106CONTROL OF MATERIAL

106.01GENERAL —Use material complying with the requirements of these specifications. At the pre-

construction conference, submit a list of material to be sampled and tested by the Contractor and a list of material to be sampled and tested by the Department. Comply with the provisions of the Pennsylvania Trade Practices Act, 71 P.S. Section 773.101, et seq., concerning the purchase of aluminum and steel products produced in a foreign country. On Federal -Aid projects, also comply with the provisions specified in Section 106.10. Comply with the provisions of the Steel Products Procurement Act, 73 P.S. Section 1881, et seq. in the performance of the contract or any subcontract. Following contract execution, furnish to the Department a complete statement of the project construction material’s origin, composition, and manufacture. For Fabricated Structural Steel materials, as identified in Section 1105.01(a) and inspected in accordance with Section 1105.01(e), and any other fabricated aluminum, precast or prestressed concrete products inspected during manufacturing, stamped, and approved for shipment by the Department’s Representative, furnish Form CS -4171 to the Inspector -in-Charge. Certified mill test reports for any steel included will be reviewed by the Department’s Inspector and retained by the fabricator. For all other steel products or products containing steel that will be permanently incorporated in the project, provide the Inspector-in-Charge the following when the product is delivered to the project site:

• For any “identifiable” steel products, certification that Section 4 of the Steel Products Procurement Act, 73 P .S. Section 1884, has been complied with. Identifiable steel products are steel products which contain permanent markings which indicate the material was both melted and manufactured in the United States.

• For all other “unidentifiable” steel products, documentation such as invoices, bills of lading, and mill certification that positively identify that the steel was melted and manufactured in the United States.

The provisions of the Steel Products Procurement Act will not be waived unless the Secretary has determined, under authority granted in Section 4(b) of the act, that a certain steel product or products is not produced in the United States in sufficient quantities to meet contract requirements. Such a determination will be set forth in a proposal for the Department’s review and response. Include with the proposal a comprehensive list of sources, including names and contact information, for verification. The Secretary does not have the authority to waive the provisions specified in Section 106.10. Steel products are defined as products rolled, formed, shaped, drawn, extruded, forged, cast, fabricated, otherwise similarly processed, or processed by a combination of two or more of these operations from steel made in the United States by the open heart h, basic oxygen, electric furnace, Bessemer, or any other steel-producing process. Included are cast iron products and machinery and equipment as listed in United States Department of Commerce Standard Industrial Classification 25, 35, and 37 and made of, fabricated from, or containing steel components. If a product, as delivered to the project, contains both foreign and United States steel, such product is considered to be a United States steel product only if at least 75% of the cost of the articles, materials, and supplies have been mined, produced, or manufactured, as the case may be, in the United States. on Federal-Aid projects, comply with the provisions specified in Section 106.10. No payment will be made on the contract if unidentified steel products are supplied, until the hereinbefore requirements are met. Any payments made that should not have been made may be recoverable from a manufacturer or supplier as well as from a contractor or subcontractor. Any person who willfully violates the Steel Products Procurement Act will be prohibited from submitting bids for any contract for a period of 5 years from the date of determination that a violation has occurred. If a subcontractor, manufacturer, or supplier, violates the Steel Products Procurement Act, such person will be prohibited from performing any work or supplying any materials to the Department for a period of 5 years from the date of determination that a violation has occurred. If steel products are used as a construction tool or appurtenance and will not serve a permanent functional use in the project, compliance with the Steel Products Procurement Act is not required. When standard manufactured items are specified and these items are identified by unit mass (unit weight), section dimensions, or similar characteristics, their identification will be considered to be nominal masses (weights) or dimensions. Unless more stri ngently controlled by specified tolerances, industry

established manufacturing tolerances will be accepted.

106.02MATERIAL—

on Form CS-200 (Source of Supply. Materials) or Form CS-201 (Source of Supply. Traffic Control Devices) and approved before delivery to project. Department Bulletin listed material and material sources are available for use by the Contractor. If non- Bulletin material or material sources are proposed for use, the requirements specified in 106.02(a)2 must be met before these materials are delivered t o the project. The Department reserves the right to obtain samples of any material provided by the Contractor for laboratory testing to verify compliance with specifications.

• Any material and material source listed in Bulletin 14 and used in the material application as specified in the Bulletin, Publication 408, or a Special Provision.

• Any material and material source listed in Bulletin 15 and used in the material application as specified in the Bulletin, Publication 408, or a Special Provision.

• Any asphalt material and material application specified in Publication 408 and produced at a source listed in Bulletin 41.

• Any cement concrete material and material application specified in Publication 408 and produced at a source listed in Bulletin 42.

Submit a CS-200 or CS-201 to the Representative with the following information: contract item number, item description, material description/type/class, product name, manufacturer/producer plant location, applicable Bulletin supplier code, Bulletin number, and Publication 408 or Bulletin Section. If a previously submitted Bulletin material source no longer provides the specified material, submit a change in material to the Representative as outlined on Form CS-200 or CS-201. Once written acceptance is received, furnish material from another Bulletin material source listed in Bulletin 14, 15, 41, or 42.

