219GEOFOAM LIGHTWEIGHT FILL

219.1DESCRIPTION—This work is furnishing, transporting, and placing geofoam lightweight fill for construction

of embankments and for backfilling behind structures.

219.2MATERIAL—

Bulletin 15 and conforming to the following requirements:

TABLE A EPS Geofoam Block Physical Requirements(1) Property Test Method Type 1 Type 2 Designation ASTM D6817 EPS22 EPS39 Density (pcf) ASTM D1622 1.35 ±5% 2.40 ±5% Compressive Strength at 1% Deformation (psi) ASTM D1621 7.3 15.0 Compressive Strength at 5% Deformation (psi) ASTM D1621 16.7 35.0 Compressive Strength at 10% Deformation (psi) ASTM D1621 19.6 40.0 Flexural Strength (psi) ASTM C203 35.0 60.0 Oxygen Index (Volume %) ASTM D2863 24.0 24.0 Water Absorption (Volume %) ASTM C272 3 (max.) 2 (max.) Dimensions (inch) - 24 by 48 by 96 (H by W by L) 12 by 48 by 96 (H by W by L)

• Provide blocks having the same dimensions as all other blocks, except where necessary for project specific fill geometries. Blocks smaller than the dimensions indicated in Table A can be provided where necessary to meet project specific geometries. Provide manufactured blocks that do not deviate from required or specified dimension of the blocks by more than 0.5 percent.

• Provide blocks having perpendicular faces, except as required for project specific geometries. Do not deviate faces from perpendicular planes more than a 1/16 inch over a length of 12 inches.

• Provide blocks with planar faces (i.e., not warped or uneven) that do not deviate from planarity by more than 3/16 inch over a length of 96 inches.

• Provide blocks manufactured using only virgin polystyrene resin. Do not use blocks manufactured with regrind or recycled material.

• Provide blocks manufactured with sufficient flame retardants to meet the minimum Oxygen Index indicated in Table A.

• Unless blocks are fully encapsulated with a geomembrane, provide blocks manufactured with an insecticide to prevent termite and other insect attack.

• Provide blocks that have been seasoned for a minimum of 72 hours after manufacture and before shipment. While seasoning, protect blocks from moisture and ultraviolet (UV) radiation, at a temperature of 68F ±2F. Before placement store blocks in a well-ventilated facility. Allow the Representative to inspect the storage facility upon request.

• Provide blocks labeled with manufacturer’s name, ASTM EPS designation as specified in Table A, the date the block was molded, the weight (in pounds), and density (in pounds per cubic foot) as measured after the required seasoning period.

Bulletin 15 and conforming to the following requirements:

• Provide a geomembrane manufactured from a tri -polymer consisting of polyvinyl chloride, ethylene interpolymer alloy, and polyurethane or a comparable polymer combination meeting the physical and chemical requirements specified in Table B.

TABLE B Hydrocarbon Resistant Geomembrane Physical Requirements(1) Property Test Method Value Thickness (mils) ASTM D751 30 Unleaded Gasoline Vapor Transmission Rate (ounces/feet2/day) ASTM D814 0.40 (max.) Grab Tensile Strength(2) (pounds) ASTM D751 550 Elongation at Break (percent) ASTM D751 20 Toughness(3) (pounds) - 11,000 Puncture Resistant (ball tip) (pounds) ASTM D751 750 Shear(4) (pounds) ASTM D751 320 Factory Seams Bonded Width (Each Seam) (inches) - 2 Pass Cold Crack (1-inch mandrel, 4 hours) (F) ASTM D2136 -30 (pass/fail)

• Provide a flexible geomembrane that covers and conforms to 90-degree edges and corners of blocks at ambient temperatures above 45F without additional heating of the geomembrane.

No. 16 sieve and a maximum of 10% passing the No. 100 sieve.

Cement Concrete Sand, or Section 703.1(c), Type C Mortar Sand.

• Material meeting the requirements of Section 206.2(a)1.a, except 100% of the material passing the 3/4 inch sieve.

• Section 219.2(e).

219.3CONSTRUCTION.

recommendations. During all stages of manufacture, shipment , storage, and construction, protect and handle blocks in a manner to prevent physical damage. Do not use any method of lifting or transporting blocks that create dents or holes in block surfaces or that cause losses of portions of block. If blocks are to be stockpiled at the project site before placement, designate a secure storage area that is located away from any heat source or construction activity that produces heat or flame. Personal tobacco smoking or flames of any kind are not allowed in the storage area. Store blocks off of the ground and out of standing water. Protect blocks from direct sunlight and UV rays. Do not place a cover directly over blocks that might allow the buildup of heat beneath the cover. Do not traverse blocks with vehicles or equipment, and foot traffic by persons must be kept to a minimum. If blocks are exposed to wind, secure with sandbags or other similar “soft” weights that do not dent or otherwise damage blocks. Protect blocks from contact with and exposure to vapors from organic solvents, including but not limited to acetone, benzene and mineral spirits, and petroleum based solvents, including but not limited to gasoline, kerosene, and diesel fuel.

