902Quality Control

902.1 Description

902.1.1 General

This Work consists of the Contractor performing Quality Control which includes sampling, testing, and inspection to moni tor and adjust its processes.

902.2 Quality Control Plan

Where a Contractor Quality Control Plan is required in the spe cifications, the Contractor shall provide a Quality Control plan as specified in this secti on. At the Pre-Construction Conference, the Contractor shall be prepared to discuss Quality Control responsibilities for specific Contract Items. The Contractor shall submit the Quali ty Control plan to the Project Manager at least two (2) weeks before starting Work on requirin g the Plan. The Contractor shall not begin Work on HMA, WMA, OGFC, Base Course and PCCP th at requires a Quality Control Plan until the Plan is reviewed and approved by the Pro ject Manager and the District Laboratory Supervisor. The Quality Control Plan shall itemize inspections, testing procedures, sampling and testing frequencies, and corrective action strateg ies that the Contractor will use to control the Work. The Contractor shall develop the Quality Control Plan in accordance with

902.2.1 Contactor Quality Control Plan for HMA/WMA and Base Cou rse

The Plan shall address pertinent specifications.

902.2.1 1 Contractor Organization

Contractor Organization: 1. The Plan shall address authority levels/duties by position a nd name of persons holding those positions. 2. The Plan shall include those who can be contacted by State p ersonnel and have decision making authority with regard to Quality Control, Mater ials, sampling and testing.

902.2.1 2 Sampling, Testing and Lab Facilities

Sampling, Testing and Lab Facilities: 1. The Plan shall include copies o f TTCP certification or Walle t Card of all personnel who will be performing Process Qu ality Control testing for the Contractor. 2. The Plan shall identify lab location. 3. The Plan shall identify person(s) responsible for identifyin g random sampling locations. 4. The Plan shall identify how and when lab Equipment will be c alibrated. 5. The Plan shall identify person(s) responsible for contacting Project Manager when lab facilities are ready for inspection. 6. The Plan shall identify person(s) responsible for maintainin g control charts and all records associated with Materials sampling, testing and calibra tion of lab Equipment. 7. The Plan shall identify person(s) responsible for dispute re solution.

902.2.1 3 HMA/WMA Mix Design

HMA/WMA Mix Design: 1. The Plan shall identify which Department approved testing la b is responsible for mix design(s). 2. The Plan shall identify amount of Material that will be crus hed or stockpiled prior to mix design submittal. 3. The Plan shall identify asphalt supplier. 4. The Plan shall outline asphalt sampling program to include f requency, storage and person(s) responsible for obtaining samples. 5. The Plan shall outline asphalt storage tank inspection proce dure prior to initial loading, it shall identify the person responsible for storage t ank inspection.

902.2.1 4 Aggregate Production

Aggregate Production: 1. The Plan shall identify pit location(s), and type of Materia l. 2. The Plan shall identify which approved testing lab is respon sible for determining aggregate index (HMA, WMA, Base Course, and OGFC). 3. The Plan shall identify anticipated production rate during c rushing. 4. The Plan shall identify number of stockpiles anticipated to be utilized in HMA/WMA mix design. 5. The Plan shall identify crushing Equipment that will be used to produce aggregate for HMA, WMA, Base Course and OGFC. 6. The Plan shall identify smallest sieve used to remove natura l fines. 7. The Plan shall describe how test data will be utilized to id entify inconsistencies and changes in aggregate being produced. 8. The Plan shall describe corrections that will be made when t est data indicates Material properties have changed. 9. The Plan shall identify testing/sampling methods and frequen cies that will be performed during crushing.

902.2.1 5 Stockpile Management, Stockpiled Material, and Qualit y Components

Stockpile Management, Stockpiled Material, and Quality Compone nts: 1. The Plan shall describe how stockpiles will be constructed. Describe as a minimum how each requirement in Section 423.2.2.3, "Stockpiling” or Sec tion 424.2.2.3, "Stockpiling” will be achieved. 2. The Plan shall identify testing/sampling methods and frequen cies that was performed on stockpiled Material (LL, PL, FF, SE, flat & elonga ted, fine aggregate angularity, wet prep, gradation) for HMA, WMA, Base Course and OGFC. 3. The Plan shall describe how test data will be utilized to id entify out of specification Material and what corrective actions will be taken.

