383 604.2.1 -Quality Control Testing: Quality control of the granular material and crushed aggregate is the responsibility of the Contractor as specified in subsection 106.1. The Contractor shall maintain necessary equipment and qualified personnel to perform all sampling and testing necessary to determine the magnitude of the various properties of the material governed by the Specifications and shall maintain these properties within the limits of the Specifications. The Contractor shall submit a quality control plan detailing the methods by which the quality control program will be conducted. This plan, prepared in accordance with the guidelines set forth in the appropriate portions of MP 307.00.50 and MP 717.04.21, shall be submitted to the Engineer at the preconstruction conference. The work shall not begin until the plan is reviewed for conformance with the contr act documents.
604.2.2 -Acceptance Testing: Quality control sampling and testing performed by the Contractor may be used by the Division for Acceptance.
604.2.3 -Sampling and Testing: Frequency of sampling and testing shall be in accordance with the contractor’s quality control plan. The minimum sampling and testing frequencies for gradation shall be as indicated in Attachment 1 of MP 307.00.50. The material shall be sampled in accordance with MP 700.00.06. The minimum sampling and testing frequenc y for compaction will be in accordance with MP 717.04.21.
604.2.4 -Acceptance Plan: 604.2.4.1 -Compaction: Compaction of backfill material shall meet 604.8.
604.2.4.2 -Gradation: The material shall be sampled and tested in accordance with random samples from a lot. A sublot is the quantity of material represented by a single gradation test as defined in MP 700.00.06 . A lot shall be considered the quantity of material represented by an average test value, not to exceed five sublots. In the case where only one sample is needed for the total plan quantity, the sublot shall be considered the lot. The average shall star t on the second sample result. The average is continued for the third through fifth sample result, averaging all previous sample results. Thereafter, only the last consecutive five sample results will be averaged, i.e., second test value through sixth te st value, third test value through seventh test value, and so forth as defined in MP 300.00.51. When the test value of a lot and the test value of the last sublot, or when the last three consecutive individual test values of a lot fall outside the gradati on limits of Table 704.6.2A the lot of material represented will be considered nonconforming to the extent that the last of its sublots are nonconforming. When this occurs, the last sublot shall have its price adjusted in accordance with Table 604.14.1.
604.2.4.3 -Degree of Nonconformance: When a sublot of material is to have its price adjusted, the percentage point difference between the nonconforming test value and the specification limit shall be determined for each sieve size determined to be nonconf orming, and this value shall be multiplied by its appropriate multiplication factor as set forth in Table 604.2.4.3 .
384 TABLE 604.2.4.3 Nonconforming Sieve Size Multiplication Factor 1 ½ in. (37.5 mm) 1.0 ¾ in. (19 mm) 1.0 No. 4 (4.75 mm) 1.0 No. 40 (425 µm) 1.0 No. 200 (75µm) 2.0
The total measure of nonconformance of an individual sublot is the sum of all nonconformance of an individual sieve sizes of that sublot. When the total degree of nonconformance has been established and it is 12.0 or less, the material will be for at an adjusted contract price as specified in Table 604.14.1. When the degree of nonconformance is greater than 12.0, the nonconforming sublot shall be resolved on an individual basis, requiring a special investigati on by the Engineer to determine the appropriate course of action to be followed.
CONSTRUCTION METHODS
604.3 -GENERAL : Subject to the provisions prescribed, the flow line of a pipe culvert may be altered from that shown on the plans. Galvanized steel pipe or bands shall not come in contact with aluminized steel pipe or bands. The diameter of pipe, as used in this Section, is the largest dimension, horizontal or vertical.
604.4 -TRENCH EXCAVATION : 604.4.1 -Pipe Culverts 18 Inches Through 96 Inches: In complete or partial fill sections, before trenching is begun, the fill shall be constructed for a minimum distance of six diameters on each side of the pipe and to a heig ht of two ( 2) feet over the top of the pipe or to the surface of the completed embankment if less than two ( 2) feet above the top of the pipe. The minimum width of the trench, in either cut of fill sections, shall be calculated using the formulas below . The Contractor shall increase these minimums to a width that allows the jointing of the pipe, and adequate placement and compaction of the backfill.
Pipe Culverts of thirty -six (36) inches diameter or less: = Outside Diameter + eighteen ( 18) Inches on each side of the pipe
Pipe Culverts with diameter greater than thirty -six (36) inches : = Outside Diameter + twenty -four ( 24) Inches on each side of the pipe
604.4.1.1 -Pipe Culverts Installed Using Controlled Low Strength Material (Type F Trench): When using a controlled low strength material (CLSM) the width of the trench shall not be less than the values in the table in Standard Detail DR -10; and f or trenches in rock , a minimum trench width of Outside Diameter plus six (6) inches on each side of the pipe.
