501Portland Cement Concrete Production

501-1DESCRIPTION. These general requirements apply to all Portland Cement Concrete (PCC)

Quality Control (QC) is defined as all activities required to produce PCC that meets all specification requirements. The Contractor shall be responsible for QC and perform QC work in accordance with the requirements of Materials Procedure (MP) 501-3 Quality Control – Plant and Field inspection for Portland Cement Concrete. Quality Assurance (QA) is defined as all activities performed to assure that PCC production meets the specification requirements for the given application. The Department will be responsible for QA and will determine acceptability of all PCC in accordance with the requirements of Materials Procedure (MP) 501- 4 Quality Assurance -Field Inspection for Portland Cement Concrete.

501-2MATERIALS. Produce concrete mixture in accordance with the requirements outlined in this

specification, including all applicable Test Methods and Materials Procedures. Concrete mixture designs must be reviewed and accepted for use by the Department prior to any concrete production. The Department reserves the right to suspend any mixture design which produces unacceptable results.

501-2.01Concrete Mixture Designs. Formulate and submit Performance Engineered Mixture (PEM)

concrete design(s) to the Regional Materials Engineer (RME) in accordance with the requirements of Materials Procedure (MP) 501-2 Mix Design and Approval Procedure for Performance Engineered Mixtures – Structural Concrete or Materials Procedure (MP) 502-1 Design and Approval of Performance Engineered Mixes for Concrete Pavement, and the Contract Documents. Table 2 – Concrete Mixtures of MP 501-2, outlines the specified mixture design and performance criteria, based on application of use. 501-2.02 190

501-2.02Material Requirements. The Contractor shall use materials meeting the requirements specified

in the following subsections of Section 700 – Materials and Manufacturing. Portland Cement 701-01 Blended Portland Cement 701-03 Rapid Hardening Cement 701-13 Fine Aggregate 703-01 Coarse Aggregate 703-02 Lightweight Aggregate 703-10 Fibers 711-01 Admixtures 711-08 Fly Ash 711-10 Microsilica 711-11 Slag Cement (GGBFS) 711-12 Calcium Nitrite Based Corrosion Inhibitor 711-13 High Reactivity Pozzolan 711-14 Misc. Supplementary Cementitious Material 711-15 Water 712-01

on the Approved List. Cementitious materials stored over the winter at concrete producing facilities will need to be retested for specification compliance. All contaminated or hardened cementitious material will be rejected and not used in Department work. B.C. Aggregates. The Contractor shall only use aggregates from sources on the Department’s Approved List Sources of Fine and Coarse Aggregates (PCC Aggregate Sources as located on the Material Suppliers Viewer). Coarse aggregates shall be crushed. When aggregates for the mixture are from more than one source or of more than one type of material, proportion and blend them to provide a uniform mixture, in accordance with the aggregate gradation requirements of MP 501- 2, MATERIALS, Subsection 3, Aggregate Gradation Requirements. C.D. Aggregate Friction. The Contractor shall use friction aggregate as specified in the contract documents, in accordance with the following requirements and Materials Method 28 Friction Aggregate Control and Test Procedures. C.

used in concrete highway wearing surfaces shall use sands (natural or manufactured) that contain at least 25.0% acid-insoluble residue in the plus No. 30 size fraction and in the minus No. 30 size fraction.

requirements: • Sandstone, granite, chert, traprock, ore tailings, slag, or other similar non- carbonate materials. • For concrete mixtures with a NMAS (Nominal Maximum Aggregate Size as defined in ASTM C125) less than or equal to 1/2 inch: o Gravel or a blend of rock types containing no less than 90.0% non- carbonate particles (by weight with adjustments to equivalent volumes for materials of different specific gravities) in the minus 1 inch, plus No. 4 sieve size fraction. 501-2.02 191 • For concrete mixtures with a NMAS greater than 1/2 inch: o Gravel or a blend of rock types containing no less than 90.0% non- carbonate particles (by weight with adjustments to equivalent volumes for materials of different specific gravities) in the minus 1 1/2 inch, plus 1/2 inch and the minus 1/2 inch, plus No. 4 sieve size fractions.

