Wisconsin WisDOT Standard Specifications (within FDM) — Section 730

Effective with the December 2018 Letting 534 2019 Standard Spec ifications Section 730 QMP Base Aggregate Add section 730 to incorporate STSP 301-010 QMP Base Aggregate.

730.1Description

730.1.1 General

(1)This section describes contractor QC and department QV testing and documentation for base

aggregates. Apply to Base Aggregate Open Graded bid items and t o Base Aggregate D ense bid items except reclaimed asphaltic pavem ent placed under the Base Aggre gate Dense bid items.

(2)Do not apply to Aggregate Detours, Breaker Run, Select Crushed , Pit Run, Subbase, or Riprap bid

items.

(3)Conform to the general QMP requirements under 701, to the base aggregate requirements under 301,

305, and 310, and to the additional requirements specified here in 730. 730.1.2 Quality Control Program 730.1.2.1 Quality Control Plan

(1)Submit a plan conforming to 701.1.2.2 and include additional information as follows:

1.Section and quarter descripti ons for all aggregates that re quire QC testing.

2.Description of stockpiling and hauling methods.

730.1.2.2 Small Quantities

(1)The department defines a small quantity of base aggregate as a contract quantity of 6000 tons or less

placed under a single bid item.

(2)For small quantity contracts:

- An abbreviated quality control plan is allowed under 701.1.2.3. - Contractor QC placement testi ng is modified as specified in 730.3.4.1 . 730.1.2.3 Documentation

(1)Submit test results for gradation, fracture, liquid limit, and plasticity to the engineer within 1 business

day of obtaining the sample.

(2)Maintain standardized control charts according to CMM 8-30 .

(3)Maintain separate gradation cont rol charts for each sieve size specified in 305 or 310 for each base

aggregate size, source or classifi cation, and type. Set the con trol limits and warning limits as follows:

1.The control limits are the upper and lower gr adation specif ication limits.

2.Warning limits:

- There are no upper warning limits for sieves requiring or all owing 100 percent passing. - There are no lower warning limits for sieves allowing 0 percent passing. - Dense-graded No. 200 sieve: warning limits are 0.5 percent wi thin the upper and lower control limits. - Dense-graded for all other sie ves: warning limits are 2 perce nt within the upper and lower control limits. - Open-graded 1-inch, 3/8-inch, and No. 4 sieves: warning limits are 2 percent wit hin the upper and lower control limits. - Open-graded No. 10, No. 40, and No. 200 sieves: warning limits are 1 percent wit hin the upper and lower control limits.

(4)Maintain a separate fracture c ontrol chart for each base aggre gate size, source or classification, and

type. Set the lower control li mit to the value specified in table 301-2 . Set the lower warning limit 2 percent above the lower control limit. There is no upper warnin g limit.

(5)Plot QC and QV test results and the 4-point running average on control charts. Include only QC

placement tests in the running average unless a QV test result is out of spec, then include it as specified in 730.3.5(5) . Document corrective action on control charts. Update control charts and submit copies to the engineer daily.

730.2Materials

(1)Provide materials conforming to 301, 305 , and 310.

(2)Use the definitions in 301.2.2 and the following:

Stockpile Sampling Coordinated QC/QV sample before beginning placement of aggregate materials.

Effective with the December 2018 Letting 535 2019 Standard Spec ifications Loadout Sampling Sample taken from the working face of a stockpile during placement of aggregate materials.

730.3Testing

730.3.1 General

(1)Test gradation, fracture, liquid limit, and plasticity for eac h base aggregate size, source or

classification, and type. Production tests only apply to small quantity projects under 730.3.4 . Use the test methods specified in table 701-1 and conform to the following:

1.Gradation

- Determine the complete gradation, includi ng P200, using a was hed analysis. - For 3-inch base, if three cons ecutive 4-point running averages for percent passing the No 200 sieve are 8.5 percent or less, the contractor may use an unwashed analysis for 9 out of 10 tests; one out of every 10 must be washed. If a single 4-point running average for perce nt passing the No. 200 sieve exceeds 8.5 percent, resume us ing a washed analysis until three consecutive running averages are 8.5 percent or less.