• Any material, product, or material source not listed in Bulletin 14 or Bulletin 15

• Any material, product, or material source listed in Bulletin 14 or Bulletin 15 being used in an application not intended or specified in the Bulletin, Publication 408, or a Special Provision

• Any asphalt material or product not produced at a source listed in Bulletin 41

• Any asphalt material or product not specified in Publication 408 or a Special Provision

• Any ready-mixed, cement concrete material or product not produced at a source listed in Bulletin 42

• Any ready-mixed, cement concrete material or product not specified in Publication 408 or a Special Provision

2.a. Construction-Aid Material. A necessary, temporary, or ancillary material that is not specified for use as part of a contract item or extra work item, but used by the Contractor only to aid in the completion of the work. The material is typically not a permanent part of the specified work (example: wood and nails for temporary formwork). The material need not be listed on Form CS-200 and does not require any Department approval for delivery to or use on the project. The Representative reserves the right to determine whether a material is a construction-aid material. Note temporary traffic control items are not construction-aid materials and

do need listed on Form CS-201 since these items must be from Bulletin 15 listed sources and are specified for use as part of contract items or extra work items.

2.b. Project -Specific, LTS Approved Material. Non- Bulletin material proposed for use on a particular project as part of a contract item or extra work item, which requires approval by the LTS. Use of material is not meant to circumvent the use of available material sources listed in Bulletin 14, 15, 41, or 42. Have each material and material source listed on Form CS -200 or Form CS -201. The material is defined as any material, product, or material source that meets one or more of the following criteria:

• Meets specified requirements in Publication 408 or Special Provision, for the material and material application.

• Meets specified requirements in AASHTO or ASTM Standard for the material and material application.

• Meets specified requirements in project Special Provision for the material and material application.

Submit material to the LTS for evaluation and testing a minimum of 90 days before planned delivery to the project. Submit the following information to the LTS, wit h a copy to the Representative: source, description, specified use, QC Plan, independent lab test data showing material meets all specified requirements as determined on a single lot of material, and material samples of the kind and quality specified. Do not deliver material to the project until written acceptance is received from the Representative.

2.c. Project-Specific, Locally Approved Material. Non-Bulletin material proposed for use on a particular project as part of a contract item or extra work item, which does not require LTS approval because of the low risk to constructed Project performance, but does require local approval by the Representative (i.e., at the District or project level). This category of material is not meant to circumvent the use of available material sources listed in the Bulletins, or the requirements of Project -Specific, LTS Approved Materials. These materials must meet specification requirements and will be clearly identified in the specification as only needing local approval by the Representative. Have each material and material source listed on Form CS-200 or Form CS -201. Submit for local approval by the Representative all required information for the material, as indicated in the specification. Examples of locally approved materials are project specific items, such as Section 860 (inlet filter bags), Section 867 (compost filter socks) , and Section 868 (compost blanket and compost filter berms) where the specification indicates that these materials are to be locally approved. Bulletin 15 will reference specific Publication 408 Sections that apply to Locally Approved Materials. Bulletin 15 will not list actual materials or material sources for this category of materials as they will be accepted for use on a project - specific basis by local approval.

for use. Do not incorporate questionable material, until material is tested by LTS and accepted in writing by the Representative. The Department reserves the right to reject questionable material delivered to the project when the LTS test results are not according to the specifications. Furnish assistance to the Inspector, as required to obtain samples. Allow designated Department representatives to inspect material being used, or intended to be used, at any time before, during, or after material preparation, while being used during the progress of the work, or after the work has been completed. Furnish or arrange with producers or manufacturers to provide necessary material, labor, tools, and equipment for such inspection. Inspections and tests, if made at any point other than the point of incorporation in the work, will not guarantee acceptance of the material. Inspection and testing performed by the Department will not relieve the Contractor’s responsibility for QC.

106.03TESTS AND ACCEPTANCE OF MATERIAL—

and construction. Material will be reviewed for acceptance through the Department’s specified acceptance procedures. Sample locations for acceptance testing will be determined by the Department. Perform sampling and testing for acceptance in the presence of the Inspector, unless otherwise specified. Lot size will be specified. If operational conditions cause work to be interrupted before the specified lot size has been achieved, the lot may be redefined by the Inspector. It is the intent of these specifications that each lot be evaluated based on the same number of samples. Transport acceptance samples from sampling point to testing site or other designated location in the presence of the Inspector. The Contractor is responsible for the control and quality of the material and construction. Prepare a QC Plan as specified in Section 106.03(a)2.a and submit it to the Inspector -In-Charge for review at the start of the project. Include QC sampling and testing frequencies and action points to initiate corrective measures. Notify the Inspector before performing QC sampling and testing. Perform QC sampling and testing and report results to the Inspector. Obtain and test samples according to the Department’s PTMs. If the required test method is not specified, use methods described in the AASHTO Standard Specifications for Transportation Materials and Methods of Sampling and Testing, and Supplements, Standards and/or Tentatives of ASTM, or other testing procedures adopted by the Department. Verification sampling and testing will be performed by the District, unless otherwise specified. QA sampling and testing will be performed or witnessed by the BOCM. Independent Assurance sampling and testing will be administered by the CQAD.

2.a Maintain a QC system that provides reasonable assurance that materials, products, and completed construction, submitted for acceptance, conform to contract requirements whether self -manufactured, processed, or procured from subcontractors or vendors. When specified, submit for review, a plan of the QC system to be used. Have performed or perform the inspections and tests required to substantiate product conformance to contract requirements. Make the inspection and test results available for review throughout the contract life. Procedures will be subject to the review of the Department before the work is started. Charts and records documenting QC inspections and tests are the property of the Department. Submit a QC Plan for use in compliance with the following guidelines, as a minimum:

2.a.1 Raw Materials. List the source of material along with methods of documentation and testing performed to assure the material quality.