902.2.1 6 Recycled Asphalt Pavement

Recycled Asphalt Pavement: 1. The Plan shall define RAP source and how representative samp les will be obtained of sufficient quantity for mix design development. 2. The Plan shall identify approved testing lab that will perfo rm AASHTO T-96 LA Wear, FF, Flat & Elongated and any additional testing that will be performed. 3. The Plan shall identify perce nt of RAP tha t will be used in each mix design. 4. The Plan shall describe process that will be used to develop mix design when using less 15% RAP. 5. The Plan shall describe process that will be used to develop mix design when using greater than 15% but less than 25% RAP. 6. The Plan shall describe process that will be used to develop mix design when using 25% to 35% RAP. 7. The Plan shall identify stockpile management and how many st ockpiles will be maintained (minimum of two (2)). 8. The Plan shall identify what fractionation each stockpile wi ll be divided into. 9. The Plan shall describe where RAP will be introduced into mi xing drum.

902.2.1 7 Production of HMA/WMA

Production of HMA/WMA: 1. The Plan shall describe Equipment that will be used to produ ce HMA/WMA. 2. The Plan shall identify plant production rate. 3. The Plan shall describe how lime/anhydrite will be introduce d into the mix and protected from wind loss. 4. The Plan shall describe how and when moisture will be added to activate lime/anhydrite. 5. The Plan shall identify amount of moisture that will be adde d and how cold feed moisture will be measured. 6. The Plan shall describe how consistent mixing temperature wi ll be maintained. 7. The Plan shall describe how sa mples will be taken on combine d Material (cold feed), excluding RAP and before addition of lime/anhydrite based Mater ial. 8. The Plan shall identify sampling and testing frequency on co mbined Material for determination of Material passing the No. 40 sieve to be non-pl astic, the plus 3/8” Material to contain a maximum of 20% flat, elongated particles with a dimensional ratio of 3:1 or greater, determination of fine aggregate angula rity, SE, FF. 9. The Plan shall describe how test data will be used to identi fy consistency and changes in HMA/WMA being produced. 10. The Plan shall describe what corrective action process will start when test results are out of specification; this will include what increased freq uency of testing is until corrective measures have brought mix back into specification. 11. The Plan shall describe method of loading and Equipment use d to transport HMA/WMA. 12. The Plan shall describe length of haul and how adequate Mat erial temperatures will be maintained. 13. The Plan shall identify specific WMA technology (must be on approved products list) and how it will be introduced in the production of WMA. 14. The Plan shall describe process used to manage WMA temperat ures.

902.2.1 8 Placement of HMA/WMA

Placement of HMA/WMA: 1. The Plan shall identify how Material will be transferred fro m haul vehicles to placement Equipment. 2. The Plan shall describe how segregation will be prevented du ring placement. 3. The Plan shall describe paver speed, roller speed, number of rollers, number of trucks and plant production that will maintain a continuation o f placement operations without stopping and starting. 4. The Plan shall describe proper use of auger extensions, if r equired and how proper amount of head in front of augers will be maintained. 5. The Plan shall describe pull widths and placement sequence t hat will achieve quantities/dimensions as shown on the plans. 6. The Plan shall describe how joints will be constructed and c ompaction of taper joints will be obtained. 7. The Plan shall describe how hand Work such as raking will be conducted on joints and how broadcasting aggregate onto mat will be prevented. 8. The Plan shall describe how acceptable compaction will be ac hieved including roller pattern and compaction monitoring process. 9. The Plan shall identify person(s) who will be tracking yield and person authorized to make adjustment to prevent overruns. 10. The Plan shall identify Department approved release agent t hat will be used to prevent mix from adhering to truck beds and other Equipment. 11. The Plan shall describe random sampling plan that will be u tilized. 12. The Plan shall identify lot and sub lot sizes. 13. The Plan shall define how and where test strip will be cons tructed and evaluated for compliance with mix design. 14. The Plan shall define shakedown period and how it will be e valuated for compliance with mix design. 15. The Plan shall describe Process Quality Control sampling an d testing frequency for each test that will be performed on the placed HMA/WMA. 16. The Plan shall identify time periods when WMA mixture can b e sampled and testing can be performed. 17. The Plan shall describe how test data will be used to ident ify consistency and changes in HMA/WMA being placed. 18. The Plan shall describe wha t information will be utilized t o make JMF changes. 19. The Plan shall describe what corrective action process will sta rt wh e n test re sults are out of specification; this will include what increased freq uency of testing is until corrective measures have brought mix back into specification.