2.Fracture

- Perform fracture testing on t he individual component materials before blending. - Fracture testing is not required on quarried stone, reclaimed asphalt, or asphalt-coated reprocessed materials.

3.Liquid limit and plasticity

- Determine the liquid limit and plasticity index using materia l passing the No. 40 sieve of each individual component material and then on the blended material. - Perform plasticity checks, as specified under 730.3.2 , by using the Hand Rolling Method detailed in section 5 of AASHTO T90. - Liquid limit and plasticity tes ting are not required on recla imed asphalt or reprocessed material.

(2)Ensure that both QC and QV st ockpile test results conform to t he specifications before placing

material. If either the QC or the QV test fails, both the QC an d QV technicians will resample the stockpile side-by-side and rerun the tests. If either side-by-s ide test fails, contact the region materials engineer to investigate.

(3)Stockpile tests[1] can be used for multiple projects. If placement on a project d oes not begin within 60

calendar days after the date the stockpile sample was obtained, retest the stockpile before placement begins. [1] Replace the stockpil e test with an in-place production test fo r concrete pavement rec ycled and processed on- site; test on the firs t day of production.

(4)Obtain placement samples after the material is bladed, mixed, and shaped, but before watering and

compacting, except as follows:

1.Sample 3-inch material and lift thicknesses of 3-inch or le ss from the stockpile at loadout.

2.Do not sample from material used to maintain local traffic or from other areas of te mporary base that will

not remain in place a fter the contract.

3.No placement testing is re quired on days when only temporar y base material is placed. Acceptance of

temporary base materials is based on visual inspection. 730.3.2 Contractor QC Testing

(1)Provide stockpile test results to the engineer before placing material.

(2)Split and label each QC sample . Retain the split for 7 placeme nt days in a dry, protected location. If

requested for department comparison testing, deliver the split to the engineer within one business day.

(3)Perform QC gradation, fracture , liquid limit, and plasticity t esting of each base aggregate size, source

or classification, and type at the following frequencies: - One stockpile test before placem ent including g radation, frac ture, and plasticity. - One gradation test per 3000 t ons of material placed, or fraction thereof. - One fracture test for each gra dation test. When the fracture 4-point running average is above the lower warning limit, the te sting frequency may be reduced to one frac ture test per ten gradation tests or fraction thereof. The reduced test frequency applies only as long as the running average remains above the lower warning limit. - One plasticity and liquid lim it test for the first gradation test. Thereafter, perform one plasticity check, per ten gradation tests or fraction thereof. If the soil cannot be rolled into a 3 mm-diame ter thread, then it is non-plastic (NP) and the comple te test need not be performed; r eport the plasticity Index as NP. If the material can be rolled into a thread, then perform both complet e tests to determine the liquid limit and the plasticity index.

Effective with the December 2018 Letting 536 2019 Standard Spec ifications (4) Submit test results to the engin eer within one business day of obtaining the sample. 730.3.3 Department QV Testing

(1)The department will notify the cont ractor’s project materials coordinator before obtaining a sample.

(2)The department will split each sample, test half for QV, and r etain the other half for 7 placement days.

(3)The department will conduct QV te sting for gradation, fracture , liquid limit, and plasticity of each base

aggregate size, source or classifi cation, and type as follows:

1.One stockpile QV test from each source prior to placement.

2.At least one QV test per 30,0 00 tons of material placed, or fraction thereof.

(4)The department will provide test r esults to the contractor wit hin 2 business days of obtaining a sample.

730.3.4 Small Quantity Testing 730.3.4.1 Contractor QC Testing

(1)For small quantity contracts wi th ≤ 6000 tons, do the followin g:

1.Conduct one QC stockpile test prior to placement.

2.Submit 2 production tests or conduct 1 loadout test instead of placement tests. Production tests are valid

for 3 years from the date the pr oduction sample was obtained; t he first day of p lacement must be within 3 years of the date sampled.