requirements: • Sandstone, granite, chert, traprock, ore tailings, slag, or other similar non- carbonate materials. • Limestone, dolomite, or a blend of the two, having an acid-insoluble residue content not less than 20.0%. • For concrete mixtures with a NMAS less than or equal to 1/2 inch: o Gravel or a blend of rock types containing no less than 20.0% non- carbonate particles (by weight with adjustments to equivalent volumes for materials of different specific gravities) in the minus 1 inch, plus No. 4 sieve size fraction. • For concrete mixtures with a NMAS greater than 1/2 inch: o Gravel or a blend of rock types containing no less than 20.0% non- carbonate particles (by weight with adjustments to equivalent volumes for materials of different specific gravities) in the minus 1 1/2 inch, plus 1/2 inch and the minus 1/2 inch, plus No. 4 sieve size fractions.

requirements: • Sandstone, granite, chert, traprock, ore tailings, slag or other similar non- carbonate materials. • Limestone or a blend of limestone and dolomite having an acid-insoluble residue content not less than 20.0%. • Dolomite. • For concrete mixtures with a NMAS less than or equal to 1/2 inch: o Gravel or a blend of rock types containing no less than 20.0% non- carbonate particles (by weight with adjustments to equivalent volumes for materials of different specific gravities) in the minus 1 inch, plus No. 4 sieve size fraction. • For concrete mixtures with a NMAS greater than 1/2 inch: o Gravel or a blend of rock types containing no less than 20.0% non- carbonate particles (by weight with adjustments to equivalent volumes for materials of different specific gravities) in the minus 1 1/2 inch, plus 1/2 inch and the minus 1/2 inch, plus No. 4 sieve size fractions.

Coarse Aggregate.

which appear on the Department’s Approved List. Admixtures for which there is no Approved List category shall be in conformance with the requirements of ASTM C494 - Standard 501-3.01 192 Specification for Chemical Admixtures for Concrete and require approval by the Director, Materials Bureau. Use of admixtures shall be in accordance with the manufacturer’s recommendation for the mixture design and anticipated field conditions, including dosage rate.

501-3CONSTRUCTION DETAILS. The Contractor shall notify the RME’s office by 3:00 PM on the

business day before any production for the Department.

501-3.01Concrete Batching Facility Requirements. Batching facilities shall meet the requirements of

Materials Procedure (MP) 501-1 Plant Production Requirements and Procedures for Portland Cement Concrete Facilities.

501-3.02Concrete Mixer and Delivery Unit Requirements. Concrete Mixer and Delivery Unit

Requirements shall be in accordance with the requirements of Materials Procedure MP 501-1.

cubic yards or less. Mix for at least 90 seconds after all materials are in the mixer.

miscellaneous work such as curb, gutter, headwalls, catch basins, manholes, drop inlets, field inlets, sign foundations, lighting structure foundations, anchor units, pullboxes, leveling footings sidewalks, curbs, ramps and similar placements. Mobile mixer approval and use shall be in accordance with Materials Method (MM) 9.4 Calibration of Mobile Mixers (Concrete Mobiles) to Produce Portland Cement Concrete.

501-3.03Self-Consolidating Concrete (SCC). The Contractor may, with the approval of the Engineer

submit a proposed mix design for Self-Consolidating Concrete (SCC). Mixture performance requirements specified in the contract documents shall apply to the SCC mixture. The Contractor shall create a mix design and prepare a trial batch using those materials to be used on the project. The Contractor must demonstrate the mix’s ability to achieve the specified properties to the RME and Engineer’s satisfaction. The design requirements for SCC mixes shall be in accordance with MP 501-

RME a minimum of three weeks before placement.

501-3.04Concrete Mixing, Transporting and Discharging. The Contractor shall mix the concrete at a

central mix plant, in truck mixers, in transit, or at the site. Transport the concrete in vehicles meeting the requirements of §501-3.02 Concrete Mixer and Delivery Unit Requirements. The Contractor shall place the fresh concrete directly into the forms or into conveyance equipment approved by the Department before evidence of initial set and within established time limits. Once discharge has started, no water additions shall be allowed unless otherwise specified. Concrete with a discharge temperature exceeding 90°F will be rejected. The Engineer or RME may disapprove the use of any type of concrete mixing or transporting units when unsatisfactory results occur.

transported in approved agitating or non-agitating delivery units to the deposition point.

mixed completely in a truck mixer at the following locations or combinations thereof: the plant, while in transit, or the discharge point. 501-3.04 193

meeting the requirements of Materials Procedure MP 501-1. D.Time Limits for Delivery and Discharge. Mixing time, completion of discharge, and required agitation after the completion of mixing is dependent on both the type of mixing unit and the type of delivery units. Table 501-1 details the minimum requirements for the various options.

subsequent lifts is included in delivery and discharge time limit.

obtained.

aggregates are loaded such that the fine aggregate is not in direct contact with the cement, the material can be transported for 90 minutes before mixing. Completion of discharge must occur within 45 minutes of mixing.

be allowed at the discharge point to obtain the desired mixture properties. After each addition, mix the concrete at least 30 mixing-speed revolutions to produce a homogeneous mixture. No water additions are allowed once discharge has begun.