902.2.1 9 Base Course Placement Base Course Placement:

1. The Plan shall identify any mixing and processing that will take place before Base Course (BC) is transported to the Roadway. 2. The Plan shall describe how BC will be transported to the Ro adway. 3. The Plan shall describe how BC will be placed and spread. 4. The Plan shall describe how compaction will be monitored and achieve. 5. The Plan shall describe how line and grade control will be a chieved. 6. The Plan shall identify lot and sub lot sizes. 7. The Plan shall identify person(s) who will be tracking yield and person authorized to make adjustment to prevent overruns. 8. The Plan shall describe random sampling plan that will be ut ilized. 9. The Plan shall describe Process Quality Control sampling and testing frequency for each test that will performed on the placed BC (FF, gradation, LL, PI, moisture content, thickness, and density). 10. The Plan shall describe what corrective action process will start when test results are out of specification; this will include what increased freq uency of testing is until corrective measures have brought BC back into specification.

902.2.1 10 OGFC Placement

OGFC Placement: 1. The Plan shall identify that the Contractor shall develop th e mix design at no additional cost to the Department. 2. The Plan shall identify any anticipated differences in plan quantity tonnage due to Material types. 3. The Plan shall describe how plan depth will be maintained. 4. The Plan shall describe how design target AC content will be maintained. 5. The Plan shall define how low and defective areas will be co rrected with hot OGFC before compaction. 6. The Plan shall define how finished surface will be smooth an d free of irregularities larger than 1/8”.

902.2.1 11 Smoothness

Smoothness: 1. The Plan shall identify if smoothness specification applies to this Project. 2. The Plan shall identify Department approved profiler that wi ll be utilized. 3. The Plan shall identify Roadway surface preparation prior to profiling. 4. The Plan shall describe sequence measurements will be taken with accompanying NMDOT representative and submission of data. 5. The Plan shall describe evaluation of profile data using Pro VAL for must grind Work and corrective Work required. 6. The Plan shall describe format of written corrective Work pl an that will be submitted to the Project Manager. Changes and data not available at time of submittal of the Pla n can be added, although need to be approved by the Project Manager and District Lab Sup ervisor.

902.2.2 Contactor Quality Control Plan for PCCP

The plan shall address pertinent specifications.

902.2.2 1 Contractor Organization

Contractor Organization: 1. The Plan shall address authority levels/duties by position a nd name of persons holding those positions. 2. The Plan shall include those who can be contacted by State p ersonnel and have decision making authority with regard to Quality Control, Mater ials, sampling and testing. 3. The Plan shall identify when Joint Layout Plan will be submi tted in accordance with Section 450.3.4, “Joints.”

902.2.2 2 Sampling, Testing and Lab Facilities

Sampling, Testing a nd Lab Facilities: 1. The Plan shall include copies of TTCP certification of all p ersonnel who will be performing Process Quality Control testing for the Contractor. 2. The Plan shall identify lab location. 3. The Plan shall identify person(s) responsible for determinin g random sampling locations, and how the original random samp ling locations will be confirmed. 4. The Plan shall identify how and when lab Equi pment will be c alibrated. 5. The Plan shall identify person(s) responsible for contacting the Project Manager when lab facilities are ready for inspection in accordance with Sect ion 901, “Quality Control/Quality Assurance (QC/QA) - General Provisions.” 6. The Plan shall identify person(s) responsible for maintainin g control charts and all records associated with Materials sampling, testing and calibra tion of lab Equipment. 7. The Plan shall identify person(s) responsible for dispute re solution.

902.2.2 3 Concrete Mix Design

Concrete Mix Design: 1. The Plan shall identify concrete supplier. 2. The Plan shall provide copies of all approved mix designs an d field report forms to be used; a. If approved mix design is not available, the Plan shall iden tify how and when the approved mix will become available.

902.2.2 4 Aggregate Production

Aggregate Production: 1. If concrete mix design is approved using Standard Stockpile procedures, the Plan shall identify how stockpiles will be maintained and monitored to com ply with; a. Required master-band gradations; and b. Fineness-modulus requirements. 2. If concrete mix design is approved using the Combined Gradat ion procedures, the Plan shall identify; a. How the required gradations will be performed; b. Who will perform the required gra dations; c. Where the required gradations will be performed; d. How often t he required grad ations will be p erformed; and e. How the informati on will be pro vided to the Department. 3. The Plan shall describe aggregate production and compliance. Includes control charts tracking items as indicated in Section 906, “Minimum Testing Re quirements” and 4. The Plan shall describe stockpile management.