3.If the actual quantity placed is more than 6000 tons, on th e next day of placement perform one additional

random QC test for each 3000 tons of overrun, or fraction there of. 730.3.4.2 Department QV Testing

(1)Conform to the QV testing under 730.3.3; the department may waive QV testing for contract bid item

quantities of 500 tons or less. 730.3.5 Corrective Action

(1)Do not blend additional material on the roadbed to correct gra dation problems.

(2)Consider corrective action when a running average trends towar d a warning limit.

(3)Notify the engineer when a running average exceeds a warning l imit. When two consecutive running

averages exceed a warning limit, the engineer and contractor wi ll discuss appropriate corrective action. Perform the engineer’s recommended corrective action and increase the testing frequency as follows:

1.Increase gradation testing to at least one test per 1000 to ns placed.

2.Increase fracture testing to at least one fr acture test for each gradation test.

(4)If corrective action improves the property in question such th at the running average is within the

warning limits, the contractor m ay return to the testing freque ncy specified in 730.3.2 . If corrective action does not improve the property in question, and the runni ng average is still in the warning band, then repeat the steps outlined above starti ng with engineer not ification.

(5)If a QV test result does not c onform to the specifications, th e engineer will inform the contractor and

the QV test will be added to the QC data and included in the ru nning average, as if it were an additional QC test.

(6)If a running average is never est ablished, individual placemen t tests are used for acceptance.

(7)If an individual QC or QV test result is significantly out of specification limits, not ify the other party, stop

placing base, suspend other ac tivities that may affect the area in question, and jointly investigate to determine the extent of nonconforming material. Both parties mu st document the investigative work.

(8)Test results are considered significantly out of spec limits i f meeting one or more of the following:

1.A gradation spec limit for the No. 200 siev e is exceeded by more than 3.0 percent.

2.A gradation spec limit for any sieve, o ther than the No. 20 0, is exceeded by more than 5 percent.

3.The fracture spec limit is exceeded by more than 10 percent .

(9)The engineer may direct the contra ctor to remove and replace a ny nonconforming material. If the

engineer allows the nonconforming material to remain in place, it is subject to a pay reduction. 730.3.6 Nonconforming Material

(1)The department will determine the extent of nonconforming mate rial as follows:

1.If an individual QC or QV g radation or fracture test is out of spec and a 4-point r unning average is never

established, the material starting from the first out-of-spec QC or QV test and en ding at the first subsequent QC or QV te st that is within spec limits is nonconforming.

Effective with the December 2018 Letting 537 2019 Standard Spec ifications 2. If a gradation or fracture 4 -point running average exceeds a control limit, the material starting from the first running average outside of the control limit and ending at the first subsequent running average that is within the control limit is nonconforming.

3.If any indiv idual QC or QV plasticit y test is out of spec, the material starting from the first out-of-spec QC or

QV test and ending at the firsts ubsequent QC or QV test that i s within spec limits is nonconforming.

4.If an individual QC or QV gradation or fracture test is sig nificantly out of spec, the material starting from the

first significantly out-of-spec QC or QV test and ending at the first subsequent QC or QV test that is within spec limits is nonconforming, ev en if the 4-point running avera ge, that includes the sign ificantly out-of-spec test, is within spec limits. 730.4 (Vacant)

730.5Payment

Added new Nonconforming QMP Base Aggregate Plasticity administrative item.

(1)The department will administer pay reductions for nonconformin g material under the Nonconforming

QMP Base Aggregate Gradation, N onconforming QMP Base Aggregate Fracture, and Nonconforming QMP Base Aggregate Plasticity administrative items.

(2)The department will calculate pay reductions for base aggregat e with nonconfor ming gradation and

fracture using the nonconforming q uantity that remains in place , the bid item contract unit price, and a pay reduction percentage from table 730-1. The department will administer a 50% pay reduction for base aggregate with nonconforming plasticity or liquid limit th at remains in place. TABLE 730-1 Pay Reductions for Nonconforming Base Aggregate % PAY REDUCTION[1] NONCONFORMING GRADATION NONCONFORMING FRACTURE NO 200 SIEVE SIEVES OTHER THAN NO 200 5% to 10% ≤ 1.5% ≤ 3% ≤ 5% 10% to 20% > 1.5% to ≤ 3% > 3% to ≤ 5 % > 5% to ≤ 10% SIGNIFICANTLY OUT OF SPEC[2] 20% to 40% > 3% > 5% > 10% [1] The engineer will use t he guidance provided in CMM 8-10 when determining pay reduction percentages from within a given range. [2] The engineer may assess pay reductions for individual QC or QV test results that are sig nificantly out of spec even if the running average is within spec limits.