Provide a scale with a rated capacity of no more than two and one half times the weight of the heaviest block delivered to the site and accurate to a tenth of a pound. Provide documentation that the scale has been calibrated after being set up at the site. Verify block density by selecting a random block from each truck load of blocks delivered to the project. If the random block is not within d ensity requirements, the entire truck load will be rejected. Individual blocks from a rejected truck load may be accepted if confirmed to be within density requirements. Record the following information: date and time of measurement, ASTM EPS designation as specified in Table A, dimensions and weight of the block, and the calculated density (i.e., block weight divided by block volume). Provide this information to the Representative upon request.

review and acceptance. Indicate on the shop drawings the proposed location and layout of all blocks ; location and thickness of bedding material, capping material, embankment material, and pavement section; and the location of the geot extile and geomembrane. The proposed layout must meet the following requirements:

• Place Type 1 blocks for the main body of the fill.

• Cap the top of the Type 1 blocks with a minimu m 12-inch-thick layer of Type 2 blocks. Type 2 blocks are not required to be used on the side slopes of the block fill.

• Use the maximum amount of full -size blocks of minimum dimensions indicated in Table A that the placement geometry allows.

• Place blocks with smallest dimension oriented vertically.

• A minimum of two layers of blocks must be used (i.e., one layer of Type 1 and one layer of Type 2, except on sideslopes).

• The plane on which any given layer of blocks is placed must be parallel to the longitud inal profile of the roadway.

• Within a given layer of blocks, the longitudinal axes of all blocks must be parallel to each other.

• Within a given layer of blocks, vertical joints between adjacent longitudinal rows of blocks must be offset a minimum of 2 feet.

• The longitudinal axes of blocks for layers above and below a given layer must be perpendicular to the longitudinal axes of blocks within that given layer.

• The longitudinal axes of the uppermost layer of blocks must be perpendicular to the longitudinal profile of the roadway.

• Cover blocks with a minimum of 4 feet of material but not to exceed 6 feet . Total cover thickness includes the pavement section, soil embankment and capping material.

• If blocks are placed adjacent to a river, stream, creek, etc., place the bottom layer of blocks a minimum of 3 feet above the 100-year storm elevation, and a minimum of 1 foot above the 500-year storm elevation.

adversely affects their qualities. Replace damaged blocks at no expense to the Department. Damaged blocks that cannot be used are defined by any of the following:

• Volumetric damage of more than 0.5% of the volume of the single block.

• Surface damage of more than 5% of the load bearing area of the single block.

• Surface damage of more than 5% of the total block surface area.

• Continuous damage of more than 20% of the length of any side of a single block.

Fill acceptable damaged areas on horizontal beari ng surfaces with dry, f ine sand, meeting the requirements of Section 219.2(d).

requirements and as approved by the Representative. Extend patches a minimum of 6 inches beyond the limits of the damaged areas in all directions. Protect the blocks from damage during welding.

areas and extend a minimum of 12 inches in all directions. Secure fabric lap with a geotextile seaming spray adhesive recommended by the manufacturer. Apply the adhesive to a minimum of 6 inches of the fabric lap. Do not bond the geotextile to the geomembrane during application of the adhesive.

by the Representative. Before placement, and for any period deemed necessary by the Representative, a representative from the manufacturer of the blocks must be on site to answer any questions regarding placement of the blocks. Before placement of blocks at or below original ground , prepare the embankment foundation area in accordance with Section 206.3(a) . Before placement of the first layer of blocks, place a leveling course consisting of a 6-inch loose layer of Bedding Material meeting the requirements of Section 219.2(e). Grade the leveling course parallel to the longitudinal profile of the roadway . The leveling course surface must be free of debris and water before placement of blocks. Place geotextile, geomembrane, and blocks as indicated in the accepted Block LayoutS hop Drawing. Where possible, place blocks with the factory skin (i.e., molded, uncut surface) as the outer layer. If blocks are warped/crowned but within the acceptable tolerance, place blocks with crown upward at all times to prevent the ponding of water. Place blocks by hand. Do not use wheeled, tracked, or other equipment on the surface of blocks, geomembrane , or geotextile at any time. Equipment may be used to transport or lift blocks, , as long as its use does not damage the blocks. Where custom shapes and smaller sizes than indicated in Table A are needed and are not provided from the factory, field cut these custom shapes and smaller sizes from full size blocks using a hot wire cutter. Do not use a chain saw, hand saw, or other mechanical shearing or cutting device to cut or shape blocks. Field cut blocks to within 0.5 inch of required or specified dimensions.