902.2.2 5 Batching & Hauling

Batching & Hauling: 1. The Plan shall identify manufacturer and type of Equipment. 2. The Plan shall define all batching procedures, including ord er of addition of individual ingredients. 3. The Plan shall identify ho w cement and fl y ash will be: a. Stored; b. Kept separate; c. Kept dry; and d. Maximum anticipated time on-site before use. 4. The Plan shall identify how c hemical admixtur es will be stor ed and protected; and introduced into the mix. 5. The Plan shall identify the process used to manage concrete temperatures. 6. The Plan shall identify how a ggregate moistures will be dete rmined, monitored and communicated to the Department. 7. The Plan shall describe wash-down and final mixing procedure s; after concrete mix has been loaded into trucks. Include process control performed , if any, at this point. 8. The Plan shall identify pre-departure procedures for all del ivery trucks. 9. The Plan shall provide written approval of Batch Plant and a ll operations by NMDOT; to include scale certification. 10. The Plan shall identify proposed delivery rate. 11. The Plan shall identify Certificate of Inspection and Certi fication of all mixer trucks to be used on the Project. 12. The Plan shall identify proposed delivery route (haul road) . 13. The Plan shall de scribe how Material te mperatures will be m aintained. 14. The Plan shall describe the corrective action process if ba tch weights are out of specification. This will include how the problem will be recog nized, and at what point production will cease and a written corrective action Plan will be presented and approved by the Project Manager before resuming production.

902.2.2 6 Placement and Finishing of Concrete

Placement and Finishing of Concrete: 1. The Plan shall address verification process that subgrade/ba se has been approved and grades have been verified prior to concrete placement. 2. The Plan shall identify and describe placement method (slip form or construction by form). 3. The Plan shall describe placement and securing of dowels and tie bars. 4. The Plan shall describe Equi pment and tools to be utilized. 5. The Plan shall identify how Material will be transferred fro m haul vehicles to placement location. 6. The Plan shall describe how Material handling Equipment will prevent segregation. a. Include discussion on how segregation will be recognized, an d how it will be eliminated, if detected; and b. Indicate how much Material w ill be maintained and monitored in front of the paver to prevent paste segregation. 7. The Plan shall describe method(s) for vibrating and consolid ating concrete. 8. The Plan shall provide balance sheets that demonstrate how p aver speed, number of trucks and plant production will maintain a continuation of pla cement operations without stopping and starting. 9. The Plan shall describe pull widths and placement sequence t hat will achieve quantities/dimensions as shown on the Plans. 10. The Plan shall describe method used to measure and maintain plan thickness. 11. The Plan shall describe joint Construction, longitudinal an d transverse. 12. The Plan shall describe sawing operations. a. What kind of sawing Equipment will be used; b. How many unit s will be used; c. How sawing operations will insu re initial saw-cuts are made within the allotted time; and d. How many and what kind of spare Equipment and parts will be maintained on- site. 13. The Plan shall describe joint sealing operations and Materi als. 14. The Plan shall describe grooving or tining operations. 15. The Plan shall describe method(s) for curing concrete. 16. The Plan shall describe how evaporation potential will be m onitored and provided to the Project Manager. 17. The Plan shall de scribe random samplin g plan that will be u tilized and documented. 18. The Plan shall identify lot and sub lot sizes. 19. The Plan shall define Shake down Period and how it will be e valuated for compliance with mix design. 20. The Plan shall describe Process Quality Control sampling an d testing used for compliance and control charts for tracking items in Section 906 , “Minimum Testing Requirements” and Section 902.8, “Control Charts.” 21. The Plan shall describe what corrective action process will be taken, and when it will be started when test results are out of specification; this wil l include what increased frequency of testing is until corrective measures have brought mix back into compliance. This will include a measure of threshold at which time concrete placement will cease and a written corrective action Plan will be present ed and approved by the Project Manager before resuming placement. 22. The Plan shall describe method and Material available for c onstructing a bulk-head if it becomes necessary. This should just be that the concrete is cu t back to the nearest joint that the surface plane meets the ten (10) ft straightedge tolerance. 23. The Plan shall describe what emergency covering and protect ive measures will be available in case of unforeseen weather or other events forcing unanticipated protection of the concrete.