2.a.2 Production Control. List lot size and samples required; include sample selection, labeling and test procedure; also include manufacturing phase.

2.a.3 Product Testing. List type and frequency of tests to be performed, along with method of documenting and reporting test results. List test equipment and calibration procedure (frequency) required. List procedure for retesting or rejecting items failing the tests. List the d isposal methods and location for test samples and rejected lots.

2.a.4 Personnel. List the personnel in charge of QC and define their areas of responsibility.

2.a.5 Packaging and Shipping. List method of identifying, storing, loading, transporting, and unloading to assure safe delivery of acceptable material and products.

2.a.6 Documentation. List the procedures used for documentation and certification. The QC Plan and process are subject to periodic review and inspection by the Department.

2.b Promptly record conforming and non- conforming inspection and test results on acceptable forms or charts. Keep these records complete and keep them available for inspection at all times during the performance of the work.

2.c Promptly correct any errors, equipment malfunctions, process changes, or other assignable causes which have resulted or could result in the submission of material, products, and completed construction not conforming to specification requirements.

2.d When required, provide, or have provided and maintain measuring and testing devices necessary to ensure that material and products conform to contract requirements. To ensure continued accuracy, calibrate these devices at established intervals against Department standards.

2.e When required, make the measuring and testing equipment available to the Representative for use in determining conformance of material, products, or completed construction with contract requirements. In addition, make personnel available for the operation of such devices and for verification of the accuracy and condition of the devices. Have calibration results available at all times. The Department reserves the right to conduct periodic inspections of the measuring and testing devices to c onfirm both calibration and condition of operation.

2.f Failure to comply with the QC Plan may result in suspension of approval to provide material for Department use and/or removal from the approved list of material suppliers in the applicable bulletins.

3.a Percent Within Limits. The percentage of each lot within the specified limits will be determined by the following procedures:

3.a.1 The “n” sampling positions on the lot will be located by use of the table of random numbers found in PTM No. 1.

3.a.2 A measurement will be made at each location, or a test portion taken and the measurement made on the test portion.

3.a.3 The lot ( X ) measurements are averaged to find X .

∑ = = n 1 i i n XX

3.a.4 The Standard Deviation, “s,” of the lot measurements will be determined as follows:

∑ = − −= n 1 i

i 1 n ) X X (s

3.a.5 The Quality Index (QU) is found by subtracting the average (X) of the measurements from the upper specification limit (U) and dividing the result by “s.”

s ) X u (Qu −=

3.a.6 The Quality Index (Q L) is found by subtracting the lower specification limit (L) from the average and dividing the result by “s.”

s ) L X (QL −=

3.a.7 The percentage of material that will fall within the upper limit (U) is estimated by entering Table A or Table B with QU, using the column appropriate to the total number of measurements (n). Use Table A if QU has a negative value, or use Table B if QU has a positive value.

3.a.8 The percentage of material that will fall within the lower limit (L) is estimated by entering Table A or Table B with QL, using the column appropriate to the total number of measurements (n). Use Table A if QL has a negative value, or use Table B if QL has a positive value.

3.a.9 In cases where both upper (U) and lower (L) limits are concerned, the percentage of material that will fall within limits is found by adding the percent (PU) within the upper limit (U) to the percent

Total percent within limits = (PU + PL ) - 100

3.a.10 When determining the percentage within limits when the calculated Quality Index (Q.I.) value is between two tabular values in Table A or Table B, the following procedure is used:

• The difference between the tabular Q.I. values on either side of the calculated value Q.I. value will be determined.

• The difference will be divided by 2 and the quotient added to the lower tabular Q.I. value, resulting in the interpolated Q.I. value.

• If the calculated Q.I. is equal to or greater than the interpolated value, the higher listed percent within limits will be used.

• If the calculated Q.I. is less than interpolated value, the lower listed percent within the limits will be used.

TABLE A Estimating Percent of Lot Within Limits (Standard Deviation Method) Negative Values of QU or QL

Percent Within Limits n=3 n=4 n=5 n=6 n=7

50 0.0000 0.0000 0.0000 0.0000 0.0000 49 0.0361 0.0300 0.0281 0.0272 0.0267 48 0.0722 0.0600 0.0562 0.0545 0.0535 47 0.1083 0.0900 0.0843 0.0818 0.0802 46 0.1444 0.1200 0.1124 0.1091 0.1070

45 0.1806 0.1500 0.1406 0.1364 0.1338 44 0.2158 0.1800 0.1689 0.1639 0.1608 43 0.2510 0.2100 0.1972 0.1914 0.1878 42 0.2863 0.2400 0.2256 0.2189 0.2148 41 0.3215 0.2700 0.2539 0.2464 0.2418

40 0.3568 0.3000 0.2823 0.2740 0.2689 39 0.3912 0.3300 0.3106 0.3018 0.2966 38 0.4252 0.3600 0.3392 0.3295 0.3238 37 0.4587 0.3900 0.3678 0.3577 0.3515 36 0.4917 0.4200 0.3968 0.3859 0.3791