During placement of blocks, secure the blocks with sandbags or other similar “soft” weights that do not dent or otherwise damage blocks until the soil cover is placed. Alternatively, mechanical connectors or EPS compatible adhesive approved by the block manufacturer may be used to secure blocks. Provide full contact between blocks. Do not leave standing water, accumulated snow or ice, or debris of any kind on previously placed blocks before placement of subsequent blocks. Do not use de- icing salts, sodium chloride or other products on the blocks that can cause degradation. Place blocks so that all vertical and horizontal joints between blocks are tight. Allow no gaps greater than 0.1 foot on vertical joints. Do not fill vertical joints with sand. Construct the top finished surface of the blocks to within a tolerance of 1/2 inch over a 10-foot interval of the design longitudinal profile of the blocks and design transverse slope of the blocks. Additionally, construct the finished surface of the blocks beneath pavement sections to within 0.1 foot of the top of block design grade. Construct the finished surface of the blocks on side slopes to within 0.2 foot of the top of block design grade. Any adjustments for grade can be made using either Type 1 or Type 2 block, so long as the Type 2 blocks have a minimum thickness of 12 inches.

bringing up the hydrocarbon resistant geomembrane to fully encapsulate all blocks in one continuous layer of geomembrane as indicated in the accepted Block Layout Shop Drawing. Field weld all geomembrane seams using a hot wedge welding machine. Do not use hot air or solvents to weld seams. Do not melt or otherwise damage the blocks during welding. Overlap seams according to manufacturer’s requirements, but no less than 3 inches. Protect the blocks as needed during field welding of the geomembrane. Replace blocks damaged from welding of the geomembrane, and repair the geomembrane at no expense to the Department. Immediately after placement of the geomembrane, continue bringing up the Class 4, Type A geotextile to fully cover the geomembrane. Overlap adjacent layers of geotextile a minimum of 12 inches. Secure all overlaps of geotextile with a geotextile seaming spray adhesive recommended by the manufacturer. Apply the adhesive to a minimum of 6 inches of the overlap. Do not bond the geotextile to the geomembrane during application of the adhesive. Prevent overspray of the adhesive onto the geomembrane. If overspray occurs, insert an additional piece of geomembrane that extends a minimum of 6 inches beyond the limits of the overspray, to act as a bond breaker between the geomembrane and geotextile.

requirements of 219.2(f) must be placed on top of the geotextile, including on the horizontal surfaces of the side slopes, before placement of embankment material. Place and compact capping material within 2 weeks after placement of the geotextile as specified in Section 206.3 except as follows: Place the capping material over top of the fully encapsulated blocks by end dumping material just off the blocks, and blading an 8- inch-thick loose lift of material across the blocks with pneumatic tire equipment. Do not end dump capping material directly on the blocks. Do not stockpile capping material on previously placed capping material. A single triaxle truck load of capping material may be dumped onto previously placed and compacted capping material. Spread capping material as quickly as practically possible. Do not drive directly on the blocks with any equipment, do not use tracked equipment, and do not make sharp, sudden turns with pneumatic tired equipment that may damage the geotextile and/or geomembrane. Repair any damage to the blocks, geomembrane or geotextile that occurs before or during fill placement. Compact capping material using a smooth drum roller in static (non-vibratory) mode.

over top of the geotextile, p lace and compact soil embankment meeting the requirements of Section 206.2(a)1.a as specified in Section 206.3 and as indicated in the accepted Block Layout Shop Drawing. Place soil embankment to pavement subgrade elevation. Do not stockpile embankment material on previously placed capping or embankment material. A single triaxle truck load of embankment material may be dumped onto previously placed and compacted capping or embankment material. Spread embankment material as quickly as practically possible. Place embankment over the side slopes of the block fill starting at the bottom of the slope in such a manner as to prevent damage to the blocks, geomembrane, and geotextile. Provide a minimum of 4 feet of embankment material cover vertically and horizontally over the blocks as measured from any exterior face of the block.

219.4MEASUREMENT AND PAYMENT.

Measure blocks in their final position. Payment will not be made for wasted material. Payment includes furnishing, storing and placing Type 1 and Type 2 geofoam blocks, bedding material, fine sand, capping material, and any incidental materials such as mechanical connectors and adhesives .

Payment includes welding seams.