902.2.2 7 Smoothness

Smoothness: 1. The Plan shall identify measures to be taken to insure smoot hness. 2. The Plan shall ident ify if profiler smoo thness specification applies to this Project. 3. The Plan shall identify Department approved profiler that wi ll be utilized. 4. The Plan shall identify Roadway surface preparation prior to profiling. 5. The Plan shall describe sequence measurements will be taken with accompanying NMDOT representative and submission of data. 6. The Plan shall describe evaluation of profile data using Pro VAL for must grind Work and corrective Work required. a. The Plan shall insure proper version of ProVAL is available before Project begins. As with HMA we should be considering the filter to be used also . 7. The Plan shall describe format of written corrective Work Pl an that will be submitted to the Project Manager. Changes and data not available at time of submittal of the Pla n can be added, although need to be approved by the Project Manager and District Lab Sup ervisor.

902.3 Quality Control Laboratory

The Contractor shall perform the Quality Control testing using a private testing Laboratory or a Contractor provided Laboratory. The Contractor shall use, at minimum, a portable or permanent Quality Control Type II Laboratory in accordance with Section 622.3.2.2, “Field Office Equipment.” The Contractor shall calibrate or check tes ting Equipment in accordance with AASHTO R-18. The Contractor shall provide written documen tation that testing Equipment is calibrated and meet s the applicable Specifications . The Contractor shall allow the Department unrestricted access to the Laboratory. The Department may conduct an independent inspection of the Contrac tor’s field Laboratory. The Project Manager in conjunction wi th the District Lab Supervisor may determine acceptability of the Quality Control Laboratory. The Project Manager will provi de the Contractor a written accounting of Laboratory deficiencies, if any.

902.4 Plan Administration and Technician Qualification

The Contractor shall identify the individual who will administ er the Plan. The individual shall have full authority to tak e actions necessary for the suc cessful operation of the Plan. Quality Control Technicians (QCT’ s) performing the actual sampl ing, testing, or inspection shall be TTCP certified as described in Section 901.1.2, “Techn ician Certification.” The Contractor shall cease producti on if certified personnel are un available on the Project.

902.5 Sampling The sampling plan shall contain a random sampling selection te chnique in accordance

with specified Department, AASHTO, or ASTM procedures, as modif ied by the State Materials Bureau. The sampling plan shall be submitted as a component of the Quality Control Plan. The Contractor shall allow the Project Manager to witness all s ampling and testing. The Contractor shall take additional s amples if directed by the Pro ject Manager.

902.6 Testing

The Department will use only test results from the random samp ling plan in the quality level analysis for pay factor determination. Additional inform ational test results will not be used in the quality level analysis. The Contractor shall provi de original Quality Control test results (on approved forms and to include all calculations, scr atch sheets, internal forms etc.) to the Project Manager within two (2) Working Days of sampling. Failure to provide the test results of sampling may result in the Project Manager ordering the Contractor to cease associated operations until said results are provided to the Pr oject Manager.

902.7 Records

The Contractor shall maintain copies of the complete set of or iginal Quality Control test records including supporting docu ments (calculations, scratch s heets, internal forms etc.), upon request, make them available to the Project Manager within 24 hours. The Technician performing the testing shall sign and certify the results as “t rue and accurate to the best of my belief and knowledge” prior to providing the results to the Dep artment. No hard copy Laboratory testing documentation shall be destroyed for any rea son, even after the data is entered into the computer spreadsheet for analysis. If complet e records are not provided as requested, the Department may determine the pay factor using th e Department’s test values only for all testing characteristics. The Contractor shall mai ntain copies of test documentation for a minimum of three (3) years after the Physical Completion Date of the Project.

902.8 Control Charts

The Contractor shall update test control charts daily on all t ests in accordance with Section 906, “Minimum Testing Requirements.” The Contractor sh all keep at a location approved by the Project Manager. The Contractor shall provide at least the following information on the charts: 1. Project number; 2. Contract Item number; 3. Test number; 4. Applicable test parameter; and 5. Upper and lower specification limit applicable to each test parameter.

902.9 METHOD OF MEASUREMENT—Reserved

902.10 Basis of Payment

The Department will pay for Contractor Process Quality Control on Projects as follows: 1. 25% of the Lump sum pay item or 0.5% of the Total Original C ontract Amount, whichever is less upon approval of the Quality Control Plan; an d 2. The remaining Lump sum prorated based on total job progress. The Department will withhold payment if the Contractor does no t provide test result documentation in accordance with the Contract. Pay Item Pay Unit Contractor Process Quality Control Lump Sum Section 903: Quality Assurance Page 932