35 0.5242 0.4500 0.4254 0.4140 0.4073 34 0.5564 0.4800 0.4544 0.4426 0.4354 33 0.5878 0.5101 0.4837 0.4712 0.4639 32 0.6187 0.5401 0.5131 0.5002 0.4925 31 0.6490 0.5701 0.5424 0.5292 0.5211

30 0.6788 0.6001 0.5717 0.5586 0.5506 29 0.7076 0.6301 0.6018 0.5880 0.5846 28 0.7360 0.6601 0.6315 0.6178 0.6095

27 0.7635 0.6901 0.6619 0.6480 0.6395 26 0.7905 0.7201 0.6919 0.6782 0.6703

25 0.8164 0.7501 0.7227 0.7093 0.7011 24 0.8416 0.7801 0.7535 0.7403 0.7320 23 0.8661 0.8101 0.7846 0.7717 0.7642 22 0.8896 0.8401 0.8161 0.8040 0.7964 21 0.9122 0.8701 0.8479 0.8363 0.8290

20 0.9342 0.9001 0.8798 0.8693 0.8626 19 0.9555 0.9301 0.9123 0.9028 0.8966 18 0.9748 0.9601 0.9453 0.9367 0.9315 17 0.9940 0.9901 0.9782 0.9718 0.9673 16 1.0118 1.0201 1.0125 1.0073 1.0032

TABLE A (continued) Estimating Percent of Lot Within Limits (Standard Deviation Method) Negative Values of QU or QL

Percent Within Limits n=3 n=4 n=5 n=6 n=7

15 1.0286 1.0501 1.0469 1.0437 1.0413 14 1.0446 1.0801 1.0819 1.0813 1.0798 13 1.0597 1.1101 1.1174 1.1196 1.1202 12 1.0732 1.1401 1.1538 1.1592 1.1615 11 1.0864 1.1701 1.1911 1.2001 1.2045

10 1.0977 1.2001 1.2293 1.2421 1.2494 9 1.1087 1.2301 1.2683 1.2866 1.2966 8 1.1170 1.2601 1.3091 1.3328 1.3465 7 1.1263 1.2901 1.3510 1.3813 1.3990 6 1.1330 1.3201 1.3946 1.4332 1.4562

5 1.1367 1.3501 1.4408 1.4892 1.5184 4 1.1402 1.3801 1.4898 1.5500 1.5868 3 1.1439 1.4101 1.5428 1.6190 1.6662 2 1.1476 1.4401 1.6018 1.6990 1.7615 1 1.1510 1.4701 1.6719 1.8016 1.8893

TABLE B Estimating Percent of Lot Within Limits (Standard Deviation Method) Positive Values of QU or QL

Percent Within Limits n=3 n=4 n=5 n=6 n=7

99 1.1510 1.4701 1.6719 1.8016 1.8893 98 1.1476 1.4401 1.6018 1.6990 1.7615 97 1.1439 1.4101 1.5428 1.6190 1.6662 96 1.1402 1.3801 1.4898 1.5500 1.5868 95 1.1367 1.3501 1.4408 1.4892 1.5184

94 1.1330 1.3201 1.3946 1.4332 1.4562 93 1.1263 1.2901 1.3510 1.3813 1.3990 92 1.1170 1.2601 1.3091 1.3328 1.3465 91 1.1087 1.2301 1.2683 1.2866 1.2966 90 1.0977 1.2001 1.2293 1.2421 1.2494

89 1.0864 1.1701 1.1911 1.2001 1.2045 88 1.0732 1.1401 1.1538 1.1592 1.1615 87 1.0596 1.1101 1.1174 1.1196 1.1202 86 1.0446 1.0801 1.0819 1.0813 1.0798 85 1.0286 1.0501 1.0469 1.0437 1.0413

84 1.0118 1.0201 1.0125 1.0073 1.0032 83 0.9940 0.9901 0.9782 0.9718 0.9673 82 0.9748 0.9601 0.9453 0.9367 0.9315 81 0.9550 0.9301 0.9123 0.9028 0.8966 80 0.9342 0.9001 0.8798 0.8693 0.8626

79 0.9122 0.8701 0.8479 0.8363 0.8290 78 0.8896 0.8401 0.8161 0.8040 0.7964 77 0.8661 0.8101 0.7846 0.7717 0.7642 76 0.8416 0.7801 0.7535 0.7403 0.7320 75 0.8164 0.7501 0.7227 0.7093 0.7011

74 0.7905 0.7201 0.6919 0.6782 0.6703 73 0.7635 0.6901 0.6619 0.6480 0.6395 72 0.7360 0.6601 0.6315 0.6178 0.6095 71 0.7076 0.6301 0.6018 0.5880 0.5846 70 0.6788 0.6001 0.5717 0.5586 0.5506

69 0.6490 0.5701 0.5424 0.5292 0.5211 68 0.6187 0.5401 0.5131 0.5002 0.4925 67 0.5878 0.5101 0.4837 0.4712 0.4639 66 0.5564 0.4800 0.4544 0.4426 0.4354 65 0.5242 0.4500 0.4254 0.4140 0.4073

TABLE B (continued) Estimating Percent of Lot Within Limits (Standard Deviation Method) Positive Values of QU or QL

Percent Within Limits n=3 n=4 n=5 n=6 n=7

64 0.4917 0.4200 0.3968 0.3859 0.3791 63 0.4587 0.3900 0.3678 0.3577 0.3515 62 0.4252 0.3600 0.3392 0.3295 0.3238 61 0.3912 0.3300 0.3106 0.3018 0.2966 60 0.3568 0.3000 0.2823 0.2740 0.2689

