Wisconsin WisDOT Standard Specifications (within FDM) — Section 715

Effective with the December 2018 Letting 528 2019 Standard Spec ifications Section 715 QMP Concrete Pavement and Structures

715.1Description

(1)This section describes contractor mix design and testing requi rements for class I concrete used in

concrete pavement, and concrete structures. 715.1.1 Quality Control Program 715.1.1.1 General

(1)Conform to the general requirements under 701 and 710 as well as the additional specific contract

QMP provisions for class I concret e specified here in section 7 15. The department defines class I concrete as cast-n-place concrete used in pavement or structure applications where all of the following apply: - Mix design requires review by the engineer. - The contract definess pec limits for strength. - The contractor may earn statis tically based incentives for superior concrete strength. [1] [1] HES and SHES concrete are not eligible for 28-day strength inc entives. 715.1.1.2 Small Quantities

(1)The department defines small quant ities of class I concrete, s ubject to the reduced requirements

under 710.2 , as follows: - Less than 150 cubic yards of structure concrete placed under a single bid item. - Less than 2500 cubic yards of s lip-formed pavement placed using a single mix design. - Less than 1000 cubic yards of non-slip-formed pavement placed using a single mix design. 715.1.1.3 Pre-Pour Meetings for Structure Concrete

(1)Arrange at least two pre-pour mee tings to discuss concrete pla cement. Discuss the placement

schedule, personnel r oles and responsibilit ies, testing and qua lity control, and how test results will be communicated. Schedule the first m eeting before placing any con crete and the second before placing any bridge deck concrete. Ensure that representatives from all parties involved with concrete work, including contractor, sub-contr actor, ready-mix supplier, teste rs, and the project manager, attend these meetings. 715.1.1.4 Quality Control Plan

(1)If a comprehensive quality c ontrol plan is required under 701.1.2.2 , submit a plan conforming to

701.1.2.2 and include additional concrete mix information as follows:

1.Preliminary concrete mix inf ormation including proposed pro duction facilities and sources of materials as

well as the name, title, and phone number of the person developing the mix design.

2.Proposed individual and combined aggregate gradation limits .

3.Proposed methods for monitori ng and recording batch weights .

715.2Materials

715.2.1 General

(1)Determine mixes for class I con crete used under the contract u sing one or more of the following

methods: - Have a HTCP-certified PCC te chnician II develop new concrete mixes qualified based on the results of mix development tests performed by a d epartment-qualified laborator y. - Submit previously-used depar tment-approved mixes qualified ba sed on field performance.

(2)The contractor need not provide separate laboratory mix designs for high early strength concrete nor

provide routine 28-day compressi ve strength tests during placement for high early strength concrete.

(3)For lab-qualified or field-qualified mixes, in addition to the mix information required under 710.4 ,

submit 2 copies of a concrete mix report at least 3 business da ys before producing concrete. For lab- qualified mixes, include strength data, test dates, and the nam e and location of the laboratory that performed mix development testing . For field-qualified mixes, i nclude historical dat a that demonstrate acceptable strength and field performance.

(4)Ensure that the concrete mix report includes a cover sheet wit h signature blocks for both the mix

developer and the engineer. Have the mix developer sign and dat e each copy attesting that all information in the report is accurate. The engineer will sign a nd date each copy of the report. The engineer’s signature verifies t hat the engineer had the opportu nity to review the mix report, to check that it meets the concrete mix r equirements, and to comment. Th e engineer will return a signed copy to the contractor within 3 busine ss days of receiving the repor t.

Effective with the December 2018 Letting 529 2019 Standard Spec ifications 715.2.2 Combined Aggregate Gradation

(1)Ensure that the combined aggr egate gradation conforms to the following, expressed as weight

percentages of the total aggregate:

1.One hundred percent passes the 2-inch sieve.

2.The percent passing the 1-in ch sieve is less than or equal to 89. The engineer may waive this requirement

for one or more of the following: - Clear spacing between reinforci ng bars is less than 2 inches. - The contractor provides an en gineer-approved optimized gradation analysis.

