent carrying poles in one circuit. 1092.2.1 Steel Pedestal Posts. Steel pedestal posts shall be 4 1/2-inch outside diameter schedule 40 steel pipe. The base shall be cast iron, free from imperfections, and shall be provided with a suitable plastic, fiberglass or cast door for wiring access. The grounding lug shall be inside the base. The bolt circle and hole diameter shall be as shown on the plans. After fabrication, posts and bases shall be fully galvanized. 1092.2.2 Aluminum Pedestal Posts. Aluminum pedestal posts shall be schedule 80 straight tubing of 6063-T6 aluminum alloy in accordance with ASTM B 210, with a 4 1/2-inch outside diameter. The pedestal base casting shall be either permanent mold casting of Alloy 356.0 F, in accordance with ASTM B 108, or sand castings of Alloy 356.0 F, in accordance with ASTM B 26. The base shall be free from imperfections and shall be provided with a suitable door for wiring access. The base and post shall be joined by a threaded connection. Welded connections will not be permitted. The grounding lug shall be provided inside the base. All hardware shall be non-ferrous metal or stainless steel. 1092.2.3 Signal Post and Mast Arm Pre-Approval. Fabricators shall submit six copies of shop drawings and supporting calculations to Traffic. Submittals shall be approved by Traffic in writing prior to fabrication of the signal posts and mast arms. Shop drawings shall indicate complete design details required for post and mast arm fabrication, including material grades and thicknesses, welding and orientation of any longitudinal seams. The projected areas and weights of signs and signals used in the design of the post and mast arms shall be shown on the shop drawings. Design details for all possible post and mast arm combinations shown on the plans may be submitted. Shop drawings shall provide post and mast arm installation and hardware details. All welding procedures shall be prepared by the manufacturer as a written procedure specification and shall be submitted with the shop drawings for approval. Approval of the weld procedures will be required before approval of the shop drawings. Shop drawings shall indicate the specific approved welding procedure to be used for each joint. Shop drawings and supporting stress calculations shall be signed and sealed by a registered professional engineer in the State of Missouri. Manufacturers shall submit all required documentation, in accordance with Sec 1092.2.4.3. Upon written approval, pre-approved drawings may be used on any project where the design conditions of the shop drawings are not exceeded. 1092.2.4 Steel Posts and Mast Arms. Steel posts and mast arms shall be continuously tapered, hollow shafts fabricated as one continuous shaft or as individual segments at least 10 feet long, joined together using electrically welded, intermediate, transverse, full penetration, circumferential joints. Steel posts and mast arms shall be fabricated from basic oxygen or open-hearth steel sheet. The continuous, tapered, hollow shafts or individual segments shall be manufactured from one or two lengths of steel sheet, with one or two continuous, welded, longitudinal seams. The longitudinal seams in the mast arm shall be located outside of the upper half of the cross section of the member. Where transverse, full penetration, circumferential welds are used, the fabricator shall furnish to the engineer written certification that 100 percent of all such welds have been radiographed or ultrasonic tested by an independent testing agency using a qualified non-destructive testing technician, as described in Section 6.14.7 of ANSI/AWS D1.1 Structural Welding Code-Steel and equipment calibrated annually. The testing agency shall be approved by the engineer prior to fabrication. Post base and mast arm attachment plates shall be plate steel attached to the larger end of the shafts by continuous welds on the inside and outside of the shaft. After manufacture, the material shall have a minimum yield strength of 48,000 psi. 1092.2.4.1 A handhole equipped with a suitable metal cover shall be provided in the post near the base, and 12 inches above the mast arm connection if luminaire mounting is specified. A grounding lug or connector shall be provided inside the post near the handhole. A removable raintight metal pole cap shall be provided on the top of the post and on the small end of each mast arm. All handhole covers and metal caps shall include a galvanized steel chain. The chain shall be capable of supporting at least six times the weight of the cover or cap and be securely attached to the inside of the post or arm, with sufficient length to allow removal of the cover or cap for maintenance access.. The pole caps and handhole covers shall be securely attached to the post with screws that penetrates through the cap or cover and the post or arm. An aluminum or stainless steel identification tag shall be provided with all posts and mast arms as shown on the plans. The letters and numbers on the tag shall be embossed or engraved. The post tag shall be attached to the pole 6 inches above the top of the handhole. The 763mast arm tag shall be attached 3 inches from the base of the end cap. The base plate shall be equipped with four cast steel or cast iron nut covers in accordance with AASHTO M 103 or M 105, or four aluminum nut covers and shall have four galvanized or stainless steel screws for securing covers to the pole. All poles, shoe bases, base plates and cast steel or cast iron nut covers shall be fully galvanized after fabrication. All anchor bolt nuts shall be completely covered by nut covers. Luminaire bracket arms, when specified, shall be included with the post and mast arm. The contractor may furnish posts with the shape, gage and dimensions meeting or exceeding those required by the plans and specifications, provided shop drawings are submitted and approved in accordance with Sec 1092.2.3. 1092.2.4.2 Welding and fabrication of the assemblies shall be in accordance with the ANSI/AWS D1.1 Structural Welding Code-Steel. All requirements of the welding code for tubular structures will apply to the fabrication for the post and mast arm shafts and shall include any welds used to attach these members to plates or other hardware. The manufacturer shall employ qualified personnel to perform all visual and nondestructive testing (NDT) required. In addition to the visual inspections and NDT that may otherwise be required by the welding code, the manufacturer shall perform 100 percent magnetic particle (MT) testing of circumferential fillet welds used to attach the flange plate to the larger end of the mast arm shaft. NDT personnel shall be qualified as set forth in paragraph 6.14.7 of ANSI/AWS D1.1 Structural Welding Code-Steel. Qualifications of NDT personnel shall be submitted to the engineer for approval. 1092.2.4.3 The post and mast arm manufacturer shall be certified under the AISC certification program, Conventional Steel Building, or higher category. Evidence of current AISC certification will be required prior to the approval of shop drawings, and lapsing of the certification will be cause for the manufacturer's removal from the approved list of suppliers. 1092.2.4.4 Steel posts, luminaire bracket arms, mast arms, nut covers and plate steel bases shall be hot-dip galvanized inside and out after fabrication, visual inspections and NDT testing. Galvanized material shall be handled in such a manner to avoid damage to the surface. Any galvanized material on which the coating has been damaged will be rejected or may, with approval from the engineer, be repaired in accordance with Sec 1081. 1092.2.5 Fabricator's Certification. Prior to erection of the posts and mast arms, the contractor shall furnish to the engineer a fabricator's certification. The certification shall specifically state the fabricated posts and mast arms have been quality control inspected by the fabricator and all material and manufacturing processes used were in full compliance with the specification requirements and the approved shop drawings and weld procedures. Certification shall be accompanied by supporting documentation, including the results of the visual inspections and NDT in accordance with Sec 1092.2.4.2 and copies of the pre-approved drawings required by Sec 1092.2.3. 1092.3 Lighting Control Cabinet. The lighting control cabinet shall contain a control panel constructed of the same material as the cabinet. Circuit breakers, the photoelectric switch, a contactor, if specified, and any other specified equipment for luminaire control shall be installed on the panel. Control cabinets shall be of sufficient size to house all equipment shown on the plans. Cabinets shall be dust tight, watertight, NEMA 4 and constructed of aluminum or stainless steel. All hinges, catches and other hardware shall be stainless steel. Cabinets shall have a No. 2 Corbin cabinet lock. Photoelectric switches and contactors shall be in accordance with Sec 901. Circuit breakers shall be Type B circuit breakers in accordance with Sec 901. 1092.4 Traffic Controller Assemblies. Traffic controller assemblies will be defined as the complete assembly of all required equipment and components for control of traffic signal indications. The type of controller assembly required for each location shall be as specified in the contract documents. 1092.4.1 NEMA TS1. Each NEMA TS1 controller assembly shall consist of a controller cabinet, signal controller, back panel, conflict monitor, card rack assembly, all required wiring, switches and connectors and all other equipment as defined in these specifications and as shown on the plans. Double controller assemblies to control two intersections shall consist of a controller cabinet, two signal controllers, two back panels, two conflict monitors, two card rack assemblies, all required wiring, switches and connectors and all other equipment as defined in these specifications and as shown on the plans.
a.Each controller and associated equipment shall be designed to operate on 120 volts, 60 hertz, single phase, alternating current. 764(b) Variations in the voltage of the power supply of ± 10 percent or sustained temperatures inside the cabinet between -20 and 165 F shall not change the total time cycle of pretimed controllers or the length of any interval, portion, period or unit extension of actuated controllers by more than five percent or cause electrical or mechanical damage. Heater elements shall not be used to attain compliance with these requirements.
c.Vibration shall not affect normal operation of any equipment.
d.All controllers and other specified auxiliary equipment shall be properly protected with fuses on each applicable unit. Fuses shall be installed in 1/4-twist or screw-in type fuse holders. Pop-out fuse holders will not be permitted. 1092.4.1.1 Controller Cabinets. Controller cabinets shall be cast aluminum or 0.125 inch reinforced sheet aluminum alloy and shall be of clean-cut design and appearance. The cabinet shall provide ample space for housing all equipment and components. Controller cabinets housing solid state controllers shall be furnished with unused cabinet space measuring 18 inches wide by 12 inches high by 12 inches deep, unless coordination equipment is specified on the plans. For pretimed and actuated NEMA controllers, the cabinet shall support a sixteen-position back panel. Double controller cabinets for two controllers shall support two sixteen-position back panels. All double cabinets shall have two doors that are hinged on the outside corners of the cabinet such that the doors open away from each other. Double cabinets shall have a divider between the two halves of the cabinet with an 8-inch opening between the compartments at the bottom of the divider for wiring between the compartments. The cabinet shall contain a rigid mounting table, sliding ways or hinged support of such construction that the controller and auxiliary equipment may be withdrawn from the cabinet without breaking any electrical connections or interrupting normal controller operation. Hinged supports shall be welded to the controller cabinet. Electrical connectors on the controller and auxiliary equipment to all circuits shall be NEMA 1/4 twist or MS type. Components of controller cabinets shall meet the following requirements.
a.A hinged door or doors shall provide complete access to the interior of the cabinet. Door holds shall secure the door in an open position at least 90 degrees from the closed position and shall be furnished with each cabinet. The doors shall fit against a raintight gasket. Each door shall have a stamped or raised outside designation, "Traffic Control" or other approved identification. Each main cabinet door shall have a No. 2 Corbin cabinet lock and provisions for locking with a padlock. The handles for each door shall swing outward. An auxiliary door, positioned on each main cabinet door, equipped with a raintight gasket, shall allow access to a police panel and shall be equipped with a lock whose key will not unlock the main door. Two keys shall be furnished for each type lock used. The door hinges and pins shall be of corrosion-resistant metal. Pins shall be rolled or solid rod, at least 1/8 inch in diameter, except if continuous hinges are furnished, the pins shall be continuous the full length of the hinges, and shall be no less than 1/16 inch in diameter.
b.The back panel in all controller cabinets shall be hinged at the bottom to permit the top of the panel to be rotated forward and down to an angle of no less than 45 degrees with all components, including load switches, attached for maintenance purposes. The bottom of the back panel shall be no less than 6 inches above the bottom of the cabinet.
c.Cabinets housing solid state controllers shall have a thermostatically controlled ventilating fan with exhausting capability in an enclosure of at least 150 cubic feet per minute for cabinets up to 30.5 cubic feet and at least 250 cubic feet per minute for cabinets 30.5 cubic feet and more, installed in the top of the cabinet. Cabinets shall be supplied with a replaceable furnace-type fiberglass filter of at least one square foot area mounted behind louvers in the lower one-fourth of the door.
d.Each controller cabinet shall be furnished with a clearly labeled switch mounted in the access or police panel to place the signals on flash. Operation of this switch shall not affect the electrical power supply to the controller. This shall be the only control switch accessible from the police panel.
e.Each cabinet shall be provided with a grounded service outlet and a switch-controlled lamp receptacle.
f.Each cabinet shall contain a separate aluminum power panel containing the following equipment. 765(1) Two Type B circuit breakers in accordance with Sec 901. One breaker shall interrupt power to the controller and signals. The frame size and trip rating will be shown on the traffic signal plans or designated in the contract. The second Type B circuit breaker shall be an auxiliary breaker that interrupts power to the cabinet lamp and receptacle. The frame size and trip rating shall be 15 amperes.