59 0.3215 0.2700 0.2539 0.2464 0.2418 58 0.2863 0.2400 0.2256 0.2189 0.2148 57 0.2510 0.2100 0.1972 0.1914 0.1878 56 0.2158 0.1800 0.1689 0.1639 0.1608 55 0.1806 0.1500 0.1406 0.1364 0.1338

54 0.1444 0.1200 0.1124 0.1091 0.1070 53 0.1083 0.0900 0.0843 0.0818 0.0802 52 0.0722 0.0600 0.0562 0.0545 0.0535 51 0.0361 0.0300 0.0281 0.0272 0.0267 50 0.0000 0.0000 0.0000 0.0000 0.0000

3.b Resampling of Lot. It is the intent of these specifications that lots will meet specification requirements at the time of submission. If permitted, nonconforming lots that can be corrected may be reworked and sampled.

3.c General Basis of Adjusted Payment. The related adjusted percentage of contract price will be determined by the method designated in the appropriate specification section.

and construction. Material will be reviewed for acceptance through the Department’s specified acceptance procedures. Sample locations for acceptance testing will be determined by the Department. Perform sampling and testing for acceptance in the presence of the Inspector, unless otherwise specified. Transport acceptance samples from sampling point to testing site or other designated location in the presence of the Inspector. The Contractor is responsible for the control and quality of the material and construction. Prepare a QC Plan as specified in Section 106.03(a)2. a and submit it to the Inspector -In-Charge for review at the start of the project. Include QC sampling and testing frequencies and action points to initiate corrective measures. Notify the Inspector before performing QC sampling and testing. Perform QC sampling and testing and report results to the Inspector. Do not incorporate any material into the work that is determined to be outside the specification limits. Obtain and test samples according to the Department’s PTMs. If the required test method is not specified, use methods described in the AASHTO Standard Specifications for Transportation Materials and Methods of Sampling and Testing, and Supplements, Standards and/or Tentatives of ASTM, or other testing procedures adopted by the Department. Verification sampling and testing will be performed by the District, unless otherwise specified. QA sampling and testing will be performed or witnessed by the BOCM. Independent Assurance sampling and testing will be administered by the CQAD.

Provide a plan of the QC system to be used for all construction work requiring acceptance testing by the Department, including QC test frequencies and action points to initiate corrective measures. Submit a copy of the QC Plan to the Project Engineer, to be maintained at the Department’s project field office, before the start of work. A QC Plan is not required for items specified in Section 901.

quality of all materials, both Bulletin and non-Bulletin materials, arriving at the project. Each Bulletin material must be certified to be from a Bulletin source and to be in compliance with the specification requirements for the material. A properly completed and submitted Form CS -4171, Certificate of Compliance, is the means for certification of Bulletin materials. Bulletin materials are defined in Section 106.02(a)1. The Department reserves the right to sample and test any material for verification that specification requirements are met. Materials of questionable quality delivered to the project will be sampled, tested, and approved by LTS before incorporation in any work. Materials on a reduced certification level may be required to be sampled, tested, and approved by LTS before incorporation in any work. Random field verification samples of the material may be taken by the Representative at the material source, from delivered project material, or at the place of the last manufacturer, fabricator, or producer before delivery. Random QA samples may also be taken by the Representative from delivered project material, at the place of supply, or at the place of the last manufacturer, fabricator, or producer before delivery. The random samples will be sent to the LTS for testing.

3.a Form CS-4171 Completion. Form CS-4171 is completed by the manufacturer, fabricator, or producer (Producer) of Bulletin material provided to the project. The Producer maintains the original Form CS-4171 and provides a copy of Form CS-4171 with each direct shipment to the project. When a Producer sells a Bulletin 15 material to a distributor/supplier (shipper), the Producer provides a copy of Form CS -4171 with each delivery to the shipper. When a shipper provides Bulletin 15 material directly to the project, the shipper completes and signs a new Form CS-4171 and provides a copy with each direct shipment to the project. The shipper will maintain the copy of the Producer’s Form CS - 4171 that they have received. Form CS-4171 must be properly signed by a legally responsible company official.

3.b Form CS-4171 Submission for Project Shipments. Ensure that Form CS-4171 is received for each project shipment of Bulletin material. Submit to the Representative a properly completed and signed copy of Form CS-4171 for each project shipment. Do not incorporate any Bulletin material in the work until certification arrives on the project, unless otherwise approved by the Representative. Payment for material will be withheld until proper certification documentation is received. Form CS-4171 may be submitted to the Department either in hard copy format or electronically. Contractors who wish to submit certification documentation to a project electronically, e.g. via e-mail, facsimile or through a PennDOT Project Collaboration Site, must notify the Department at the preconstruction meeting.

3.c Supplemental or Alternate Certification. Certain Bulletin materials require the submission of supplemental CS -4171 certification in addition to Form CS -4171, to provide traceability of materials in multi-step manufacturing processes.

• Epoxy coated or galvanized reinforcement steel requires the submission of supplemental certification Form CS-4171C (Epoxy Coating or Galvanizing Facility) and/or Form CS-4171F (Fabrication Facility).