2 Concrete Uniformity. It will only be necessary to verify that mixing equipment meets uniformity requirements if evidence of non-uniform concrete is found or a reduced mixing time for central mixers is requested. Samples shall be taken at the mixer discharge point and test in accordance with the requirements of MP 501-4. TABLE 501-2 CONCRETE UNIFORMITY Test Permissible Variation 1 Weight per cubic foot calculated to an air-free basis 2.0 lb/cf Air Content, % by volume of concrete 1.0% Slump or Spread: Average slump 4 in or less 1 in Average slump greater than 4 in 1 1/2 in Average spread 2 in TABLE 501-1 TIME LIMITS FOR DELIVERY AND DISCHARGE Plant Type/Delivery Unit Minimum Mixing Time Or Minimum Mixing Revolutions Maximum Time to Completion of Discharge (Minutes)1 Truck or Transit Unit Mixing Speed Post Mixing Agitation Central Mix Concrete in Non- Agitating / Open Haul Units 90 Seconds 30 2, 3 N/A N/A Central Mix in Agitating - rotating drum units 90 Seconds 90 2,3, 4 N/A 2-6 RPM Transit Mix Concrete 100 Revolutions 90 3, 4, 5 6-18 RPM 2-6 RPM Truck Mix Concrete 100 Revolutions See Note 6 6-18 RPM 2-6 RPM 501-3.05 194 Coarse aggregate content, portion by weight of each sample retained on a No. 4 sieve 6.0% Note 1. Sampled from 2 different locations in the batch

501-3.05Production Facility Laboratory. Maintain an approved production facility site laboratory to

perform all required concrete mixture sampling and testing in accordance with the requirements of MP 501-1.

501-3.06Plant Production Quality Control (QC) Sampling and Testing. The Contractor shall perform

Quality Control (QC) sampling and testing in accordance with the requirements of MP 501-3. Contractor testing results will not be used for acceptance. All QC testing data shall be provided to the Department within 24 hours of testing.

501-3.07Field Delivery Quality Control (QC) Sampling and Testing. The Contractor shall provide an

American Concrete Institute (ACI) Certified Concrete Field Testing Technician, Grade 1, or higher to perform sampling and testing in accordance with the requirements of MP 501-3. The Contractor shall provide acceptable proof of ACI Certification before placing any concrete. All testing equipment being used by the Contractor shall be properly maintained and calibrated. The Contractor shall provide calibration records for all equipment being used. The QC sampling and testing shall be documented in accordance with the requirements of MP 501-3. All QC testing data shall be provided to the Department within 24 hours of testing.

loading, the Contractor shall: • Provide an American Concrete Institute (ACI) Certified Concrete Field Testing Technician -Grade I, or higher to perform all sampling and fabrication of test samples. • Cast cylinders following the requirements of ASTM C31 for each placement, with a minimum of one set of three 4 in x 8 in cylinders for each age that cylinder breaks are to be performed. • The Contractor shall field cure the cylinders in accordance with the requirements of ASTM C31 that simulates the condition of the placement. • The Contractor shall transport test cylinders to the Regional Materials Lab for record compressive strength determination at the desired evaluation time interval. The Contractor shall notify the Regional Materials Lab to arrange delivery of samples a minimum of 24 hours prior to the desired testing time frame. The average strength shall meet or exceed the design strength requirement and no individual cylinder in the set shall be less than 90% of the design strength.