2.One mercury contactor controlling power to the signal bus.
3.One radio frequency line filter.
4.One line surge protector.
5.One terminal block for alternating current power input.
6.One ground bus terminal block.
7.One isolated neutral bus terminal block.
g.If specified, a manual operation push button shall be installed in the police panel. The push button shall be wired for manual operation of the signals. The push button shall be water-resistant, designed to protect the user against electrical shock, and shall be supplied with a coiled cord with a nominal 6-foot stretched length. A clearly labeled switch shall also be installed in the police panel to switch between manual or automatic operation of the controller. 1092.4.1.2 Flasher Unit. Each controller, through terminal options, shall permit yellow-red or red-red flash operation. Indications shall be flashed at no less than 50 or more than 60 flashes per minute, with approximately 50 percent dwell time. A two-circuit flasher, alternate flash and three flasher field circuits for each of the two flasher circuits will be required. A separate flasher shall provide flashing pedestrian indications when required by the contract. The timing of flashing pedestrian intervals shall be separately adjustable from all other timed intervals. The flasher shall be solid state with ratings of at least 15 amperes per circuit and shall comply with the latest revision of NEMA Standards Publication TS. The flasher units shall have a 150-volt metal oxide varistor (MOV) placed on each output flash terminal. Uniform code flash circuitry will be required for each controller. Flashing operation shall be in accordance with the MUTCD. 1092.4.1.3 External Time Switches. External time switches shall be solid state, keyboard entry and shall contain filtering and shielding circuitry to protect the unit's operation against electrical interference. Timing shall be based on the 60-hertz power supply frequency. Each unit shall contain a programmable automatic central daylight time compensation feature and a back-up power source to maintain time and memory functions during loss of alternating current power. Each unit shall provide a weekly program with at least 20 event changes per week. 1092.4.1.4 Wiring. The controller cabinet shall be equipped with a 600-volt heavy-duty one-piece mechanical screw connector offset tang assembly attached to a barrier terminal strip for terminating field conductors. Each mechanical screw connector shall accommodate up to four No. 12 AWG conductors. The connector shall be mounted horizontally on the inside back of the cabinet, approximately 6 inches from the bottom of the cabinet. All wiring to the terminal strips, except the incoming field circuits, shall be performed by the controller manufacturer. The terminal strips shall accommodate at least:
a.Two terminals for the power supply.
b.An unfused terminal for neutral side of power supply line.
c.One terminal for each signal lamp circuit and one terminal for the common return from each signal face.
d.If detectors are used:
1.Two terminals for each detector. 766(2) Screw terminal strips mounted vertically on the side of the cabinet approximately 6 inches from the bottom of the cabinet.
3.All inductive loop detector inputs shall be protected with two 30-volt MOVs with a 30-j rating. An MOV shall be connected between each field terminal and cabinet ground.
e.Terminals for interconnect cable when the controller is to be hard-wire interconnected shall be fused and provided with a 150-volt MOV with an 80 j rating.
f.Terminals for closed loop system interconnect cable shall be fused and provided with a 30-volt MOV with a 30 j rating. 1092.4.1.5 Back Panel Wiring. Regardless of the number of phases specified on the plans, all load switch positions shall be completely wired for use. If pedestrian phases are not specified, twelve-position back panels for actuated NEMA controllers shall be configured for operation of eight phases and four overlaps. If pedestrian phases are specified, 12-position back panels shall be configured for operation of eight phases and four pedestrian phases or a combination of overlaps and pedestrian phases if specified on the plans. If flashing yellow arrow operation is called for, the appropriate load switches shall be configured as specified on the plans. Twelve-position back panels for pretimed controllers shall be configured for operation of 36 circuit outputs from the controller unless otherwise specified on the plans. A flash transfer relay socket shall be provided for each pair of load switch positions. Flash circuit one shall be wired to positions one, 3, 5, 7, 9 and 11. Flash circuit 2 shall be wired to positions 2, 4, 6, 8, 10 and 12. All flash transfer relay sockets shall be fully wired for operation. All controller harness wiring shall be connected to labeled terminals on the front of the panel. 1092.4.1.6 Solid State Controllers. This section describes the general specifications for actuated solid state controllers. If requested by the engineer, the contractor shall provide a prototype controller for testing and evaluation.
a.Each controller shall be solid state keyboard entry and the circuit design shall use microprocessor techniques.
b.Timing shall be accomplished in a digital manner by counting the 60 hertz power supply frequency. Timing circuits, interval and phase switching functions shall be accomplished by solid state circuitry. Removing, changing wires or using any tools to make timing interval adjustments shall not be necessary. The controller shall indicate the right of way conditions of the phase timing interval in effect, detector or actuation on each phase and memory conditions or demand on each phase for vehicles and pedestrians by use of status lights or display panels. The controller shall be capable of flashing yellow arrow operation without any external devices or special software upgrades.
c.Opening and closing of signal lamp circuits shall be performed by plug-in solid state load switches, rated at no less than 10 amperes and loaded at a maximum of 6.7 amperes, located external to the controller. All load switch jacks shall be completely wired to field output terminal strips. Actuated and pretimed controllers shall have a minimum of twelve load switch jacks. Each load switch shall provide three independent circuits with "on" indicator lamps and shall comply with the latest revision of NEMA Standards Publication TS.
d.Each controller assembly shall contain a conflict monitor external to the controller circuitry conforming to NEMA Standards Publication TS and be capable of monitoring flashing yellow arrow operation on any channel. The monitor shall cause immediate transfer to flashing operation when conflicting or absent indications occur or when a voltage fault occurs. When the conflict monitor actuates flashing operation, the controller shall freeze or stop timing in the condition causing the actuation until manually reset. A single lamp failure in any signal head shall not cause the monitor to actuate.
e.For double controller cabinets, two sets of switches shall be provided, one set for each controller installed in each compartment. Each controller cabinet shall be furnished with the following switches:
1.Power Interrupt Switch - A switch located inside the main cabinet shall interrupt electrical power to the controller during maintenance on the controller. Operation of this switch shall not affect the flash operation. This switch shall not be accessible via the police panel. 767(2) Flash Switch - A switch mounted in the police panel shall place the signal on flash. Operation of this switch shall not affect the electrical power supply to the controller. When the signals are returned to normal operation the external start shall be activated causing the controller to revert to the programmed initialization phase(s).
3.Stop Time Switch - A three-position switch mounted inside the main cabinet shall provide the following functions:
i.Stop Time - Causes the controller to stop time. (ii) Normal - Allows the controller to cycle all phases, but during conflict monitor flash causes the controller to stop time. (iii) Run - Allows the controller to cycle all phases and during any flashing operation allows the controller to continue cycling all phases without displaying them on the signal heads.
f.During all direction flash condition, controller operation shall permit the cycling of all signal phases without an external load being connected to the field terminals.
g.Solid state controllers shall have electronic filters to prevent interference caused by the opening and closing of circuits in electro-mechanical auxiliary equipment.
h.The controller shall be of modular design constructed for individual removal and replacement in the controller by multiple prong jacks or outlets without modifying wiring. Hand operable positive locking devices shall be used to hold the modules securely in the controller.
i.The functional operating circuits and associated components shall be grouped in plug-in printed circuit assemblies. Similar assemblies shall be interchangeable between controllers manufactured by the same company.
j.The controller shall contain the necessary phase sequence, interval sequence timing, power supply and monitoring equipment required to supervise the operation for the phasing shown on the plans, including any future controller expansion. If future phases are specified, the controller shall be completely configured to accept the future phases.
k.Controllers that are interconnected shall have a coordinated/free operation switch to allow the controller to operate in coordination with the system or run free.
l.High energy transient surge protection shall be provided on all solid state controllers to minimize damage to the controller and auxiliary equipment. This device shall be located on the incoming 120 volts, 60 hertz power service between the controller and signal circuit breaker and the power inputs to the controller and auxiliary equipment. The surge protector will plug-in to a hardwired base. Two LEDs that indicate the status of the surge protector shall be incorporated on the surge protector. One LED will indicate the surge protector is still operable and the other will indicate it has failed. The surge protector and base shall be capable of operating in the temperature range of -40 C to +85 C. The arrestor shall meet the latest NEMA specifications for surge protection.
m.Every all direction flash operation called from a source external to the controller shall occur through the flash transfer relay.
n.Any multi-conductor cable shall be contained in an expandable braided sleeve.
o.Switches or relays that completely interrupt power to the signal heads other than the protective circuit breaker shall not be installed in the cabinet.
p.All controllers shall be capable of downloading all programming data to a printer via a front panel RS-232 connection. The controller shall be capable of printing directly to a printer or via an external 768computer. If an external computer is required, the required software shall be provided with the controller.
q.All controllers shall be provided with internal pre-emption functions and circuitry. 1092.4.1.6.1 Solid State Actuated Controller. Each solid state actuated controller shall meet the latest revision of NEMA Standards Publication TS. Actuated controllers shall meet the following requirements:
a.Recall by keyboard entry shall be provided for each phase to furnish continuous recall. With the recall function in the "OFF" position, the controller shall operate normally with the right of way being transferred only upon pedestrian or vehicle actuation or external force-off control.
b.Controllers shall be furnished with provisions for external maximum control for each signal phase complete with wiring to permit installation of a coordination unit. All wiring to facilitate coordination shall be terminated on terminal strips and complete information stating the function of each terminal shall be shown on the controller-wiring diagram.
c.All phases shall contain a non-locking memory feature that can be energized or de-energized by keyboard entry.
d.All phases shall be capable of being activated or inactivated by keyboard entry.
e.On the cabinet inside door test panel, an external push button switch for each vehicle and pedestrian phase shall be provided. Each switch shall provide call to the phase assigned and ability to extend the phase. This detector input shall be independent of the circuitry between the amplifier and back panel.
f.A MoDOT D-plug shall be provided between the D-plug on the controller and the interconnect panel on the cabinet. In the absence of the sync signal, the coordination interface shall be configured to cause the controller to default to free operation. Configuration of the MoDOT D-plug shall be as follows: PinAssignmentPin AssignmentPin Assignment D1Cycle 1 D10Split 4 D19Future (Pre-empt 4) D2Cycle 2 D11Offset 1 D20Flash D3Cycle 3 D12Offset 2 D21Hardware Interconnecta D4Cycle 4 D13Offset 3 D22Future D5Future (Cycle 5)D14Future (Offset 4)D23Future D6Future (Cycle 6)D15Future (Offset 5)D24Future D7Split 1 D16Pre-empt 1 D25Future D8Split 2 D17Pre-empt 2 D9Split 3 D18Pre-empt 3 aOmit when activated through the cycle, split or offset inputs.
g.The MoDOT D-Plug shall be a Cinch TRW Super D Connection as follows: 1 - Part #TB 25 P Plug 1 - Part #SHD-25GL Hood with Latch 1 - Part #TB 25SLB-1Socket 1 - Part #SHD-25GFCSHood with Filler Ends
h.Actuated controllers shall be fully configured for operation of a minimum of eight vehicle phases, four pedestrian phases and four overlaps, regardless of the number of phases shown on the plans. 1092.4.1.6.2 Timing Function. Timing intervals or periods shall be set by means of keyboard entry. Each timing interval shall be adjustable to any value within the following minimum ranges for each phase. Zero may be satisfied by a time increment of up to 100 milliseconds. Interval Range 769(seconds) Minimal Initial 0 - 99 Unit Extension or Passage Time0 - 9.9 Yellow Clearance 0 - 9.9 Red Clearance 0 - 9.9 Maximum I Green 0 - 99 Maximum II Green 0 - 99 Walk 0 - 99 Pedestrian Clearance 0 - 99 Seconds per Actuation 0 - 9.9 Maximum Initial 0 - 99 Time Before Reduction 0 - 99 Time to Reduce 0 - 99 Minimum Gap 0 - 9.9 1092.4.2 Type 170. Except as herein modified, the Microcomputer 170E controller, cabinet and equipment shall be in accordance with the Caltrans Transportation Electrical Equipment Specifications, Chapter 2, dated August 16, 2002, which shall form a part of these specifications. A copy of the Caltrans specifications is available upon request. In case of conflict, MoDOT specifications will govern. Certification that the equipment proposed is included on the most current Qualified Products List of Caltrans and MoDOT Approved Products List shall be provided. A list of pre-approved equipment and material is available through Traffic or MoDOT’s web site. Department-specific equipment not defined in the Caltrans specification will be exempt from this Qualified Product List requirement. 1092.4.2.1 Type 170 Controllers.