3.The percent passing the No. 4 sieve is less than or equal t o 42, except if the coarse aggregate is

completely composed of crushed st one, up to 47 percent may pass the No. 4 sieve. For pavement, coarse aggregate may be completely composed of crushed concrete, in wh ich case up to 47 percent may pass the No. 4 sieve.

4.The percent passing the No. 2 00 sieve is less than or equal to 2.3 percent.

(2)Submit proposed combined gradation limits and target individua l gradations along with the mix

information required under 710.4 . 715.2.3 Class I Concrete Mixes 715.2.3.1 Pavements

(1)Use at least 5 pairs of cylinders to demonstrate the compressi ve strength of a mix design. Use either

laboratory strength data for new mixes or field strength data f or established mixes. Demonstrate that the 28-day compressive strength of the propo sed mix will equal or exceed the 85 percent within limits criterion specified in 715.5.2.

(2)Provide a minimum cement content of 565 pounds per cubic yard, except if using type I, IL, or III

cement in a mix where the geolog ic composition of the coarse ag gregate is primarily igneous or metamorphic materials, provide a minimum cement content of 660 pounds per cubic yard.

(3)The contractor may use class C fly ash or grade 100 or 120 sla g as a partial replacement for cement.

For binary mixes use up to 30 percent fly ash or slag, except f or slip-formed work the contractor may use up to 50 percent slag. For te rnary mixes use up to 30 perce nt fly ash plus slag in combination. Replacement values are in percen t by weight of the total cementitious material in the mix.

(4)Ensure that the target ratio o f net water to cementitious mate rial for the submitted mix design does not

exceed 0.42 by weight. Include fr ee water on the aggregate surf ace but do not include water absorbed within aggregate particles.

(5)Do not use chloride based accele rators in mixes for new constr uction.

Add 715.2.3.1(6) to include super air meter (SAM) testing fo r new lab-qualified pavement mix designs. This change was implemented in ASP 6 effective with the December 2017 letting.

(6)For new lab-qualified mixes, te st the air void system of the pr oposed concrete mix conforming to

AASHTO provisional standard TP 118. Include the SAM number as a part of the mix design submittal. 715.2.3.2 Structures

(1)Qualify compressive strength a ccording to ACI 301 - Specifications for Structural Concrete -

subsections 4.2.3.1 through 4.2. 3.4. Use either laboratory stre ngth data for new mixes or field strength data for established mixes. Demonstrate that the 28-day compressive strength of the proposed mix will equal or exceed the 90 percent within limits criterion specifie d in 715.5.3 .

(2)Provide a mix grade containing fl y ash (A-FA), slag (A-S), bot h fly ash and slag (A-T), or blended

cement (A-IP, A-IS, or A-IT) En sure that the cementitious conte nt equals or exceeds 565 pounds per cubic yard. Unless the engineer a pproves otherwise in writing, conform to one of the following:

1.Use class C fly ash or grade 100 or 120 slag as a partial r eplacement for cement. F or binary mixes use

15% to 30% fly ash or 20% to 30% s lag. For ternary mixes use 15 % to 30% fly ash plus slag in combination. Replacem ent values are in percent by weight of the total cementitious m aterial in the mix.

2.Use a type IP, IS, or IT blended cement.

(3)Ensure that the target ratio o f net water to cementitious mate rial (w/cm) for the submitted mix design

does not exceed 0.45 by weight. In clude free water on the aggre gate surface but do not include water absorbed within aggregate particles. Control the w/cm ratio throughout production by adjusting batch weights for changes in the aggregate moisture as required under 715.3.3.2 .

(4)Do not use mixes containing ac celerators, except the contractor may use mixes containing non-

chloride accelerators in substructure elements.

Effective with the December 2018 Letting 530 2019 Standard Spec ifications 715.3 Testing and Acceptance 715.3.1 Class I Concrete Testing 715.3.1.1 General Revise 715.3.1.1(1) to include super air meter (SAM) testing for pavements at least once per lot. This change was implemented in ASP 6 effective with the December 2017 letting.

(1)Provide slump, air content, concr ete temperature and compressi ve strength test results as specified in

710.5 . Provide a battery of QC tests , consisting of results for each specified property, using a single sample randomly located with in each sublot. If a sublot random test location falls within a mainline pavement gap, relocate the test to a different location within the sublot. Cast three cylinders for strength evaluation.