• Structural steel, aluminum, or precast/prestressed concrete products, produced in a Bulletin 15 approved facility with an on-site Inspector or a Representative, must be stamped with an approved inspection stamp at the plant and certified with a Form CS-4171.

• Steel products containing foreign steel require the submission of supplemental Form CS -4171S.

Certain Bulletin materials require a form of certification other than the Form CS -4171, as identified in the particular material specification.

• Section 701 and Section 702 materials require a properly completed vendor bill of lading.

• Certification of daily asphalt mixtures by submission of Form CS-4171B.

• Certification of locally approved non-Bulletin materials by submission of Form CS-4171LA.

Organize and submit only Forms CS-4171 and supplemental or alternate certifications for material supplied to the project. Submissions containing irrelevant forms or documentation for materials not incorporated into the project will not be accepted.

3.d CS-4171 Record Retention. Retain Form CS-4171 and supplemental and alternate certifications as defined in Section 106.03(b)3.c, for a period of not less than 3 years from the date of the last project shipment. Make files available for inspection and verification by the Department. Notify shippers that a certification file must be maintained for purchased Bulletin materials to provide an audit trail to the Producer. Certifications for purchased Bulletin materials must be maintained at their place of business for a period of not less than 3 years from the date of the last shipment to the project and must be available for inspection by the Department. Notify Producers that all component certifications for purchased Bulletin materials must be maintained at their place of business for a period of not less than 3 years from the date of the last shipment to the project and must be available for inspection by the Department.

3.e Levels of Certification for Bulletin 15 Producers. The BOCM determines the Level of Certification for each Producer based on the Producer’s ability to comply with the material specifications. The Levels of Certification are defined in Table C. Bulletin 15 will indicate if a Producer is at a certification level other than Level 1. Material provided by Producers listed in Bulletin 15 is approved for use only in its intended application(s).

TABLE C Levels of Certification for Bulletin 15 Producers Producer Material Shipment Procedure Producer Additional Requirements Level 1 Standard Certification Ship on Certification with Form CS-4171* None Level 2 Standard Certification - Reduced Ship on Certification with Form CS-4171* See Section

(b)3.e.2

Level 3 Lot Approval Certification Ship only after Material Lot Approval using Modified Certification, with Form CS-4171* See Section

(b)3.e.3

Suspension or Removal According to the State’s Contractor Responsibility Program: • Producer may be suspended or removed from Bulletin 15 for any of the reasons stated in the Bulletin 15 Preface, regardless of Producer certification level. • Failure of Producer to advance above Certification Level 3 will result in PennDOT’s initiating action for suspension or removal from Bulletin 15. * Certain Bulletin materials require supplemental or alternate forms of certification, as specified in Section 106.03(b)3.c.

3.e.1 LEVEL 1 (Standard Certification).

• Initial Level of Certification typically issued to Bulletin 15 listed Producers.

• Material is produced and tested in accordance with the Producer’s approved QC Plan.

• No known material performance or quality issues exist that warrant a reduced level of certification.

• Material is shipped on certification using Form CS-4171.

3.e.2 LEVEL 2 (Standard Certification - Reduced).

• Reduced Level of Certification issued to Bulletin 15 listed Producers who have exhibited minor/moderate material performance or quality issues.

• Producer is required to work with PennDOT on submission of an improvement plan that may include, but is not limited to, any or all of the following items: a revised QC Plan, a failure analysis/action plan to assess why failures are occurring and how to prevent these failures from occurring in the future, correlation testing between in -house and independent lab testing to assist with validating results.

• Material is produced and tested in accordance with the improvement plan approved by PennDOT.

• Material is shipped on certification using Form CS-4171.

3.e.3 LEVEL 3 (Lot Approval Certification).

• This Level of Certification is issued to Bulletin 15 listed Producers who have exhibited major material performance or quality issues.

• Producer is required to work with PennDOT on an improvement plan as defined in Level 2.

• Material cannot be shipped to projects using the standard CS-4171 certification process.

• Producer must arrange for independent, in- plant acceptance testing (IPAT) that will be conducted side-by-side with “in -house” Producer testing at the designated frequencies in the revised QC plan. IPAT will be at the Producer’s expense. PennDOT’s LTS must approve the Producer’s proposed IPAT provider before it begins.

• Any material lot to be used on a project must be tested and approved by the IPAT as meeting the required PennDOT specification before shipment to the project.

• Each material lot meeting the specification may be shipped to a project using a modified certification process as follows: submit, to both the Project Representative and LTS, Form CS- 4171 along with a signed letter from the IPAT (on their official letterhead) indicating that the material lot meets testing and specification requirements.

• Correlate results from parallel “in- house” Producer testing and IPAT testing and submit to the LTS on a monthly basis.

106.04USE OF MATERIALS FROM WITHIN THE PROJECT—With written permission, material found in

the excavation areas and meeting the Department’s specifications may be used in the project construction. Material used will be paid for, as specified in Section 110.01. However, replace any portion removed with suitable material, if required to complete the embankments. The replaced quantity will be 110% of the volume of stone or gravel removed and 100% of the volume of sand and other material removed. Do not use reserved material, as specified in Section 104.06, or as indicated in the proposal.

106.05STORAGE OF MATERIAL—

Stored material, even though accepted before storage, may again be inspected before use in the work. Locate stored material to facilitate prompt inspection and control.