a.The controller shall be fully compatible with the software specified on the plans.
b.The C2, C20, C30 and C40 connectors shall be amp standard.
c.One spare set of internal printed circuit boards shall be furnished with each controller unit. This shall include, but is not limited to, the power supply, front panel, I/O, central processing unit and modem, if specified. 1092.4.2.1.1 Master Controller. If a master controller or master coordination unit is specified in the plans, the master controller shall be a Type 170 controller. This controller shall be in addition to the intersection controller and shall be installed in the same cabinet unless otherwise specified on the plans. 1092.4.2.1.2 Diagnostic Test Program. For each ten or fewer Model 170E controllers purchased, a Diagnostic Test Program Prom Chip shall be provided. The Diagnostic Test Program Prom Chip shall test the operation of the Model 170E controller units including, but not limited to, internal memory, the program module, the real- time clock, input-output circuitry, the modem, the display and keyboard. The program shall be capable of operating with an external monitor and controller keypad. Full documentation on the program shall be included. The software shall be configured to work on a 412C prom module. 1092.4.2.1.3 Prom Module. Each Model 170E controller unit shall be furnished with one prom module, Model 412C, including a back up lithium battery and real time clock adjuster circuit, one Dallas 1225 chip and two 6264 ram chips. 1092.4.2.2 Type 170 Controller Cabinets. Type 170 controller cabinets, including the auxiliary door, shall be cast aluminum or 0.125 inch reinforced sheet aluminum alloy and be of clean-cut design and appearance. An auxiliary door equipped with a raintight gasket, shall allow access to a police panel and shall be equipped with a lock whose key will not unlock the main door. The doors shall be louvered to direct the incoming air downward. The cabinet shall be supplied with a replaceable furnace-type fiberglass filter mounted behind the louvers and shall cover the vent openings. A filter shell shall be provided to fit over the filter to provide mechanical support. Each cabinet door shall have a No. 2 Corbin cabinet lock and provisions for locking with a padlock. Two keys 770shall be furnished for each type of lock used. The handles for each door shall swing outward. Components of the Type 170 controller cabinets shall meet the following requirements:
a.The cabinet shall contain a pull out, hinged-top drawer, including sliding tracks, with lockout and a quick-disconnect feature, such as a Vent-Rak Retractable Writing Shelf, #D-4090-13, or equivalent. The pull out drawer shall extend a minimum of 14 inches to facilitate removal of the processor by providing an aluminum platform covered with a formica-type, chemical-proof plastic sheet while the rear connector is being removed. The interior of the drawer shall be accessible. Minimum interior dimensions of the drawer shall be one inch high, 13 inches deep and 16 inches wide. The drawer shall be capable of supporting 40 pounds when fully extended and shall be mounted immediately below the controller assembly.
b.All cabinet assemblies shall be supplied with a power distribution assembly Number 2, (PDA#2). If an auxiliary output file is specified, C5 connections shall be included.
c.Each Type 336S cabinet shall include two fluorescent lighting fixtures mounted inside the front and back portion of the cabinet. The fixtures shall include a cool white lamp with protective cover and shall operate by a normal power UL listed ballast. The fixtures shall be installed to automatically power on when the cabinet door is opened and automatically power off when the cabinet door is closed. A manual on/off switch shall be provided for each fixture. Each switch should work each individual light. The Type 332 cabinet will require only one lighting fixture meeting the above requirements.
d.Each controller cabinet shall be furnished with a clearly labeled switch, mounted in the access or police panel to place the signals on flash. Operation of this switch shall not affect the electrical power supply to the controller. The switch shall be labeled FLASH/AUTOMATIC. This shall be the only control switch accessible from the police panel.
e.All output field conductors shall be terminated in the cabinet on a one-piece copper 600-volt heavy duty mechanical screw connector offset tang assembly. Each mechanical screw connector shall accommodate up to four No. 12 AWG conductors. Each clamp shall be captive to the contact screw and the screw captive to the contact. Field wiring shall not be spade lugged. The alternating current neutral bus and chassis ground bus shall be a 17-position solid copper neutral bar with set screws that allow the wires to be attached without tang or spade assemblies.
f.The output file shall be hand wired and printed circuit boards will not be allowed, except for red fail monitoring. The back of the load switch bay and the conflict monitor bay shall be enclosed to prevent wires interfering with plugging in of components.
g.A 420 auxiliary output file will be required when specified on the plans or if more than 12 load switches are required.
h.I and J input files shall be provided unless otherwise specified.
i.All cables shall be located and secured such that the cables do not interfere with removal of the controller or the opening of the controller front panel.
j.A diagnostic cabinet test program, including documentation, shall be provided with each ten or fewer cabinets. 1092.4.2.3 Surge Protection. Each cabinet shall be provided with devices to protect the control equipment from surges and over voltages. This shall include incoming power lines, the input and output files and communication lines. 1092.4.2.3.1 All input file inputs shall be protected with a 30-volt MOV with a 30-j rating. All load switch outputs shall be protected with a 150-volt MOV with an 80-j rating. Each MOV shall be connected from the alternating current positive field terminal to the chassis ground. Each output MOV shall be mounted on the field terminal side of the output assembly. 1092.4.2.3.2 For the 332A cabinet, appropriate input surge protection shall be mounted on the lower input termination panel (LIP). The PDA#2 of each controller cabinet shall include a surge protection unit on the 771alternating current service input. The protector shall be installed between the applied line voltage and earth ground. The surge protector shall be capable of reducing the effect of lightning transient voltages applied to the alternating current line. The protection device shall be a two-stage series parallel device. The device shall include the following features and functions:
a.Maximum alternating current line voltage shall be 140 volts during 20 pulses of peak current, each of which shall rise in 8 microseconds and fall in 20 microseconds to one half of the peak of 20,000 amps.
b.The protector shall be provided with the following terminals:
1.Main line (alternating current line first stage terminal).
2.Main neutral (alternating current neutral input terminal).
3.Equipment line out (alternating current line second stage output terminal, 10 amps.).
4.Equipment neutral out (neutral terminal to protected equipment).
5.GND (earth connection).
c.The main alternating current line in and the equipment line out terminals shall be separated by a minimum 200 microhenry inductor rated to handle 10-amp alternating current service. The first stage clamp shall be between the main line and ground terminals.
d.The second stage clamp shall be between the equipment line out and equipment neutral.
e.The protector for the first and second stage clamp shall have an MOV or similar solid state device rated at 20 kiloamps and shall be of a completely solid stage design. Gas discharge tubes will not be allowed.
f.The main neutral and equipment neutral out shall be connected internally and shall have an MOV similar solid state device or gas discharge tubes rated at 20 kiloamps between the main neutral and ground terminals.
g.Peak clamp voltage shall be 350 volts at 20 kiloamps measured between the equipment line out and equipment neutral out terminals. Current shall be applied between the main line and ground terminals. Ground and main neutral terminals shall be externally tied together. The voltage shall not exceed 350 volts.
h.The protector shall be epoxy-encapsulated in a flame retardant material.
i.Continuous service current shall be 10 amps at 120 volts alternating current root means squared (RMS).
j.The equipment line out shall provide power to the Type 170 controller and to the 24 volt power supply.
k.Communications line protector for incoming and outgoing communication lines shall be EDCO part #PC642C-008 or equivalent with mounting connector #PCB1B or equivalent. If fiber or radio communications are specified, these communications line protectors will not be required. 1092.4.2.4 Cabinet Accessories. Each cabinet shall be equipped with the following, unless specified otherwise:
a.A minimum of one direct current isolator.
b.Load switches, quantity as specified in the contract documents.
c.Two flashers. 772(d) Alternating current isolators, quantity as specified in the contract documents.
e.Four flash transfer relays. Two additional flash transfer relays shall be provided when a 420 auxiliary is shown on the plans.
f.Modem, quantity as specified in the contract documents.
g.SM modem, quantity as specified in the contract documents.
h.Fiber optic modem, quantity as specified in the contract documents.
i.Computer cable. The computer cable shall consist of both male and female amp connectors. The female connector shall be located in the front of the cabinet and shall extend past the front edge of the rack a minimum of 0.5 inches and a maximum of 1 inch. The male connector shall be located in the back of the cabinet. The cable shall extend 14 inches along the side of the rack with a minimum of 12 inches free that can be used to plug into any of the controller’s four ports. The cable shall consist of one wire connecting the like pin in the other connector starting with A and ending with R. The wire shall be 20 AWG. One cable shall be supplied for each cabinet. The mounting of this cable shall not interfere in any way with the installation or removal of the controller. If the cable is mounted within the pull out drawer, any hole that is drilled in the drawer shall be equipped with a rubber grommet to protect the cable and the cable shall have enough slack to prevent binding.
j.Conflict monitor.
1.The conflict monitor shall be external to the controller circuitry in accordance with the Caltrans specifications. The monitor shall cause immediate transfer to flashing operation when conflicting or absent indications occur or when a voltage fault occurs. When the conflict monitor actuates flashing operation, the controller shall freeze or stop timing in the condition causing the actuation until manually reset. A single lamp failure in any signal head shall not cause the monitor to actuate.
2.A connector and terminal assembly designated as P20 ,Magnum P/N 722120 or equivalent, for monitoring the absence of red shall be an integral part of the output file. The connector shall terminate and shall be compatible with the cable and connector of the conflict monitor unit. The pin assignments of the P20 connector and terminal assembly shall be provided with the cabinet plans. The P20 connector shall be designed such that the cable may only be inserted into the P20 connector in one direction. Unused red channels shall be programmed through jumpers. These jumpers shall cause 115 volts alternating current to be applied to any and all unused red monitoring channels. These jumpers and the respective attachment points shall be part of the output file. 1092.4.2.5 Software. Software shall be provided with each Type 170 controller unless otherwise specified. Requirements for software will be as follows. 1092.4.2.5.1 District 4 - Kansas City Area. The 412C prom module shall be configured for Wapiti software. For intersection controllers, the most recent revision of Wapiti W4IKS shall be mounted on the prom module. For master controllers, the most recent revision of Wapiti W70SM shall be mounted on the prom module. 1092.4.2.5.2 District 8 - Springfield Area. The 412C prom module shall be configured for Bi-Trans software that will be provided by District 8. 1092.4.2.6 Testing Requirements. All equipment shall be tested for conformance to these specifications. Testing may be done by an independent laboratory if the manufacturer does not have sufficient facilities to conduct the testing. A copy of the test results for all equipment shall be supplied by the manufacturer to the engineer. 1092.4.2.6.1 Conflict Monitor Test Cable. To facilitate testing of the conflict monitor, one additional 4-foot connector cable shall be furnished by the manufacturer and installed in each cabinet. The cable shall utilize an 18 AWG wire to connect a 36-pin plug to the back panel terminals as specified below. The connector cable shall utilize a 36-circuit polarized nylon Waldon Molex type receptacle, P/N 03-06-1361, using a 0.062-inch female 773terminals made of 70/30 spring tempered 0.010 inch thick tin-plated brass with contact of resistance 0.0025 ohm millivolts, drop of 2.5 millivolts at one amp with 250 volts, 4 amps maximum per circuit. This connector cable shall "free float” in the bottom front 6 inches of the cabinet and shall not be used in the normal operation of the controller. A moisture-proof cap shall be provided to prevent the accumulation of moisture on the plug terminals. The cap shall remain attached to the connector when the cable is in use. Receptacle CircuitTerminal Phase Receptacle CircuitTerminal Phase 1 1 G 19 4 WALK 2 1 Y 20 8 WALK 3 2 G 21 1 AUX Ga 4 2 Y 22 1 AUX Ya 5 3 G 23 3 AUX Ga 6 3 Y 24 3 AUX Ya 7 4 G 25 5 AUX Ga 8 4 Y 26 5 AUX Ya 9 5 G 27 6 AUX Ga 10 5 Y 28 6 AUX Ya 11 6 G 29 I14-W STOP TIME 12 6 Y 30 DC GROUND 13 7 G 31 MONITOR RESET 14 7 Y 32 DC GROUND 15 8 G 33 2 AUX Ga 16 8 Y 34 2 AUX Ya 17 2 WALK 35 4 AUX Ga 18 6 WALK 36 4 AUX Ya aCircuits used only in a 332A cabinet with an auxiliary output file 1092.4.2.6.2 Controllers. Each Model 170E controller unit shall be tested over a temperature range of -29 to 165 F. Proper operation of the unit shall be verified at both temperature extremes and at ambient temperature. Testing shall be conducted prior to final inspection, and will not constitute a substitute for any quality control testing or final inspection testing normally performed. 1092.4.2.6.2.1 The environmental chamber(s) shall have provisions for remotely operating the Model 170E controller under test. Front panel displays shall be visible from a window in the environmental chamber. Signal outputs shall be brought out of the chamber to display board if controllers cannot be directly observed. Cold and hot soak times shall be sufficient to allow all components in the device to reach the specified temperatures. A minimum soak time of three hours shall be used for all testing. 1092.4.2.6.2.2 The manufacturer shall submit to the engineer a proposed testing procedure and schedule 30 days prior to testing for evaluation. Test procedures, environmental chambers, automatic test equipment, display boards, power supplies and controls shall be described in detail. 1092.4.2.6.2.3 The controller shall pass the following test at least five times at each temperature extreme and ambient:
a.Recovery from a short power interruption of approximately 500 milliseconds.