(2)For pavement concrete, also test t he air void system conforming to AASHTO provisional standard

TP118 at least once per lot and enter the SAM number in the MRS for information only. SAM testing is not required for the following: - High early strength (HES) concrete pavement - Special high early strength (SHES) concrete pavement - Concrete placed under the Concrete Pavement Approach Slab bid i tems - For concrete pavement lots with less than 4 sublots 715.3.1.2 Lot and Sublot Definition 715.3.1.2.1 General

(1)Designate the location and size of all lots before placing concrete. Ensure that no lot contains concrete

of more than one mix design or placement method defined within 715.3.1.2 as follows: Mix design change A modification to the mix requiring the engineer's approval un der 710.4(5) . For paving mixes, a source change under item 1 of 710.4(5) for fly ash of the same class that does not require a modification unde r items 2 through 4 of 710.4(5) does not constitute a mix design change. Placement method Either slip-formed, not slip-f ormed, or placed under water.

(2)Lots and sublots include ancilla ry concrete placed integrally with the class I concrete.

715.3.1.2.2 Lots by Lane-Feet

(1)The contractor may designates lip-formed pavement lots and sub lots conforming to the following:

- Lots and sublots are one paving pass wide and may include one or more travel lanes, integrally placed shoulders, integrally placed ancillary concrete, and pavement g aps regardless of mix design and placement method. - Sublots are 1000 feet long fo r single-lane and 500 feet long for two-lane paving. Align sublot limits with ride segment limits defined in 740.3.2 . Adjust terminal sublot lengths to match the project length or , for staged construction, the stage length. Ensur e that sublot limits match for adjacent paving passes. Pavement gaps do not affect the location of sublot limits. - Create lots by grouping 4 to 8 adjacent sublots matching lots created for adjacent paving passes.

(2)If a sublot random test locati on falls in a pavement gap, test at a different random location within that

sublot. 715.3.1.2.3 Lots by Cubic Yard

(1)Define standard lots and sublots conforming to the following:

- Do not designate more than one sublot per truckload of concre te. - Lots for structures are a max imum of 500 cubic yards divided into approximately equal 50-cubic-yard or smaller sublots. - Lots for pavement are a maxim um of 2000 cubic yards divided i nto approximately e qual 250-cubic-yard or smaller sublots.

(2)The contractor may designate l ots smaller than standard sized. An undersized lot is eligible for

incentive payment under 715.5 if the contractor defines 4 o r more sublots for that lot. 715.3.1.3 Department Verification Testing Revise 715.3.1.3(1) to require a 1 in 5 QV testing frequency with at least one QV test per lot for class I concrete. This change was implemented in ASP 6 effective with the December 2017 letting.

(1)The department will perform verification testing once for each 5 contractor QC tests with additional

testing as required to obtain at least 1 verification test per lot fo r air content, slump, temperatur e, and compressive strength.

Effective with the December 2018 Letting 531 2019 Standard Spec ifications Add 715.3.1.3(2) to specify time limits for reporting department QV test results to the contractor.

(2)The department will report QV test results to the contractor within 2 business days after the

department obtains the sample, or in the case of long-term testing, within 2 business days after conducting the test. 715.3.2 Strength Evaluation 715.3.2.1 General

(1)The department will make pay adjus tments for compressive stren gth on a lot-by-lot basis using the

compressive strength of contrac tor QC cylinders. The department will assess concrete for removal and replacement based on a sublot-by- sublot analysis of core streng th. Perform coring and testing, fill core holes with an engineer-approved no n-shrink grou t, and provide t raffic control during coring.

(2)Randomly select 2 QC cylinders to test at 28 days for percent within limits (PWL). Compare the

strengths of the 2 randomly sel ected QC cylinders and determine the 28-day sublot average strength as follows: - If the lower strengt h divided by the higher strength is 0.9 o r more, average the 2 QC cylinders. - If the lower strengt h divided by the higher strength is less than 0.9, break one additional cylinder and average the 2 higher strength cylinders. 715.3.2.2 Removal and Replacement 715.3.2.2.1 Pavement

(1)If a sublot strength is less than 2500 psi, the department may direct the contractor to core that sublot

to determine its structural adequ acy and whether to direct removal. Cut and test cores according to AASHTO T24 as and where the engineer directs. Have an HTCP-cert ified PCC technician I perform or observe the coring.