Adhere to the restrictions below for the storage of construction materials with known physical hazards (explosive, flammable, or combustible) or storage of any motorized equipment under any structure with vertical clearance measured:

• Less than 16 feet. No storage is allowed.

• Between 16 feet and 24 feet . Short term operational storage will be allowed provided the materials are stored in an enclosure which meets all ANSI and OSHA requirements for said material(s) and a fire prevention plan has been submitted for the short term operational storage. Short term operational storage is limited to the amount of material and/or equipment required for a 24- hour period.

• Greater than 24 feet. No restriction.

Vertical clearance is measured from the lowest structure member to the ground level below that member. Do not use private property for storage purposes without written permission of the owner or lessee. Make copies of this permission available to the Department. Restore storage sites to conditions acceptable to property owners and the Department.

concrete plants. Do not use aggregates that become segregated or mixed with earth or foreign material. If divided aggregate bins are used for storage or for proportioning, take measures to prevent mixing of aggregates. Provide an area for storage of aggregates for use in Portlan d cement concrete and asphalt concrete. Store aggregates on one of the following constructed according to standard practice:

• Asphalt concrete base course, 4 inches minimum depth.

• Class C concrete, or better, 4 inches minimum depth.

plant in enough time before batching to allow inspection and testing. Handle the aggregates so they may be field tested and accepted, before storing them with previously accepted agg regates. Batch fine and coarse aggregates separately. Properly control uniformity of moisture and uniformity of gradation. Provide a system of water sprays, then use when required, to maintain coarse aggregate moisture cont rol. During cool and cold weather concrete production, maintain aggregates required for individual concrete placements, whether stored in proportioning bins or stockpiles, at a temperature of not less than 40F before and during batching operations, for a sufficient length of time to eliminate the presence of frost in or around the aggregate particles.

condition on a platform, in an orderly manner, plainly marked to facilitate inspection.

106.06HANDLING AND TRANSPORTATION OF MATERIAL—

segregation, or inconsistency in quantities after weighing or measuring for incorporation in the work.

of the vehicle, unless otherwise specified or allowed. Clean the vehicles and provide tight batch partitions at least 4 inches higher than the batched aggregate level being hauled, to prevent any spillage from one compartment to another.

If bulk cement is used, transport to the mixer in acceptable metal, rubber, or plastic, watertight containers or compartments.

each batch into the mixer skip. If permitted, bag cement may be transported from storage to the mixer by placing the correct number of bags per batch on the batched aggregate in the aggregate compartments. When transported, the bag cement may be dumped on the aggregate after having been checked by the inspector, and if done not more than 100 feet from the mixer. Bag cement that is allowed to lie on the batched aggregates longer than 2 hours, or cement dumped on the batched aggregate longer than 1 hour, will be rejected.

106.07UNACCEPTABLE MATERIAL—

Representative’s decision will be final as to the acceptance, rejection, or acceptance at an adjusted price of sampled lots.

resubmitted for acceptance sampling. For nonconforming lots that are not adaptable to correction by reworking, remove and replace them, have them accepted without payment, or have them accepted at an adjusted price as stated in the specifications or, if not stated, as directed.

of the specifications, whether in place or not, will be rejected. Remove such material promptly from the site of the work, unless otherwise directed. Do not return rejected material to the work site until defects have been corrected and the material has been accepted for use.

Products. Plant produced fabricated materials or products having materials substitutions, dimensional deviations, specifications deficiencies, or damage which result in materials or products which may be serviceable but, do not meet all contract requirements will be addressed as follows:

defects, resolution of the deficiencies or defects will be made directly by the precaster or fabricator with the BoB’s Structural Materials Division. Minor defects and defic iencies are generally defined as those which will not require:

• engineering design review

• revisions to approved installation or erection plans or methods.

• anticipated premature maintenance or rehabilitation.

The Structural Materials Division may determine that one or more of the minor deficiencies or defects are actually significant deficiencies or non-conformances and require the precaster or fabricator to resolve the deficiency or defect as a significant deficiency or non-conformance as specified in Section 106.07(c)2.

significant deficiencies or non-conformances, which cannot be corrected to meet the contract specifications and which the Department determines may require one or more of the bulleted items listed in Section

(c)1., submit documentation to support acceptance of the material or product (provided by the precaster

or fabricator) and a request for Department evaluation and final disposition of the materials or products. Where visible defects are present, or when otherwise requested, include detailed sketches, drawings, or photographs along with the supporting documentation form the precaster or fabricator to support acceptance of the material or product. Include a detailed repair procedure to correct the deficiency, if applicable. For requests submitted for acceptance of the material or product “as is”, provide supporting justification to demonstrate that the significant deficiency or non-conformance will not result in additional constructability

issues during erection or construction or unanticipated premature maintenance work. Obtain approval of any revisions required to the shop drawings to reflect as built conditions prior to shipment. Submit engineering calculations, when required or requested, to support the acceptability of the significant deficiency or non-conformance, sealed by a registered Professional Engineer that is licensed in the State. Submittals must include a statement by the Engineer that the defect will not compromise either the structural capacity or service life of the original design. Submit the above to the District Assistant Construction Engineer with copies to the following:

• Chief Structural Materials Engineer, Bureau of Bridge, Structural Materials Division

• District Structural Control Engineer

• District Bridge Engineer

• Chief Bridge Engineer, Bureau of Bridge, Structural Materials Division (when calculations are required or requested).