b.Recovery from a long power interruption of approximately 5 seconds. 7741092.4.2.6.2.4 The vendor shall provide a method of testing controller inputs and outputs. Diagnostic software and wraparound connector for controller harnesses may be used. If diagnostic software is not used, outputs shall be brought out to a display board. Inputs may be paralleled to each controller. 1092.4.2.6.3 Cabinet Testing. Cabinets shall be tested at ambient conditions only. An automatic or semi- automatic method of checking cabinet wiring between equipment harnesses and field connections will be required. 1092.4.2.6.4 Card Rack Assemblies. Card rack assemblies shall be in accordance with Caltrans. 1092.4.3 Auxiliary Equipment and Interfaces for Controllers. Interface panels shall be aluminum panels installed in the controller cabinet containing the required terminals and equipment. Interface panels shall be neatly laid out, neatly wired and easily accessible. Each auxiliary unit shall be enclosed in a suitably finished metal case and shall be mounted in the controller cabinet unless otherwise specified. The function of each auxiliary unit shall be indicated by an identification plate on the case. Auxiliary equipment cases shall be ventilated. Temperature, voltage and frequency shall be in accordance with Sec 1092.4. 1092.4.3.1 Pre-Emption Interface. The pre-emption interface shall consist of internal pre-emption functions in the controller, any field wire termination panels, relays, wiring and connectors required for proper operation. The pre-emption interface shall be wired to transfer control of the signals to the pre-emption sequence when actuated and shall provide the color sequence specified. After release of pre-emption, normal controller operation shall be automatically resumed except that actuated controllers shall be on recall for one complete cycle. 1092.4.3.2 Master and Local Coordination Interface. The coordination interface shall consist of internal coordination functions in the controller, and of any field wire termination panels, wiring and connectors required for proper operation. The master coordination interface shall supervise the actuated controller operating the signals in the intersection at which the actuated controller is located. Local coordination interfaces shall be supervised by the master coordination interface and shall in turn supervise the actuated controllers operating the signals at the intersections where the controllers are located. Coordination interfaces shall be connected to one another or to a telephone interconnection unit by a multi-conductor cable. The master coordination interface shall be furnished with internal time-based functions in the controller. The coordination interface shall provide the following:
a.Fully actuated operation.
1.Cycle length of the actuated controller may vary with traffic demand, but shall not exceed the cycle length set on the coordination interface.
2.Vehicle and pedestrian detectors shall remain energized.
3.During periods of light traffic, the actuated controller shall respond to detector demand on any signal phase.
4.When there is continuous demand for all signal phases, the coordination interface shall cause termination of each signal phase in accordance with the time intervals set on the coordination interface for each signal phase.
5.The actuated controller shall not be forced to transfer right of way to a signal phase if there is no demand.
b.Semi-actuated operation.
1.Signal phases, controlling the street on which signal progression is desired, shall be placed on maximum recall.
2.Vehicle and pedestrian detectors shall remain energized.
3.Transfer of right of way from the coordinated signal phase(s) shall not occur until there is detector actuation for a non-coordinated signal phase and only after the coordination interface 775has terminated the coordinated signal phase(s).
4.The right of way interval awarded the coordinated signal phase(s) shall be governed by the time interval set on the coordination interface.
5.If detector actuations for a non-coordinated signal phase(s) causes the phase(s) to time to maximum, the phase(s) shall be forced off and the coordinated phase(s) awarded right of way.
6.If demand for the non-coordinated signal phase(s) is not sufficient to extend the phase(s) to maximum, right of way shall transfer to the coordinated phase(s) and remain there until demand for the non-coordinated phase(s) occurs and the coordination interface times the coordinated phase(s) to maximum.
7.Detector actuation on a non-coordinated signal phase(s) occurring during the coordinated phase(s) right of way interval shall cause a call to be placed and retained for the non- coordinated signal phase(s).
c.Fixed cycle length operation.
1.All signal phases shall be placed on maximum recall.
2.Vehicle and pedestrian detectors shall remain energized.
3.The coordination interface shall control the time interval that each signal phase is awarded right of way.
d.Free operation.
1.When permitted by internal time-based functions, the coordination interface shall provide free operation of associated actuated controllers. During this operation the actuated controller shall operate without supervision by the coordination interface.
2.Pretimed controllers, in a signal system supervised by a master coordination interface, shall revert to dial 1, reset 1 or internal time based coordination during free operation at the user's option. 1092.4.3.2.1 Each coordination interface shall have the following minimum operational characteristics:
a.Three cycles.
b.Eight splits.
c.Eight force off periods per split.
d.Three offsets per cycle.
e.Selectable recall by signal plan. 1092.4.3.2.2 Each coordination interface shall have all of the following methods of synchronizing to the master sync pulse:
a.Dwell. The coordinator shall establish a new offset by stopping the cycle timer in the coordinated phase(s) green, until the new offset value is reached.
b.Dwell with Interrupt. The coordinator shall establish a new offset by stopping the cycle timer in the coordinated phase(s) green. The maximum time the coordinator can dwell shall be adjustable from 1 to 99 seconds.
c.Shortway. The coordinator shall establish a new offset by the shortest route possible. 7761092.4.3.2.3 Each master coordination interface shall be furnished with necessary relays and internal functions in the controller to provide the following supervisory functions:
a.Semi-actuated operation.
b.Fixed cycle length operation.
c.Free operation.
d.Cycle Transfer (cycle 1 to cycle 2, cycle 3 or cycle 4 and vice versa; cycle 2 to cycle 3 or cycle 4 and vice versa; cycle 3 to cycle 4 and vice versa). 1092.4.3.2.4 Each controller shall be capable of permitting the manual selection of the following:
a.Cycle Length 1, 2, 3, 4 or System.
b.Offset 1, 2, 3, 4 or System.
c.Semi-actuated operation, fixed cycle length operation or free operation. 1092.4.4 Remote "ON - OFF" Switch (Pedestrian Interval Sequence). The following type of "On - Off" switches shall be furnished as specified:
a.Type I. Type I switches shall consist of one manually operated heavy-duty switch in a circuit not exceeding 18 volts. Necessary relays shall be located in the controller cabinet for including or excluding the pedestrian phase in the phasing sequence or switching signals between flashing and sequence operation. This shall be accomplished by energizing or de-energizing the pedestrian signal indications and push-button detectors. The switch shall be enclosed in a weatherproof, cast aluminum housing equipped for post mounting. The housing shall have a suitable lock, the key of which shall not unlock the controller cabinet. The housing shall be tapped for conduit.
b.Type II. The Type II switch shall be operationally identical to the Type I, except the switch may be 120 volts and shall be located inside the police panel of the controller cabinet. 1092.4.5 Interconnect Types. 1092.4.5.1 Time Base Coordination Interface. The time base coordination interface shall consist of internal time base coordination functions in the controller.
a.Timing base shall be the 60-hertz power line frequency. Timing error due to power failure or low voltage shall not exceed ± 0.005 percent during these conditions. Changes to and from standard time and daylight time shall be programmed to automatically occur at the specified times. Memory and timing shall be maintained for at least 48 hours during an alternating current power failure. A power failure indicator shall be provided.
b.The interface shall have a multi-digit security access code or key and lock security access.
c.The interface shall be zero time based, settable to the second, programmable for 52 weeks, accommodate at least three weekly programs, twelve day programs and no less than twelve exception day programs. Total event changes shall be a minimum of 160. Interrogation of the interface to determine the year, month, day, hour, minute, second, a.m. and p.m., as well as program information programmed in the unit, shall be possible. Indicators shall show the condition of all outputs.
d.The interface shall permit the controller to operate free or in coordination. When in coordination, all maximum green limits shall be inhibited. The interface shall be capable of continuously generating no less than four cycle lengths from 40 to 255 seconds.
e.The interface shall be capable of continuously generating eight individual force-off commands in each cycle length even though the use all of the force-off commands may not be necessary. The 777interface shall also place a continuous call to the detector inputs of the coordinated phases. Position of the force-off and continuous call functions shall be settable at any percentage point or seconds in any selected cycle length.
f.The first program of the day shall be implemented at the beginning of the minute selected. When changing from one cycle length to another while in the coordination mode, the change to the new cycle length shall not occur until the present cycle length has terminated. If the controller is operated in the free mode between cycle lengths, the next cycle length programmed shall begin at the beginning of the minute selected.
g.The interface shall be furnished with the capability of generating a daily reference point at which time all cycles are resynchronized. This daily reference point shall be either 12:00 midnight or a selectable time of which 12:00 midnight could be selected. The resynchronization reference time is an arbitrary point in time that marks the beginning of all cycles on a daily basis.
h.When designated, the interface shall be capable of generating an absolute reference point at which time all cycles are resynchronized. This absolute reference point shall be a selectable time by date and hour and minute that marks the beginning of all cycles.
i.While under coordination, the designated coordinated phase(s) shall be capable of releasing from a hold status and operating in the actuated mode. The controller unit shall operate in actuated mode from a designated hold release point to the corresponding force-off point(s) of the coordinated phase(s).
j.Three instruction manuals covering operational information shall be furnished with each interface. 1092.4.5.2 Closed Loop Systems. 1092.4.5.2.1 Equipment. New systems shall be compatible with any existing components in the system. 1092.4.5.2.1.1 System Software. The system software shall be designed to operate a traffic-responsive signal system with two-way communications between all local controllers and the system master. The software shall be capable of time-of-day system operation and a mix of time-of-day and traffic responsive operation. The software shall also provide for two-way communication between the system master and a remote personal computer, via a dial-up modem and a direct connect to the system master. The system software shall be fully compatible with all equipment supplied in the system and shall be compatible with the latest Windows operating system. The software shall be new and in the original packaging provided by the manufacturer. The system manufacturer shall provide software updates at no cost to the Commission for a period of at least two years from the date of final acceptance of the project. All licensing issues shall be addressed by the contractor. 1092.4.5.2.1.2 Closed Loop System Components. The principal components of the closed loop system shall consist of the system master, local intersection controller(s) and a modem. 1092.4.5.2.1.2.1 System Master. The system master controller shall consist of a NEMA or Type 170 microcomputer signal controller as specified in the plans, prom module and all necessary connectors and cables. The system master controller shall be installed in the local controller cabinet designated on the plans. A separate cabinet will not be required. 1092.4.5.2.1.2.2 Local Intersection Controller. The local controller assembly shall consist of a NEMA or Type 170 complete actuated traffic controller assembly, as specified in the plans and in accordance with these specifications. 1092.4.5.2.1.3 Cabinet Accessories. 1092.4.5.2.1.3.1 Telephone Interface Panel. The panel shall provide for interfacing of a leased, unconditioned telephone drop to a Hayes compatible modem that connects to the on-street system master. The panel shall be fabricated from 0.125-inch sheet aluminum with deburred edges and rounded corners. The panel shall be mounted on the inside of the cabinet as directed by the engineer. A telephone network interface, such as a Siecor CAL3000 or other approved interface acceptable to the local telephone company, shall be attached to the aluminum panel. The telephone interface shall include the installation of all necessary equipment to connect the 778interface to the telephone drop. The contractor shall be responsible for the installation of the telephone line. The system acceptance test shall not begin until the telephone line is in operation. 1092.4.5.2.1.3.2 Extra Service Outlet. One extra duplex service outlet shall be provided in the controller cabinet housing of the system master. The extra duplex service outlet shall not be located on the door of the cabinet. The receptacle shall be connected to the 120 volts alternating current auxiliary circuit in the cabinet. 1092.4.5.2.1.3.3 Interconnect Panel. The interconnect panel shall provide for system communication between the system master and local intersection controller units. An interconnect panel shall be provided in each controller cabinet. The panel may include terminations for system detector inputs and other auxiliary input/output functions. All controller assemblies shall be configured with inputs for system detectors. The panel shall be fabricated from 0.125-inch sheet aluminum with deburred edges and rounded corners. The panel shall be mounted on the inside of the cabinet on the left side. Over-voltage protectors shall be provided and shall be an encapsulated, three-element gas tube type equipped to mate with a ten-circuit Buchannan Connector PnPcB1B. As a minimum, the over-voltage protection ratings shall be:
a.Primary surge current – 10 kiloamps (80 x 20 us, waveshape).