(2)The sublot pavement is conformi ng if the compressive strengths of all cores from the sublot are 2500

psi or greater or the engineer does not require coring.

(3)The sublot pavement is nonconfo rming if the compressive streng ths of any core from the sublot is less

than 2500 psi. The department may direct removal and replacement or otherwise determine the final disposition of nonconforming material as specified in 106.5 . 715.3.2.2.2 Structures

(1)The department will evaluate the sublot for possible removal and replacement if the 28-day sublot

average strength is lower than f’c minus 500 psi. The value of f’c is the design stress the plans show. The department may assess further strength price reductions or require removal and replacement only after coring the sublot.

(2)The engineer may initially evaluat e the sublot strength using a non-destructive method. Based on the

results of non-destructive testing, the department may accept the sublot at the previously determined pay for the lot, or direct the c ontractor to core the sublot.

(3)If the engineer directs coring, obtain thre e cores from the sublot in question. Have an HTCP-certified

PCC technician I perform or observe core sampling according to AASHTO T24. Determine core locations, subject to the enginee r’s approval, that do not inte rfere with structural steel.

(4)Have an independent consultant te st cores according to AASHTO T24.

(5)If the 3-core average is greater than or equal to 85 percent o f f’c, and no individual core is less than 75

percent of f’c, the engineer will accept the sublot at the prev iously determined pay for the lot. If the 3- core average is less than 85 percent of f’c, or an individual core is less than 75 percent of f’c, the engineer may require the contract or to remove and replace the s ublot or assess a pr ice reduction of $35 per cubic yard or more. 715.3.3 Aggregate 715.3.3.1 General

(1)Except as allowed for small quantities in 710.2 , provide aggregate test results conforming to 710.5.6 .

715.3.3.2 Structures

(1)In addition to the aggregate testing required under 710.5.6, determine the fine and coarse aggregate

moisture content for each sampl e used to test the percent passi ng the No. 200 sieve.

(2)Calculate target batch weights for each mix when production of that mix begins. Whenever the

moisture content of the fine or coa rse aggregate changes by mor e than 0.5 percen t, adjust the batch weights to maintain the design w/cm ratio.

Effective with the December 2018 Letting 532 2019 Standard Spec ifications 715.4 Measurement

(1)The department will measure Incentive Strength Concrete Pavement and Incentive Strength Concrete

Structures by the dollar, calculated as specified in 715.5 .

715.5Payment

715.5.1 General

(1)The department will pay incentive for compressive strength under the following bid items:

ITEM NUMBER DESCRIPTION UNIT

715.0415 Incentive Strength Concrete Pavement DOL

715.0502 Incentive Strength Concrete Structures DOL

(2)Incentive payment may be more or less than the amount the sche dule of items shows.

(3)The department will administer di sincentives for compressives trength under the Disincentive Strength

Concrete Pavement and the Disinc entive Strength Concrete Structures administrative items.

(4)The department will adjust pay fo r each lot using PWL of the 28-day sublot average strengths for that

lot. The department will measure PW L relative to the lower spec ification limit of 3700 psi for pavements and 4000 ps i for structures. The department will not pay a strength incentive for concrete that is nonconforming in another specified property, for ancillary concrete accepted based on tests of class I concrete, or for high early strength concrete unless placed in pavement gaps as allowed under 715.3.1.2.1 .

(5)Submit strength results to the department electronically using the MRS software. The department will

validate contractor data befor e determining pay adjustments.

(6)All coring and testing costs under 715.3.2.2 including filling core holes a nd providing traffic control

during coring are incidental to the contract. 715.5.2 Pavements

(1)The department will adjust pay fo r each lot using equation “QM P 3.01” as follows:

Percent within Limits (PWL) Pay Adjustment (dollars per square yard) >= 95 to 100 (0.1 x PWL) - 9.5 >= 85 to < 95 0 >= 30 to < 85 (1.5/55 x PWL) - 127.5/55 < 30 -1.50

(2)The department will not pay incentive if the lot standard devi ation is greater than 400 psi.