501-3.08Quality Assurance (QA) Acceptance Sampling and Testing. Acceptance sampling and

testing will be performed by the Department in accordance with MP 501-4 after QC testing is complete and the concrete is presented to the Department in compliance with Contract requirements. Plastic concrete will be sampled and tested for air content and temperature. Cylinders will be cast for compressive strength and surface resistivity testing. Samples will be taken randomly from placements. TABLE 501-3 QUALITY ASSURANCE FREQUENCY Application Procedures Minimum Rate Structural Concrete Air, Temperature, and Cylinders 1 set from each structural element per day. An additional set will be required for placements at a rate of 1 set per ± 200 yd3 for the duration of that placement. 1 501-3.08 195 Concrete Pavement Air, Temperature, and Cylinders 1 set per ± 1000 yds3 and a minimum of 2 sets per each day’s placement Other Applications Refer to Materials Procedure 501-4 Quality Assurance Field Inspection of Portland Cement Concrete, Section 5. Sampling and Testing Frequency - Table 2 Note 1. The structural component/placement will be defined by the Engineer.

representing structural concrete placements will be tested at 28 days of age and cylinders representing concrete pavements will be tested at the time specified in the contract plans for opening to traffic, in accordance with the requirements of AASHTO T22 - Standard Method of Test for Compressive Strength of Cylindrical Concrete Specimens. The results of all test cylinder specimens representing an element placed, or part thereof, on a given day will be averaged to determine the compressive strength for each placement. The average shall meet or exceed the design strength requirement and no individual cylinder in the set shall be less than 90% of the design strength.

be cured for 28 days following the requirements of AASHTO T358 - Standard Method of Test for Surface Resistivity Indication of Concrete’s Ability to Resist ChlorideIon Penetration. Testing will be performed at 28 days of age. Specimens not meeting resistivity criteria at 28 days will be returned to curing. Specimens may be retested until 56 days of age. The results of all test cylinder specimens representing an element placed, or part thereof, on a given day will be averaged to determine the resistivity for each placement.

design compressive strength or below 70% of the project design surface resistivity, the placement represented by the cylinders tested shall be rejected. Corrective action will be determined by the Department and will be completed by the Contractor at no additional cost to the State.

evidence that the concrete cylinders being used for acceptance testing were sampled improperly or if irregularities were observed during acceptance cylinder fabrication, curing, or handling up to the point of cylinder transport from the work site. The written notification including supporting evidence must be presented to the Engineer within 7 days of the date the cylinders were fabricated.

501-4METHOD OF MEASUREMENT. The Engineer will compute the volume of concrete within the

payment lines indicated on the plans or as specified by the Engineer for the item placed. No deductions will be made for the volume of embedded reinforcement, structural shapes or joint materials. Also, no deductions will be made in concrete pavement for catch basins, manholes, etc. unless otherwise indicated in the contract documents.

501-5DETERMINATION OF QUALITY ADJUSTMENT

completed in accordance with §501-3.08 and Table 501-3- Quality Assurance Frequency. The values for average concrete cylinder compressive strength (𝐹𝐶 𝐴𝑣𝑒𝑟𝑎𝑔𝑒) and the average concrete 501-3.08 196 cylinder surface resistivity (𝑆𝑅𝐴𝑣𝑒𝑟𝑎𝑔𝑒) for that day will be used to calculate the adjustment factor.

design surface resistivity (𝑆𝑅 𝐷𝑒𝑠𝑖𝑔𝑛) values will be compared to the QA test results using the formulas given in Table 501-4, QAF Determination. Table 501-4 QAF Determination Quality Adjustment Factor Fc (28 Day) Quality Adjustment Factor SR (56 Day) 1.25 ∗ ( 𝐹𝐶 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐹𝑐 𝐷𝑒𝑠𝑖𝑔𝑛 − 1) ∗ 100 = 𝑄𝐴𝐹_𝐹𝐶 0.416 ∗ ( 𝑆𝑅𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑆𝑅 𝐷𝑒𝑠𝑖𝑔𝑛 − 1) ∗ 100 = 𝑄𝐴𝐹𝑆𝑅 Note 1: Quality Adjustment Factors greater than zero will be rounded down to zero for computation of quality units. Quality Adjustment Factors less than zero will be rounded to the nearest tenth.

501-5, Quantity of Quality Unit Determination. Cubic yards placed will be the total cubic yards placed per item, per day, represented by the cylinders cast during that placement. Table 501-5 Quantity of Quality Units Determination QAF_FC * Cubic Yards Placed + QAFSR * Cubic Yards Placed = Quantity of Quality Units1 Note 1. The quantity of quality units will be rounded to the nearest tenth. Noe 2. Refer to MP 501-4 for additional information on Quality Adjustment Factor (QAF) determination.