b.Secondary protector: Solid state clamps 1.5 kilowatts.
c.Response time < 5 nanoseconds.
d.Clamp voltage – 8 volts. 1092.4.5.2.1.3.4 Door Alarm. A limiting switch shall be installed and wired to activate an alarm when the cabinet door is opened. 1092.4.5.2.1.3.5 Dial-Up Modem. The modem shall be in accordance with Sec 1092.4.6 and shall be installed in the controller cabinet housing of the on-site system master. 1092.4.5.3 Twisted Pair Interconnect. If 3-pair cable is specified, the interconnect cable for system communication between the on-street master and local controllers shall be 16 AWG, stranded copper conductor, twisted pairs individually shielded. The cable shall be PVC insulated, aluminum shielded, in accordance with specifications of Belden No. 1037A. Each interconnect cable shall have three pairs. Each pair shall be wired to a terminal strip on the interconnect panel. Each shield shall be grounded on at least one end. 1092.4.5.4 Wireless Interconnect. 1092.4.5.4.1 Wireless Closed Loop System Components. The wireless system shall consist of a fully operational wireless interconnect system between the system master and all local controllers. Components shall include telemetry radios, interface cables between the radios and signal controllers, radio power supply and handheld diagnostic/programming keypads. 1092.4.5.4.1.1 Telemetry Radios. The telemetry radio shall be an unlicensed frequency hopping spread spectrum and shall be a Microwave Data Systems, Model 9810 or equivalent, in accordance with the following: Item Requirement Frequency Band902-928 Megahertz FCC Part 15 Spread Spectrum Band or1.2 Gigahertz FCC Part 15 Spread Spectrum Band Frequency Hopping Range8 Selectable Zones @ 128 frequencies – 1019 total frequencies Frequency Stability ± 1.5 ppm @ -20 to 140 F Data Interface RS232 (or as required by the system) Data Interface Rate Std. Baud Rates up to 19200 bytes/second, minimum Latency <10 milliseconds typical (buffer off mode) Transmitting Power Output1 watt minimum, adjustable Transmitting Duty CycleContinuous Transmitting Max Voltage Standing Wave RatioInfinite, all phase angles 779(VWSR) (No Damage) Receiving Bit Error RateLess than 10-6 at -110 decibels Receiving Intermodulation75 decibels, minimum Receiving Desensitization65 decibels, minimum Receiving Spurious 70 decibels, minimum Operating Humidity 95% Relative Humidity at 104 F Operating Temperature -20 to 140 F with full performance 1092.4.5.4.1.1.1 Telemetry radios shall provide transparent communications between signal controllers. All radio equipment shall be installed in the signal controller cabinets. Radio power supplies shall meet all requirements of the radio manufacturer, including power, temperature and humidity. All required interface cables and connectors shall be provided with the radios. 1092.4.5.4.1.1.2 The radio shall have the capability to monitor receiver signal strength and be programmed through a diagnostic/programming keypad. Two handheld diagnostic/ programming keypads for the radios shall be provided with the system. 1092.4.5.4.1.2 Antenna System. The antenna system shall consist of the omnidirectional antenna or yagi directional antenna, as specified, antenna mounts, coaxial cable and surge and lightning protection. Antennas shall be products manufactured by Decibel Products, Celwave, Scala or Antenna Specialists, and shall meet the following requirements. 1092.4.5.4.1.2.1 Omnidirectional Antenna. All omnidirectional antennas shall be in accordance with the following: Item Requirement General Frequency Range896-960 Megahertz Bandwidth at Rated VSWR70 Megahertz, min. VSWR 1.5:1, min. Polarization Vertical Maximum Power Input 250 watts, min. Connector N Female Antenna Housing Fiberglass Radome Radiating Elements Brass or Copper Support Pipe 6061-T6 Aluminum Lightning Protection Direct Ground Rated Wind Velocity 100 mph, min. 1092.4.5.4.1.2.2 Yagi Directional Antenna. All yagi directional antennas shall be in accordance with the following: Item Requirement General Frequency Range896-960 Megahertz Gain 10 decibels, min. Bandwidth at Rated VSWR60 Megahertz, min. VSWR 1.5:1, min. Horizontal Beamwidth 45 degrees, min. Vertical Beamwidth 30 degrees, min. Polarization Vertical or Horizontal Maximum Power Input 100 watts Min. Connector N Female Radiating Elements Gold Anodized Welded Aluminum Alloy Lightning Protection Direct Ground 780Rated Wind Velocity 100 mph Min. 1092.4.5.4.1.2.2.1 Directional antennas shall be in accordance with the level of gain shown on the plans and with the following: Antenna Gain Vertical Beam Width 3 decibel3 decibels, min.30 degrees, min. 6 decibel6 decibels, min.16 degrees, min. 9 decibel9 decibels, min.7 degrees, min. 1092.4.5.4.1.2.3 Antenna Mounts. Mounts shall provide a rigid mounting of the specified antenna that will withstand winds of up to 100 mph minimum. Mounts and associated hardware shall be constructed of galvanized steel, aluminum or stainless steel. 1092.4.5.4.1.2.4 RG-8/U Coaxial Cable. All antenna cable shall be a low loss, RG-8/U, Belden 9913 or equivalent, coaxial cable in accordance with the requirements listed below. Connectors for antenna cable shall be Type N male connectors constructed of silver-plated brass with a gold plated pin and soldered center connection. Item Requirement Impedence 50 ohms, nominal Attenuation at 900 Megahertz5.7 decibels/100 ft., max. Overall Diameter 0.405 in., nominal Outer Conductor Tinned Copper Braid with 95% min. coverage Inner Conductor 0.108 in. Copper Dielectric Foam-Polyethylene Outer Jacket Black Polyvinyl Chloride 1092.4.5.4.1.2.5 Antenna Surge and Lightning Protection. A lightning and surge arrestor shall be provided for the coaxial cable in the controller cabinet. The arrestor shall be bulkhead-mounted or flange-mounted and shall be securely fastened to a grounded metal surface inside the cabinet. The arrestor shall be manufactured by Polyphaser and shall be in accordance with the following: Item Requirement Throughput Energy 220 µj Maximum Surge Current50 kiloamps Turn On Voltage 600 volts Turn On Response 2.5 nanoseconds Connectors (both ends)N Female Housing Aluminum Hardware Stainless Steel 1092.4.5.5 Fiber Optic Interconnect. The fiber optic system shall consist of a fully operational fiber optic interconnect system between the system master and all local controllers. Components shall include fiber optic cable, splice cabinet, closed loop system components, modem and a fiber distribution unit. 1092.4.5.5.1 Splice Cabinet. The Type 336 cabinet and EIA 19-inch rack cage shall be in accordance with the Traffic Signal Control Specifications published by the California Business, Transportation & Housing Agency, Department of Transportation (Caltrans), dated January 1989, including all current addenda and revisions. Housing shall include, but will not be limited to, the enclosure, doors, latches/locks, hinges and door catches, ventilation, gaskets, cage supports and mounting, the rack cage, and anchor bolts. 1092.4.5.5.1.1 Each splice cabinet shall include a fiber distribution unit to provide a termination and service access point for the fiber optic cables. The fiber distribution unit shall be mounted on the 19-inch rack cage and shall be a modular design to support both fusion and mechanical splices of multimode and single mode fiber. 781The single cabinet construction shall have a minimum termination/connection capacity of 48 fibers and four splice trays. The connector panel, to be located at the top of the unit, shall be designed to accommodate stick and turn (ST) and other standard connectors. Six ST couplings with ceramic inserts, designed to accommodate both single mode and multi-mode fiber, shall be provided and installed for future use. One single mode splice tray and one multi-mode splice tray, each with a closure for 12 fusion splices, as a minimum, shall be provided in each cabinet. Additional trays shall be provided as necessary to splice or terminate fibers in accordance with the system design and this specification. 1092.4.5.5.1.2 The design of the unit shall allow stacking of splice trays in a manner that permits access to individual trays without disturbing other trays and splicing to be conducted at a distance from the unit. The lower portion of the unit shall provide for the neat storage of continuous tubes. Excess cable may be stored either in the fiber distribution unit or within the splice cabinet. The unit shall provide both front and rear access with hinged door access and cable strain relief accommodations. The unit and splice tray shall be constructed of durable aluminum designed for outdoor applications. Plastic doors may be considered for approval by the engineer. 1092.4.5.5.2 Fiber Optic Data Link for Closed Loop System. The data link between the fiber optic cable and the master or local intersection NEMA or Type 170 controller arranged in a closed loop system shall be accomplished using a data link, referred to as a modem on the plans, compatible with daisy chain operation to transmit RS-232 data using fiber optics. This data link shall be compatible with and installed in the NEMA or Type 170 controller unit in accordance with the manufacturer’s recommendations. 1092.4.5.5.2.1 The fiber optic data link shall be capable of operating in a full duplex mode of operation, employing asynchronous RS-232 data link protocols. RS-232 signals shall be converted to light and transmitted from data link to data link until the light is reconverted to RS-232 electrical signals sent to a particular controller. The fiber optic data link shall operate in a daisy chain communication mode. 1092.4.5.5.2.2 On the data link assembly, there shall be two pairs of clearly labeled optical emitters and optical detectors, designed to attach to standard ST connectors. There shall be two clearly labeled LED's, one for transmit and one for receive. These LED's shall illuminate when the fiber optic data link is either receiving or transmitting at the local controller. There shall be a slide switch labeled "M" for master operation and "L" for local operation. 1092.4.5.5.2.3 In the master mode of operation, the electrical data entering the fiber optic data link from the controller unit shall be transmitted as optical signals in a parallel mode from each of the two emitters. The optical signals received by the two detectors shall be converted to electrical signals and sent in parallel to the controller. 1092.4.5.5.2.4 In the local mode of operation, optical signals received by Detector 1 shall be converted to electrical signals and sent to the controller unit. These same signals shall be regenerated and transmitted by Emitter 2 to the next adjacent fiber optic data link downstream in the daisy chain. Optical signals received by Detector 2 shall be regenerated and transmitted by Emitter 1 to the next adjacent fiber link upstream. Electrical signals received by Emitter 1 from the controller shall be transmitted to the next adjacent fiber link upstream. Regeneration shall maintain pulse fidelity within ± 0.1 percent for each data link. 1092.4.5.5.2.5 The fiber optic data link shall have an emergency backup power source that allows continued daisy chain operation when the NEMA or Type 170 controller unit is removed or if the power to the controller has been turned off. The backup power source shall provide uninterrupted operation of the daisy chain interconnect system, both upstream and downstream from the affected data link, for a period of 12 hours. An RJ11/4 jack shall be available on the assembly to interface an external data link, allowing fiber optic communications in four directions. 