Include the following minimum information on a cover page, attached to the submission:

• ECMS or other contract identification including State Route, Section and County

• Structure Number, if applicable

• Specific identification of the affected unit(s), i.e. girder-beam-culvert number, etc.

• Anticipated shipping date

• Detailed sketches, drawings, or photographs of the defect, if visible or when requested.

After evaluation, the disposition of the material or product, including any conditions of acceptance, will be provided by the Chief Structural Materials Engineer from information provided by the Engineering District. Replace materials or products which are rejected via this policy with those complying with the contract specifications and requirements.

106.08DEPARTMENT FURNISHED MATERIAL—The Department will furnish material, if specified in the

proposal, in the quantities required. Material will be delivered or made available at the point specified. The cost of handling and placing material after delivery will be included in the contract price for the item. After delivery and acceptance by the Contractor, the cost of replacing material due to shortages, deficiencies, or damage, including demurrage charges, will be deducted from money due or to become due.

106.09PENNSYLVANIA TRADE PRACTICES ACT —This section does not apply to projects which are

partially or totally financed with Federal funds.

purchase, or permit to be furnished or used in any contract aluminum or steel products as set forth below made in the countries set forth below. The Department may utilize the discretionary waiver provision of Act 3- 1978 as to steel products. As to aluminum products, if the sole source is from a banned country relief may be permitted under the Statutory Construction Act, 1 PA C.S. 1901 et seq.

steel products including hot-rolled stainless steel bar; stainless steel wire rod and cold-formed stainless steel bar; pre-stressed concrete steel wire strand; hot-rolled carbon steel plate in coil; hot-rolled carbon steel sheet; and cold-rolled carbon steel sheet.

bars, and cold-formed stainless steel bars; pre-stressed concrete steel wire strand; certain steel products, including hot-rolled steel plate, cold- rolled carbon steel plate, carbon steel structural shapes, galvanized carbon steel sheet, hot-rolled carbon steel bars; and cold-formed carbon steel bars.

steel sheet; and galvanized steel sheet.

106.10BUY AMERICA PROVISIONS AND CONVICT PRODUCED MATERIALS—This section only applies

to projects partially or totally financed with Federal funds.

work according to 23 CFR 635.410 and as follows:

• Pig iron and processed, pelletized, and reduced iron ore manufactured outside of the United States is acceptable for use in domestic manufacturing process for steel and/or iron materials.

• All manufacturing processes of steel or iron materials in a product, including coating; and any subsequent process that alters the steel or iron material’s physical form or shape, or changes its chemical composition; are to occur within the United States. This includes rolling, extruding, machining, bending, grinding, drilling, and coating. Coating includes all processes that protect or enhance the value of the material, such as epoxy coatings, galvanizing or painting.

• Provide certification to the Inspector -in-Charge, that all manufacturing processes for steel and iron materials in a product, including coating, have occurred in the United States; certify as specified in Section 106.01.

Products manufactured of foreign steel or iron materials may be used, provided the cumulative cost of such products as they are delivered to the project does not exceed 0.1% of the total contract amount, or $2,500, whichever is greater.

July 1, 1991 may not be used for Federal-aid highway construction projects, unless produced at a prison facility which had been producing convict-made materials for Federal-Aid construction projects before July 1, 1987. Material produced by convicts who are on parole, supervised release, or probation from a prison may be incorporated in a Federal-Aid highway construction project.

106.11BUILD AMERICA, BUY AMERICA ACT PROVISIONS—

includes the Build America, Buy America Act that requires all iron, steel, manufactured products, and construction materials used to be produced in the United States.

The term produced in the United States defined as:

application of coatings occurred in the United States according to Section 106.10(a).

into the project must be manufactured in the United States.

2.a A manufactured product, not predominantly steel or iron, is defined as an article, material, or

supply that has been processed into a specific form and shape, or combined with other articles, materials, or supplies to create a product with different properties than the individual articles, materials, or supplies.

2.b Predominantly steel or iron is defined as greater than or equal to 50 percent of the total cost of the manufactured product.

2.c Manufactured products that are predominantly steel or iron must comply with Buy America provisions according to Section 106.10(a).

2.d. If an article, material, or supply meets this definition but could also be classified as an excluded material or other product category, that article, material, or supply is not a manufactured product.

2.e. Mixtures of excluded materials delivered to a work site without final form for incorporation into a project are also not manufactured products.

2.f Manufactured products where the final assembly did not occur in the United States may be used, provided the cumulative cost of such manufactured products is no more than the lesser of $1 million or 5% of total applicable costs for the project.

3.a All manufacturing processes for construction materials occurred in the United States.

3.b Construction materials includes an article, material, or supply that is or consists primarily of:

• non-ferrous metals,

• plastic and polymer-based products including polyvinylchloride, composite building materials, and polymers used in fiber optic cables,

• glass including optic glass,

• lumber, or

• drywall

Items that consist of two or more of the listed materials that have been combined together through a manufacturing process, and items that include at least one of the listed materials combined with a material that is not listed through a manufacturing process, should be treated as manufactured products, rather than as construction materials.

3.c Limitation with Respect to Aggregates. Shall not include cement and cementitious materials, aggregates such as stone, sand, or gravel, or aggregate binding agents or additives.

3.d Construction materials where all manufacturing processes did not occur in the United States may be used, provided the cumulative cost of such construction materials is no more than the lesser of $1 million or 5% of total applicable costs for the project.