(3)For lots with a full battery of Q C tests at less than 4 locati ons, there is no incentive but the department

will assess a disincentive based on the individual sublot average strengths. The department will reduce pay for sublots with an average strength below 3700 psi by $1.50 per square yard.

(4)For integral shoulder pavemen t and pavement gaps accepted usin g tests from the adjacent travel

lane, The department will adjust pay using strengt h results of the travel lane for integrally placed concrete shoulders and pavement gaps regardless of mix design a nd placement method, included in a lane-foot lot. 715.5.3 Structures

(1)The department will adjust pay fo r each lot using equation “QM P 2.01” as follows:

Percent within Limits (PWL) Pay Adjustment (dollars per cubic yard) >= 99 to 100 10 >= 90 to < 99 0 >= 50 to < 90 (7/8 x PWL) - 78.75 < 50 -35

(2)The department will not pay incentive if the lot standard devi ation is greater than 350 psi.

(3)For lots with less than 4 subl ots, there is no incentive but the department will assess a disincentive

based on the individual sublot average strengths. The department will reduce pay for sublots with an average strength below 4000 psi by $35 per cubic yard.

Effective with the December 2018 Letting 533 2019 Standard Spec ifications Section 716 QMP Ancillary Concrete

716.1Description

(1)This section describes contractor mix selection and testing re quirements for class II and class III

concrete. 716.1.1 Quality Control Program 716.1.1.1 General

(1)Conform to the general requirements under 701 and 710 as modified here in 716 for class II and class

III concrete defined as follows: - Class II: ancillary concrete th e department accepts based on field testing during placement. - Class III: ancillary concrete th e department accepts by certi fication. 716.1.1.2 Quality Control Plan

(1)The contractor need only submi t an abbreviated quality control plan as defined in 701.1.2.3 .

716.2Materials 716.2.1 Class II Concrete

(1)Determine mixes for class II conc rete used under the contract according to 501. If a grade A mix is

allowed under standard spec 501.3.1.3 , the contractor may use a cla ss I mix design approved under 715.2 . Ancillary concrete placed integrally with mainline pavement is accepted using tests of class I concrete but not eligible for incentive payment under 715.5 . Document the locations and quantities of integral concrete and identify the class I sublot tests used fo r acceptance. Revise 716.2.1(2) to require air and slump testing every 100 CY and cylinders every 200 CY for base patching.

(2)Perform random QC testing a t the following frequencies:

1.Test air content and slump a minimum of once per 100 cubic yards for each mix gr ade and placement

method.

2.Cast one set of 2 cylinders per 200 cubic yards for each mi x grade and placem ent method. Cast a

minimum of one set of 2 cylinders per contract for each mix gra de and placement method. Random 28-day compressive strength cylinders ar e not required for HES or SHES concrete.

3.For deck overlays, perform te sts and cast cylinders once pe r 50 cubic yards of grade E concrete placed.

4.For concrete base, one set of tests and one set of cylinders per 250 cubic yards.

(3)Conform to the initial curing requirements under 710.5.5 except the contractor may extend initial curing

for 72 hours before transporting the cylinders to a department- qualified laboratory.

(4)Test aggregate gradations, including P200, as specified in 710.5.6 at the frequency listed below which

results in the least number of tests: - A maximum of one test per day. - A minimum of one test per 400 c ubic yards of cumulative concrete placed. Alternatively the engineer may ac cept aggregate based on docume nted previous testing.

(5)Department verification testing is optional for aggregate used in class II concrete.

716.2.2 Class III Concrete

(1)Acceptance of class III concrete i s based on a certificate of compliance. Submit the certificate of

compliance at least 3 business days before producing concrete a long with the initial concrete mix documentation as required under 710.4(2) .

(2)Contractor testing for the mix and mix aggregates is not requi red for the items contained within the

certificate of compliance. Conform to 716.2.1 for items not contained within the certificate of compliance.

(3)Department verification testing is optional for class III conc rete. Correct any deficiencies found during

the QV testing. 716.3 (Vacant) 716.4 (Vacant) 716.5 (Vacant)

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 537–541 of 601.

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710 General Concrete QMP

716 QMP Ancillary Concrete