1092.4.5.5.2.6 The fiber optic data link shall operate with all fiber ranging from 50/125 glass to 1 mm plastic fiber and shall meet the following electrical requirements: Item Requirements Voltage 12-volt direct current Current 26 milliamps continuous Wavelength 850 nanometers 782Data Link SensitivityMaximum 0 decibels, Minimum –40 decibels Data Rate 100 to 19.2 k baud Operating Range 1.9 miles from data link to data link Temperature Range-30 to 165 F 1092.4.5.5.2.7 Fiber Distribution Unit. Each controller cabinet shall be equipped with a fiber distribution unit to provide a termination, storage and service access point for fiber optic cables. The fibers in the interconnect cable(s) shall be terminated on one side and duplex jumpers shall extend on the other side to the data links. The fiber distribution unit shall be a modular design to support a minimum termination/connection capacity of 12 fibers, one splice tray and strain relief for up to four cables. No splice tray will be required. The connector panel shall be designed to accommodate ST connectors for both multi-mode and single mode fibers, as appropriate. ST couplings with ceramic inserts shall be provided to accommodate all fibers brought into the controller cabinet from the splice cabinet. The unit shall provide both front and rear access with hinged door access. The unit shall be constructed of durable aluminum constructed for outdoor applications. Plastic doors may be considered for approval. The unit shall be sized to fit in the controller cabinet and shall be positioned to allow fiber cables to be routed with bending radii exceeding manufacturer's recommendation. The unit shall not conflict with other cabinet components or panels. Fiber cables shall not conflict with other cabinet wiring. 1092.4.5.5.3 Training for Fiber Optic Installation. When specified in the contract documents, training on system software and system operation shall be provided. Training shall be conducted by qualified instructors and shall be provided to personnel designated by the engineer on all facets of the system. Personnel shall be trained to operate the system, analyze system performance and revise critical operating parameters based on the analysis. The training shall be in a classroom atmosphere and shall be for a minimum of 16 hours over two days. The first eight-hour training session shall be conducted prior to the system acceptance test. The second eight- hour session shall be conducted at the conclusion of the system acceptance test. Maintenance personnel shall be trained on maintenance and repair of all serviceable equipment. Training shall include field level troubleshooting and bench repair. The training shall be for a minimum of eight hours in one day. 1092.4.6 Dial Up Modems. The dial-up modem shall be an auto-dial, auto-answer modem and shall be installed in the controller cabinet as specified on the plans. If specified, an identical modem shall be installed at the central office computer facility in the MoDOT district office. The modem shall be Hayes compatible capable of responding to the standard "Hayes command set" and shall be self-contained. The unit shall be powered by a nominal 120-volt alternating current from the duplex service outlet provided in the cabinet. The modem shall be capable of operating at all standard baud rates from 300 to 56k baud over a standard dial-up, unconditioned telephone line and shall be capable of reliable operation from -35 to 165 F. Installation shall include the appropriate interface cable to connect to an RJ-11 telephone jack on the telephone interface panel, the RS-232 cable from the modem to the system master and all other cabling, connectors and incidental items necessary for operation. 1092.4.7 Detectors. 1092.4.7.1 Induction Detector Probes. The encapsulated induction detector probe shall detect the passage or presence of all vehicles with a standard induction loop detector amplifier. The induction detector probe shall operate in a temperature range from -35 to 165 F with 0 to 100 percent humidity. The operating field intensity range shall be 0.2 to 1.0 oersted with a nominal inductance of 20 microhenries plus 20 microhenries per 100 feet of cable. The nominal direct current resistance shall be 0.5 ohm plus 3.2 ohms per 100 feet of probe cable. Induction detector probes shall be as specified on the plans and shall meet the following:
a.The sensing probes shall be cylindrical having maximum dimensions of 7/8-inch diameter by 4 inches long. The sensing probes shall be suitable for installation in a one-inch diameter bored hole. The interconnecting four-conductor cable and lead-in cable shall be suitable for installation in a 1/4-inch wide pavement sawed slot.
b.The jacket on the interconnecting cable and the casing on the sensing probe shall be an abrasion resistant polyurethane elastomer. The device shall be impervious to moisture and chemically resistant to all normal motor vehicle petroleum products. Lead-in cables shall be shielded, chemical resistant and completely waterproof. 783(c) The combined probe sets, manufacturer specified lead-in cable and detector probe shall detect all vehicles up to a lead-in cable length of 750 feet with up to six probes per set.
d.The conductor cable from the probes to the detector panel in the controller assembly shall be as specified by the detector manufacturer, shall be continuous and unspliced and shall be a minimum of 50 feet in length. Probes shall be assembled in a set to form a vehicle detector as shown on the plans. No more than six probes shall be assembled as a set. The cables between probes shall be long enough to provide the spacing shown on the plans plus 5 feet. If spacing is not shown on the plans, 15 feet of cable shall be provided between probes. Each set of probes shall have one lead-in cable. 1092.4.7.2 Pedestrian Push Button. Pedestrian push-button detectors shall be of the pressure-activated type with essentially no moving parts. The housing shall be aluminum, black, round in shape and shaped to fit the curvature of the post to which it is attached and shall provide a rigid installation. Contacts shall be normally open, entirely insulated from the housing and actuator, and have connecting terminals. The housing shall have one outlet tapped for ½ inch pipe. The actuator shall be a minimum of 2 inches in diameter, raised, contrast visually with the housing and be made of brass or corrosion-resistant metal alloy or non-metallic material. A maximum force of 5 pounds shall be required to activate the switch. Switch shall be of the solid-state electronic, piezo type, The operating voltage shall not exceed 24 volts. The entire assembly shall be weatherproof, secure against electrical shock to the user and vandal resistant. Entire assembly shall be rated to operate between –30 degrees F to 165 degrees F and shall not allow ice to form such to impede the operation of the button. 1092.4.7.2.1 Accessible Pedestrian Signal (APS). APS pushbutton detectors shall be in accordance with Sec 1092.4.7.2, except a maximum force of 3.5 pounds shall be required to activate the switch. APS pushbutton detectors shall include tactile arrows and actuators made of brass or corrosion-resistant metal alloy or non- metallic material. Tactile arrows shall be located on the pushbuttons, raised, with high visual contrast (light on dark or dark on light). 1092.4.7.3 Induction Loop Detectors. Induction loop vehicle detectors shall detect a vehicle stopped within the field of the loop or passing over the loop at speeds up to 80 mph. Induction loop detectors shall be card rack mounted. For double controller cabinets, card rack assemblies and detectors shall be installed in the same compartment as each respective associated controller. 1092.4.7.4 NEMA Card Rack Assemblies. The supporting and connecting rack shall contain space for a minimum of two power supplies and shall have a minimum of eight card positions for two-channel detector units. Upper and lower slide guides shall be provided for the power supply and each detector card. Where detectors are specified, the rack and power supplies shall be included with the detectors, and no direct payment will be made.
a.The card mounting rack shall be attached to the controller cabinet by a hinge or pivot assembly, which allows the rack to rotate horizontally so as to expose the rack wiring to facilitate maintenance operations. The rack shall be positioned to rotate out freely 90 degrees without conflicting with other wiring, equipment or the controller cabinet. Sufficient wire lengths shall be provided for rotation. The rack shall not block the back panel or other termination panels.
b.The power supply shall be capable of supplying a minimum of 200 milliamps to each detection channel position. The power supply shall be capable of operating a full rack of time delay detectors regardless of the amount and type of detectors required. Each power supply channel shall power no more than one detector card. Each channel shall be individually fused.
c.Each card rack detector shall have a regulator for the power input. The regulator shall have the appropriate power and voltage rating for operation of the detector.
d.Card racks shall mate with a 44-terminal, double row, 0.156-inch contact spacing, Cinch Jones card edge connection 50-44A-30M or equivalent. Input/output connector pin terminations shall be in accordance with NEMA Specification TS. All useable functions shall be fully wired for use.
e.All circuitry shall be of solid state, temperature compensating components.
f.Unless shown otherwise on the plans, each detector in the card rack shall be associated with the appropriate phase as follows: 784Channel Card Position 1 2 345 6 78 1 ø 1ø 1 or 6ø 6ø 6ø 3ø 3 or 8ø 8ø 8 2 ø 5ø 5 or 2ø 2ø 2ø 7ø 7 or 4ø 4ø 4
g.Each detector channel shall be clearly labeled with phase and direction. 1092.4.7.4.1 Card Rack Detectors. Card rack detectors shall meet the following requirements:
a.Card rack-mounted detectors shall incorporate two detection channels.
b.Each detector channel shall have at least a two-frequency selection capability, at least two levels of operational sensitivity and shall be capable of tuning to a minimum inductance range of 70 to 1000 microhenries.
c.All controls and indications shall be mounted on the front panel of the sensing unit, with the exception of extension and delay timing controls on card rack mounted detectors.
d.A manual control shall be provided for each channel to select pulse or full presence operation.
e.Each detector channel, after installation and initial adjustment, shall automatically tune to various loop configurations ranging in size from 6 x 6 feet minimum to 6 x 100 feet maximum. The maximum lead-in length shall be 750 feet.
f.Each detector channel shall time out and retune automatically if a continuous vehicle occupation of the loop field for a nominal time of 10 to 30 minutes is sensed.
g.In the event of power loss to the detector or channel, a continuous call shall be made to the controller.
h.All circuitry shall be of solid state, digital design and incorporate temperature-compensating components, with the exception of the output relay.
i.If specified, each channel shall have extension and delay timing features, as follows:
1.Delay timing range from 0 to 30 seconds in 1.0-second increments.
2.Extension timing range from 0 to 7.5 seconds in a maximum of 0.5-second increments.
j.The sensing unit shall have a light that will illuminate when a vehicle is within the loop field. Other visual indications of relay closure may be used if approved by the engineer.