(3)The department will not apply mor e than one pay adjustment to a given quantity of material. If a

quantity of material is nonconforming in more than one property , the department will apply the greater pay reduction. Effective with the December 20 18 Letting 538 2019 Standard Spec ifications Section 740 QMP Ride Add section 740 to move the Ride Quality specifications from 440.

740.1Description

740.1.1 General (1)This section describes profili ng with a non-contact profiler, locating areas of localized roughness, and determining the International Roughness Index (IRI) for each wh eel path. (2)Profile the final mainline riding surfaces greater than 1500 f eet in continuous length. Include bridges, bridge approaches, and railroad crossings in the calculation of IRI. Exclude ro undabouts and pavements within their entry and exit curves from the calculati on of IRI. (3)Also profile final riding surfaces of pavement greater than 15 00 feet in continuo us length for the following: - Auxiliary lanes in Category I and II segments. - Mainline pavement on county, state, or U.S. highway crossroads reconstructed under the contract. (4)The engineer may direct straightedging under 415.3.10 or 450.3.2 .9 for pavement excluded from localized roughness under 740.3.4.2(1) , for bridges, for roundabouts , and for pavements within 150 feet of the points of curvature of roundabout intersections. (5)Conform to the general QMP requirements under 701 and to the additional requirements specified here in 740. 740.1.2 Quality Control Program 740.1.2.1 Quality Control Plan (1)Conform to 701.1.2.2 , except omit items 3, 4 and 9; and include the followi ng:

1.The methods and timing used for monitoring and testing ride quality throughout the placement process.

Also indicate the approximate timing of acceptance testing in r elation to placem ent operations.

2.The segment locations of eac h profile run used for acceptance testing.

3.A traffic control plan.

740.1.2.2 Personnel (1)Have an HTCP-certified profile r operate the equipment, collect the required data, and analyze the results using the methods taugh t in the HTCP profiling course. Ensure that an HTCP-certified profiler supervises data entry into t he department's MRS software. 740.1.2.3 Equipment (1)Furnish a profile-measuring device capable of measuring IRI fr om the list of department-approved profilers at: https://wisconsindot.gov/Documents/doing-bus/eng-consultants/cnslt-rsrces/tools/qmp/profilers.pdf (2)Unless the engineer and contract or mutua lly agree otherwise, arrange to have a calibrated profiler available when paving the final riding surface. (3)Verify profiler equipment calibration daily using test methods the profiler manufacturer reco mmends. Notify the engineer before veri fying the calibration. If the en gineer requests, arrange to have the engineer observe the calibrati on verification and profiler oper ation. Maintain records of calibration verification activities; provi de those records to the engineer upon request. 740.1.2.4 Documentation (1)After profiling, compute the segment IRI for each segment and analyze are as of localized roughness using the ProVAL software available for download at: http://www.atwoodsystems.com/iibv2/default.cfm (2)Prepare the ProVAL ride quality module reports showing the segment IRI for each segment and areas of localized roughne ss exceeding 200 in/mile on pavements that are not continuously diamond-ground or designated for continuous diamond grinding. Generate the rid e quality module reports in ProVAL using the following parameters: FIXED INTERVAL (segment IRI) CONTINUOUS (localized roughness) BASE-LENGTH 500 feet 25 feet THRESHOLD 140 in/mile 200 in/mile (3)Field-locate the areas of loc alized roughness before the engin eer’s assessment for corrective action. Document the reasons for areas excluded.

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 543–546 of 601.

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716 QMP Ancillary Concrete

740 QMP Ride