k.Each detector and channel shall be in accordance with NEMA Standard Publication TS. 1092.4.7.4.2 Dual Output Card Rack Detectors. Dual output card rack detectors shall be in accordance with NEMA and shall provide two relay outputs per induction loop detector. One output shall be capable of pulse detection for the purpose of traffic counting, speed and occupancy measurements. The other output shall be capable of presence detection. Each detector output shall be assigned to a separate detector input into the controller. 1092.4.7.5 Calling Detector Relay. A calling detector relay shall operate with any detector and allow the detector to place only one actuation when the red indication is being displayed to the associated phase. The relay shall be self-contained. 1092.4.7.6 Microwave Vehicle Detectors. The product shall be designed for traffic management application and detect vehicles within user definable fields of detection. The number of lanes covered and number of detection outputs shall be sufficient to support the specific traffic signal design or application. The product shall have a minimum detection range of 120 feet for any vehicle type. The product shall be designed to place a 785constant call to the controller in the event of any failure. All product components shall meet or exceed NEMA environmental standards, including a continuous operating temperature range of -29° F to 165° F (-34° C to 74° C). The unit shall have FCC certification and shall be tested to the applicable FCC specifications. Sensor enclosures shall be weather and UV resistant. All user operated controls and adjustments shall be clearly marked and easily accessible. The product shall include all interface circuitry and cabinet modules necessary to interface with NEMA TS1, NEMA TS2 or Type 170 traffic signal control cabinets as appropriate to support the specific traffic signal design or application. All cabling installed shall be as specified by the detection system manufacturer. The product shall include mounting hardware designed for attachment to typical signal and lighting structures. Power supply equipment shall be specified by the detection system manufacturer and shall be provided with the unit. Any software required for configuration, operation or maintenance shall be included. 1092.4.7.7 Video Detection System. 1092.4.7.7.1 System Requirements. The video detection system shall provide flexible detection zone placement at any location and at any orientation within the combined field of view of the image processors. Preferred presence detector zone configurations shall be a box or lines placed across lanes of traffic or lines placed parallel with lanes of traffic. Detection zones shall be capable of overlapping. 1092.4.7.7.1.1 The detection zones shall be created by using a track ball to draw the detection zones on the video image. A graphical user interface shall be built into the automatic control unit (ACU) and displayed on a video monitor or computer. Editing of previously defined detector configurations to fine-tune detection zone placement shall be possible. 1092.4.7.7.1.2 When a vehicle is detected by crossing a detection zone, there shall be a visual change on the video display, such as a flashing symbol or a change in color or intensity to verify proper operation of the detection system. 1092.4.7.7.1.3 Overall performance of the video detection system shall be comparable to inductive loops. Using camera optics and in the absence of occlusion, the system shall be able to detect vehicle presence with 95 percent accuracy under normal day and night conditions with only slight deterioration in performance under adverse weather conditions, including fog, snow and rain. When visibility exceeds the capabilities of the camera, the system shall default to placing a call on all detectors. 1092.4.7.7.1.4 The video detection system shall be programmable via one dial up modem connection at a minimum of 19,200 bytes per second to the camera(s). Still image and real time detection displays to a remote computer using supplied system software through the modem shall be provided. 1092.4.7.7.2 System Components. The video detection system will be defined as the complete assembly of all required equipment and components for detection of vehicles. Each system shall consist of the video camera(s), lightning arrester for video cabling, an ACU, a track ball, software and license, if applicable, for system control via a computer, one dial-up modem, 56.6 kilobytes per second maximum connection and V.90 compliant and a monitor. All camera views shall be obtainable without requiring the disconnection and reconnection of cables within the system. 1092.4.7.7.2.1 System Software. The system shall include software that detects vehicles in multiple lanes using only the video image. Detection zones shall be defined using a video monitor and a pointing device to place the zones on a video image, which may include a laptop computer. A minimum of 12 detection zones per camera shall be available. 1092.4.7.7.2.2 Automatic Control Unit. The bus connections used to interconnect modules of the ACU shall be gold-plated DIN connectors. Serial communications to a computer shall be through an RS-232/RS-422 serial port. The port shall have the capability to access detection system data as well as the real-time imagery needed to show detector actuations. A subminiature "D" connector on the front of the ACU shall be used for serial communications with a computer running supplied system software. 1092.4.7.7.2.2.1 The equipment shall be provided with either a NEMA TS1 or NEMA TS2 interface as shown on the plans. 1092.4.7.7.2.2.1.1 For TS1 systems, the ACU process unit shall be equipped with a TS1 detector interface for a minimum of 16 detector outputs or 32 detector outputs, if required by specifications. NEMA red/green inputs 786for each phase shall be available to provide delay/extend functions, either through the detector or the controller. Logic output levels shall be compatible with the TS1. A subminiature "D" connector on the front of the ACU shall be used for interfacing to these outputs. 1092.4.7.7.2.2.1.2 For TS2 systems, the ACU processor unit shall be equipped with a TS2 Type 1 detector interface, where detector information is transmitted serially via an RS-485 data path. NEMA red/green inputs for each phase shall be available to provide delay/extend functions, either through the detector or the controller. A 15-pin subminiature "D" connector, meeting the requirements of the TS2 standard, shall be used for the serial detector output. A minimum of 32 detector outputs will be required. 1092.4.7.7.2.2.2 The video detection system shall be provided for either single camera or multiple camera installations as shown on the plans. 1092.4.7.7.2.2.2.1 For single camera installations, the ACU shall have an RS-170 (NTSC) video input to process the camera or any other synchronous video source in real-time. The ACU shall have an RS-170 (NTSC) video output. 1092.4.7.7.2.2.2.2 For multiple camera installations, the ACU shall have a minimum of four RS-170 (NTSC) composite video inputs to process the synchronous video cameras or any other synchronous video source in real-time. A fifth video input shall be provided to allow connection of a local surveillance camera or other non- detection video source. The video from the auxiliary input shall not be processed for video detection. The ACU shall have an RS-170 (NTSC) composite video output, which may correspond to any of the video inputs, as selected remotely via RS-232 or locally by front panel switch. Multiple video inputs requiring external cable connections will not be permitted. 1092.4.7.7.2.2.3 The ACU or computer shall store a minimum of two separate detection zone configurations. The ACU shall be capable of switching to any of the different detector patterns at the request of the user and shall be a menu selection with a track ball. 1092.4.7.7.2.3 Monitor. The monitor shall have a 9-inch screen, an NTSC-M system and BNC video in-out connections. 1092.4.7.7.2.4 Video Camera and Housing. The ACU supplier shall furnish the video camera for traffic detection. The camera shall produce a video image of vehicles under normal roadway lighting conditions regardless of time of day. The video shall produce a clear image for scenes with a luminance from 0.009 to 929 footcandles. 1092.4.7.7.2.4.1 The camera shall provide a minimum resolution of 500 lines horizontal and 350 lines vertical. 1092.4.7.7.2.4.2 The camera shall include an electronic shutter or auto iris control based on average scene luminance and shall be equipped with an auto iris lens. 1092.4.7.7.2.4.3 The camera shall have a variable focal length. The maximum aperture of the lens shall not be smaller than f1.8 and the minimum aperture shall not be larger than f300. The camera shall have a horizontal field of view ranging from a minimum angle of view between 5 degrees and 10 degrees wide to a maximum angle of view 45 degrees or more. The adjustments for focus and focal length shall be made without opening up the camera housing. 1092.4.7.7.2.4.4 The camera shall be contained in an enclosure that is waterproof and dust-tight to NEMA-4 specifications. A heater shall be incorporated in the camera to prevent the formation of condensation and to assure proper operation of the lens' iris mechanism. The heater shall not interfere with the operation of the image sensor electronics and shall not cause interference with the video signal. The enclosure shall allow the camera to be rotated in the field during installation. 1092.4.7.7.2.4.5 The housing shall be equipped with a sun shield that prevents sunlight from directly entering the lens. The sun shield shall include a provision for water diversion to prevent water from flowing in the camera field of view. 1092.4.7.7.2.4.6 The total weight of the enclosure, camera, lens, housing, sun shield and mounting bracket shall be less than 10 pounds. 7871092.4.7.7.2.5 Cable. Coaxial cable shall be a 75 ohm, precision video cable with 20 AWG solid or stranded bare copper conductor, maximum of 10.1 ohms/m Nom. direct current resistance, solid polyethylene insulating dielectric, 96 percent minimum tinned copper double-braided shield with a black polyethylene outer covering. The signal attenuation shall not exceed 0.8 decibels per 100 feet at 10 megahertz. Nominal outside diameter shall be 0.305 inches. The cable shall be in accordance with Belden Type 8281, West Penn P806 or approved equal. 1092.4.7.7.2.5.1 Seventy-five ohm BNC plug connectors shall be used with coaxial cable. The supplier of the video detection system shall approve the coaxial cable, BNC connectors and crimping tool. The manufacturer's instructions shall be followed. 1092.4.7.7.2.5.2 Multi-conductor cable shall be per the manufacturer's recommendations and in accordance with Sec 1061. 1092.4.7.7.2.6 Maintenance and Support. The supplier shall maintain an ongoing program of technical support and software updates for the video detection system following expiration of the warranty period. The supplier shall maintain an adequate inventory of parts to support maintenance and repair of the video detection system. 1092.4.7.7.2.7 Warranty of Video Detection System. The video detection system shall be warranted to be free of defects in material and workmanship for a minimum of two years. During the warranty period, technical support from factory certified personnel or factory certified installers shall be available from the supplier. Ongoing software support by the supplier shall include updates for the ACU and computer software and shall be provided at no cost to the Commission during the warranty period. The update of the ACU software to be National Transportation Communications for ITS Protocol (NTCIP) compliant shall be included. 1092.4.7.7.2.8 Training of Video Detection System. A minimum of one day of training shall be provided in the operation, setup and maintenance of the video detection system. 1092.5 Detector Loop Sealant. Loop sealant shall have the following minimum characteristics:
a.The loop sealant used to fill the saw cuts and other gaps shall be of a type intended for and designed to be used as traffic loop embedding. The sealant shall be designed for installation when the surface temperature of the roadway is between 40 and 120 F and exhibit minimal shrinkage and stringing during and after installation. The curing time of the sealant shall be a maximum of 72 hours. Cured sealant shall retain permanent flexibility to 0 F, be temperature stable and ensure the integrity of the loop detector installation from -40 to 200 F. The loop sealant shall adhere to the roadway pavement and resist the effects of weather, including freeze-thaw cycles, de-icing chemicals, salts, gasoline and motor oils, such that the operation of the detector is not affected.
b.The three types of allowable loop sealant will be two-part polyester resin, one-part moisture curing polyurethane and hot-melt bituminous.
c.The loop sealant shall provide a minimum shelf life of nine months. Prior to the installation of any detector loop sealant, the MSDS or an OSHA Form 20 along with the manufacturer's technical data sheet, shall be submitted to the engineer. Any sealant used on loop detectors shall meet the approval of the engineer. 1092.6 Warranty. All traffic controller assemblies, excluding video detection systems, shall be warranted by the manufacturer to be free from defects in workmanship and material for at least one year from the date of project acceptance. Any components found to be defective during the warranty period shall be replaced free of charge. All warranties provided shall be transferred to the Commission upon project acceptance. Video detection systems shall be warranted in accordance with Sec 1092.4.7.7. 788Table of Contents 100 General Conditions of the Contract 3 101 Definition of T erms 16 102 Bidding Requirements and Conditions 25 103 A ward and Execution of Contract 33 104 Scope of W ork 35 105 Control of W ork 43 106 Control of Material 60 107 Legal Relations and Responsibility to the Public 67 108 Prosecution and Progress 75 109 Measurement and Payment 86 110 State and Federal W age Rates and Other Requirements 98 200 Grading and Removals 4 201 Clearing and Grubbing 99 202 Removal of Roadways and Buildings 102
202.10 Plugging and Closure of W ells 104
202.20 Septic T ank Plugging and Disposal 104
202.30 Removal of Improvements for Roadway Contracts 105
202.40 Demolition and Removal of Buildings 105
202.50 Removal of Contaminated Material and Storage T anks 109
202.60 Individual W astewater Lagoon Closures 111
203 Roadway and Drainage Excavation, Embankment and Compaction 112 204 Embankment Monitoring 123
204.10 Settlement Gauges 123
204.20 Pore Pressure Measurement Devices 123
205 Modified Subgrade 127 206 Excavation for Structures 129 207 Linear Grading 134 208 Interception Ditch 136 209 Subgrade Preparation 137 210 Subgrade Compaction 138 211 Subgrade Scarifying 139 212 Subgrading and Shouldering 140 214 Rock Fill 141 215 Shaping Slopes 142 216 Removal of Bridge Structures 143
216.10 Removal of Bridges 143
216.20 Scarification of Bridge Deck 143
216.30 Seal Coat and W earing Surface Removal 143
216.40 Removal and Storage of Existing Bridge Rail 144
216.50 Removal of Existing Bridge Deck 144
216.60 Partial Removal of Existing Bridge Deck 145
216.70 Partial Removal of Culvert and Substructure Concrete 145
216.80 Curb Removal 146
216.90 Removal of Existing Expansion Joint and Adjacent Concrete 146
216.100 Removal of Existing Expansion Joint Seal or Sealant 147 789216.1 10 Total Surface Hydro Demolition 147 300 Bases and Aggregate Surfaces 5 302 Stabilized Permeable Base 152 303 Rock Base 154 304 Aggregate Base Course 156 310 Aggregate Surface 160 400 Flexible Pavements 6 401 Plant Mix Bituminous Base and Pavement 162 402 Plant Mix Bituminous Surface Leveling 171 403 Asphaltic Concrete Pavement 174 404 Bituminous Mixing Plants 195 407 T ack Coat 201 408 Prime Coat 203 409 Seal Coat 204 413 Surface T reatments 207
413.10 Micro-Surfacing 207
413.20 Scrub Seal 214
413.30 Ultrathin Bonded Asphalt W earing Surface 215
413.31 Bonded Hot Mix Asphalt Using Polymer Modified Emulsion Membrane 220
413.40 Bituminous Fog Sealing 221
413.50 Bituminous Pavement Crack Sealing 222
413.60 Portland Cement Concrete Pavement Joint/Crack Sealing 223
413.70 Bituminous Pavement Crack Filling 223
413.80 Portland Cement Concrete Pavement Crack Filling 224
500 Rigid Pavements 7 501 Concrete 225 502 Portland Cement Concrete Base and Pavement 236 503 Bridge Approach Slab 254 504 Concrete Approach Pavement 255 505 Bridge Deck Concrete W earing Surface 256
505.10 Low Slump Concrete 256
505.20 Latex Modified Concrete 262
505.30 Silica Fume Concrete 265
505.40 Latex Modified V ery Early Strength Concrete 267
505.50 CSA Cement V ery Early Strength Concrete 272
505.60 Steel Fiber Reinforced Concrete 277
505.70 Polyester Polymer Concrete 278
506 Concrete Overlays for Pavement 282
506.10 Bonded Concrete Overlays of Asphalt Pavements 282
506.20 Unbonded Concrete Overlays of Concrete Pavements 284
506.30 Unbonded Concrete Overlays on Asphalt Pavements 287
507 Strength of Concrete Using the Maturity Method 288 600 Incidental Construction 8 601 Field Laboratories 291 602 Markers 293 603 W ater Line Installation 294 604 Miscellaneous Drainage 296
604.10 Concrete Headwalls, Drop Inlets and Manholes 296
790604.20 Adjusting Drainage Facilitites 297
604.30 Adjusting House Sewer Connections 297
604.40 Pipe Collars 298
604.50 Connecting Pipe to Existing Structures 298
604.60 Slotted Drains 298
605 Underdrainage 300
605.10 Pipe-Aggregate Pavement Edge Drain 300
605.20 Geocomposite Pavement Edge Drain 302
605.30 Pipe-Aggregate Pavement Cross Drain 302
605.40 Structural Underdrain 303
605.50 French Underdrain 303
605.60 Outlet Pipes and Splash Pads 304
605.70 Aggregate Drains 305
606 Guardrial, Crashworth End T erminals, One-Strand Access Restraint Cable and Three-Strand Guard Cable306
606.10 Guardrail 307
606.20 Blank 308
606.30 Crashworthy End T erminals 308
606.40 One-Strand Access Restraint Cable 309
606.50 Three-Strand Guard Cable 309
607 Fencing 311
607.10 Chain-Link Fence 311
607.20 W oven W ire Fence 312
608 Concrete Median, Median Strip, Sidewalk, Curb Ramps, Steps and Paved Approaches 314 609 Paved Drainage 317
609.10 Concrete Curb, Gutter and Paved Ditch 317
609.20 Integral Curb 318
609.30 Asphalt Curb 319
609.40 Drain Basin Asphalt Curb 319
609.50 Blank 320
609.60 Rock Ditch Liner 320
609.70 Rock Lining 321
610 Pavement Smoothness 322 611 Embankment Protection 327
611.10 Blank 327
611.20 Blank 327
611.30 Rock Blanket 327
611.40 Blank 328
611.50 Revetment 328
611.60 Concrete Slope Protection 328
611.70 Gabions 329
612 Impact Attenuators 331 613 Pavement Repair 333
613.10 Full Depth Pavement Repairs 333
613.20 Class A Partial Depth Pavement Repairs 335
613.30 Class B Partial Depth Pavement Repairs 338
613.35 Class C Partial Depth Pavement Repair 339
613.40 Dowel Bar Retrofit 340
613.50 Cross Stitching 341
791614 Drainage Fittings 343
614.10 Grates and Bearing Plates 343
614.20 Automatic Floodgate 343
614.30 Manhole Frame and Cover and Curb Inlet 344
616 T emporary T raffic Control 345 617 Concrete T raffic Control 352
617.10 Permanent Concrete T raffic Barrier 352
617.20 T emporary T raffic Barrier 352
617.30 T raffic Barrier Delineators 353
618 Mobilization 355 619 Pavement Edge T reatment 356 620 Pavement Marking 357
620.10 T emporary Pavement Marking 357
620.20 Permanent Pavement Marking 361
620.30 Drop-On Glass Beads 364
620.40 Quality Control and Quality Assurance 364
620.50 Pavement Marking Removal 366
620.60 Contrast Pavement Marking 366
621 Flowable Backfill 368 622 Pavement and Bridge Surface Removal and T exturing 370
622.10 Cold Milling Existing Pavement for Removal of Surface 370
622.20 Cold Milling Pavement for a Driving Surface 371
622.30 Diamond Grinding of Existing Portland Cement Concrete Pavement 373
622.40 Diamond Grinding of New Portland Cement Concrete Pavement 375
623 Polymer Products 377
623.10 Concrete Bonding Compound 377
623.20 Epoxy Mortar 377
623.30 Epoxy Polymer W earing Surface 378
623.40 Polymer Concrete 381
623.50 Methyl Methacr Yla Te Pol Ymer Slurr Y Wearing Surf Ace 381
624 Geotextile Construction 385 625 Slab Stabilization 386
625.10 Slab Undersealing 386
625.20 Slab Jacking 388
626 Rumble Strips 390 627 Contractor Surveying and Staking 391 700 Structures 10 701 Drilled Shafts 393 702 Load-Bearing Piles 408 703 Concrete Masonry Construction 413 704 Concrete Masonry Repair 423 705 Prestressed Concrete Members for Bridges 429 706 Reinforcing Steel for Concrete Structures 430 707 Conduit System on Structure 432 710 Epoxy Coated Reinforcing Steel 433 711 Protective Coatings for Exposed Concrete Surfaces 434 712 Structural Steel Construction 435 713 Thrie Beam for Bridge Guardrail 442 792715 V ertical Drain at End Bents 443 716 Neoprene Bearings 444
716.10 Plain and Laminated Neoprene Bearing Pad 444
716.20 Laminated Neoprene Bearing Pad Assembly 444
716.30 T ype "N" Polyetrafluoroethylene (PTFE) Bearings 444
717 Neoprene and Silicone Joint Systems 446
717.10 Preformed Compression Seal 446
717.20 Strip Seal 446
717.30 Silicone Expansion Joint Sealant 447
717.40 Silicone Joint Sealant for Saw Cut and Formed Joints 448
717.50 Open Cell Foam Joint 449
717.60 Preformed Silicone or EPDM Expansion Joints 450
718 T emporary Bridge 452 720 Mechaznically Stabilized Earth W all Systems 454 724 Pipe Culverts 458 725 Metal Pipe and Pipe-Arch Culverts 463 726 Rigid Pipe Culverts 466 727 Structural Plate Pipe and Structural Plate Pipe-Arch Culverts 469 730 Thermoplastic Pipe Culverts 471 731 Precast Reinforced Concrete Manholes and Drop Inlets 473 732 Flared End Sections 474 733 Precast Concrete Box Culverts 476 734 Installation of Pipe by Horizontal Boring Methods 478 735 Culvert Pipe Liner 480 800 Roadside Development 11 801 Lime and Fertilizer 482 802 Mulching 483 803 Sodding 484 804 T opsoil 485 805 Seeding 486 806 Pollution, Erosion and Sediment Control 490
806.10 T emporary Berms 491
806.20 T emporary Slope Drains 492
806.30 T emporary Ditch and Inlet Checks 492
806.40 Sediment Basins 493
806.50 T emporary Seeding 494
806.60 Sediment T rap 495
806.70 Silt Fence 495
806.80 T emporary Pipe 496
806.90 Erosion Control Blankets and T urf Reinforcement Mats 497
806.100 T emporary Stream Crossing 497 806.1 10 Sediment Removal 498 808 Planting T rees, Shrubs and Other Plants 499 900 Traffic Control Facilities 12 901 Highway Lighting 501 902 T raffic Signals 508 903 Highway Signing 524 1000 Materials Details 13 7931001 General Requirements for Material 530 1002 Aggregate for Asphaltic Concrete 534 1003 Aggregate for Seal Coats 536 1004 Graded Aggregate for Bituminous Surface 538 1005 Aggregate for Concrete 539 1006 Aggregate for Surfacing 543 1007 Aggregate for Base 544 1009 Aggregate for Drainage 545 1010 Select Granular Backfill for Structural Systems 547 1011 Geotextile 549 1012 Geocomposite Drainage Material 552 1013 Miscellaneous Drainage Material 553 1015 Bituminous Material 554
1015.10 Performance Graded Asphalt Binder 556
1015.20 Liquid Bituminous Material 558
1017 Ground Granulated Blast Furnace Slag 565 1018 Fly Ash for Concrete 568 1019 Cement 571 1020 Corrugated Metallic-Coated Culvert Pipe, Pipe-Arches and End Sections 574 1021 Bituminous-Coated Corrugated Metal Culvert Pipe and Pipe-Arches 580 1022 Corrugated Metallic-Coated Steel Pipe Underdrain 581 1023 Structural Plate Pipe and Pipe-Arches 582 1024 Corrugated Aluminum Alloy Culvert Pipe and Corrugated Aluminum Alloy Structural Plate 585 1025 Corrugated Aluminum Alloy Pipe Underdrains 586 1026 Reinforced Concrete Culvert Pipe 587 1027 Polymer -Coated Corrugated Metal Culvert Pope and Pipe-Arches 591 1028 Polyvinyl Chloride Culvert Pipe 592 1029 Fabricated Prestressed Concrete Members for Bridges 595 1030 V itrified Clay Sewer and Culvert Pipe 604 1031 Clay Drain T ile 605 1032 Precast Concrete Flared End Sections 606 1033 Precast Drainage Units 607 1034 Reinforced Concrete Elliptical Culvert Pipe 611 1035 Reinforced Concrete Arch Culvert 612 1036 Reinforcing Steel for Concrete 613 1037 Shear Connectors 614 1038 Bearing Pads for Structures 616 1039 Polymer Products 620
1039.10 T ype II Epoxy 620
1039.20 T ype III Epoxy 620
1039.30 Epoxy or Polyester Bonding Agents for Dowels 620
1039.40 Epoxy Bonding Agents for Resin Anchors 621
1039.50 Sand for Epocy Mortar 622
1039.60 Epoxy Polymer W earing Surface 622
1039.70 Polymer Concrete 624
1039.80 Methyl Methacrylate (MMA) Polymer Slurry W earing Surface 625
1039.90 Polyester Polymer W earing Surface 626
1040 Guardrail, End T erminals, One-Strand Access Restraint Cable and Three-Strand Guard Cable Material 628 1041 Polypropylene Culvert Pipe 633 7941042 Highway Sign Material 636 1043 Fence Material 640 1044 Posts for Markers and Delineators 644 1045 Paint for Structural Steel 646 1046 Pipe Liner 653 1047 Corrugated Polyethylene Culvert Pipe 654 1048 Pavement Marking Material 657
1048.10 T emporary Pavement Marking Materials 657
1048.20 Permanent Pavement Marking Materials 661
1048.30 Drop-On Glass Beads 667
1049 Precast Concrete Box Culverts 669 1050 Lumber , Timber , Piling, Posts and Poles 673 1051 Slotted Drain 676 1052 Mechanically Stabilized Earth W all System Components 677
1052.10 Metallic Soil Reinforcement 677
1052.20 Non-Metallic Soil Reinforcement 677
1052.30 MSE Panel and Sound W alls 678
1052.40 Small Block W all System - Concrete Blocks 681
1053 Concrete Sealer 683 1054 Concrete Admixtures 685 1055 Concrete Curing Material 689 1056 Concrete T inting and Staining Material 691
1056.10 Concrete T inting Material 691
1056.20 Concrete Staining Material 691
1057 Material for Joints 692 1058 Polyethylene Sheeting 696 1059 Protective Coating Material 697
1059.10 Protective Coating-Concrete Bents and Piers (Urethane) 697
1059.20 Protective Coating - Concrete Bents and Piers (Epoxy) 697
1059.30 Concrete and Masonry Protection System 698
1059.40 Sacrifical Graf fiti Protection System 699
1059.50 T emporary Coating - Concrete Bents and Piers (W eathering Steel) 700
1060 Electrical Conduit 701 1061 Electrical Conductors 703 1062 Pull and Junction Boxes 705 1063 T emporary T raffic Control Devices 707 1064 T emporary Concrete T raffic Barrier 711 1065 Delineators 713 1066 Mortars and Grout 714 1067 T runcated Domes 715 1068 T rench Drains 716 1070 W ater 717 1071 Asphalt Release Agents, Fiber Additives and Liquid Anti-Strip Additives 718 1073 Joint Material for Structures 721 1075 Centrifugally - Cast Fiber glass-Reinforced Polymer Mortar Pipe 724 1080 Structural Steel Fabrication 725 1081 Coating of Structural Steel 741
1081.10 Protective Paint Systems 741
1081.20 Galvanizing of Structural Steel 751
7951091 Lighting Equipment 753 1092 Signal Equipment 759
Source: Missouri Standard Specifications for Highway Construction, 2023 Edition. Pages 623–797 of 797.