385 604.4.2 -Pipes Greater than 96 Inches: In complete or partial fill sections, before trenching is begun, the fill shall be constructed for a di stance of six diameters on each side of the pipe and to a minimum height of 25 percent (25%) of the vertical dimension of the pipe. Installation of the pipe shall be as detailed in the plans, including the type and amount of backfill and bedding. The C ontractor shall submit shop drawings detailing all erection procedures including anticipated movements during backfilling operations. Backfill operations shall also be detailed to show lift thicknesses, sequence of lifts and shape of the culvert during th ese operations. The Contractor shall submit a plan of field control for the installation insuring the pipe is erected in accordance with the shop and erection drawings.
604.4.3 -Structural Plate Box Culvert: Excavation for the foundations of structura l plate box culvert shall be in accordance with 212.3.
604.4.4 -Precast Concrete Box Culvert: The minimum width of the trench shall be eighteen ( 18) inches on each side of the box culvert.
604.5 -BEDDING : Unless otherwise noted in the plans, bedding shall conform to the following requirements. Rigid pipe bedding shall be granular material or crushed aggregate with a three ( 3) inch minimum thickness. Flexible pipe bedding shall be crushed aggregate with a four ( 4) inch minimum thickness. The bedding material placed under the middle ⅓ of the pipe diameter shall be loosely placed and uncompacted to allow for cradling of the pipe bottom. Bedding outside of the middle ⅓ shall be compacted. When rock or unyie lding material is present in the trench bottom, six (6) inches of granular material shall be installed below the bottom of the pipe or box culvert. Box culvert bedding shall be fine aggregate with a four ( 4) inch minimum thickness.
604.6 -LAYING AND JOINI NG: 604.6.1 -Rigid and Flexible Pipe and Concrete Box Culvert: The pipe/culvert placing, unless the Contractor is otherwise directed, shall begin at the downstream end of the pipe/culvert. The lower segment of the pipe/culvert shall be in contact with the bedding throughout its full length. Bell or groove ends of pipes and outside circumferential laps of corrugated steel pipe shall be placed facing upstream. Paved or partially lined culverts shall be laid so that the longitudinal centerline of the paved segment coincides with the flow line. Rigid pipes/culverts may be of either bell and spigot or tongue and groove design, unless one type is specified. The method of joining pipe sections shall be such th at the ends are fully entered, and the inner surfaces are reasonably flush and even. Joints for rigid pipes/culverts shall be made with flexible gaskets that conform to ASTM C443 or bitumen sealant combined with an external sealing wrap which conforms to ASTM C877, Type III. All joints shall be installed to form a leak resistant seal. Flexible pipes shall be joined by bell and spigot joints, and the pipe shall be installed to preserve the alignment, provide a leak resistant joint that conforms to ASTM D 3212 performance requirements, and prevent the separation of sections. Pipe culverts shall be inspected before any backfill is placed. Any pipe found to be out of alignment, unduly settled, or damaged shall be removed and re -laid or replaced.
386 604.6.2 -Structural Plate Box Culvert: Plate box culvert shall be set on footings as shown on the Plans. Beginning at the upstream end, the first side plates shall be set on the base angles. Then the remaining side plates and the top plates shall be bolted into place using only enough bolts to hold them without tightening securely. Drift pins may be used to assist in matching bolt holes. Temporary props may be used to hold plates in place until connections are made. After the plates comprising the first set h ave been assembled, the next set shall be placed in the same manner, finishing each set of side plates with a top plate before placing in the same manner, finishing each set of side plates with a top plate before placing the next set of side plates. New p lates shall be lapped one corrugation on the outside of the preceding plates. When all the plates are in position, the remaining bolts shall be inserted and all nuts firmly tightened. Steel bolts shall be torqued during installation to a minimum of 100 f t-lbs., and a maximum of 300 ft -lbs., Aluminum bolts shall be torqued during installation to a minimum of 100 ft -lbs., and a maximum of 150 ft -lbs. For power driven tools, the hold -on period may vary from 2 to 5 seconds. Bolts shall be of sufficient leng th to provide for a full nut.
604.7: Blank
604.8 -BACKFILLING : The use of a bulldozer or other bladed equipment in placing backfill is expressly forbidden. Mechanical equipment with various type buckets may be used. All pipe, after being bedded and backfilled, shall be protected by a four ( 4) foot cover of fill, or more if necessary, before heavy equipment is permitted to cross during the construction of the roadway. The Contractor will be held responsible for any damage to the pipe resulting from movement of equipment over the structure.
604.8.1 -Initial Backfill Zone: Rigid Pipe initial backfill material shall be suitable granular material free from particles larger than 1 -½ inch, crushed aggregate, or controlled low strength material. For flexible pipe, the initial backfill material shall be crushed aggregate o r controlled low strength material. The initial backfill material shall be placed along the pipe in layers not to exceed four ( 4) inches and compacted to 95% standard proctor; to a minimum of the spring line for rigid pipe and to a minimum height of six (6) inches over the top of flexible pipe. Controlled low strength material (CLSM) shall be placed according to Section 219; and any type of CLSM may be used unless otherwise indicated on the Plans or Standard Details. Unless otherwise specified in the plans, CLSM can be used as a substitute for granular material or crushed aggregate at the contractor’s option. At the contractor’s option, and if permitted by the Engineer, Class B concrete may be used as a substitute for CLSM at no additional cost to the Division. Care shall be taken to compact the material under the haunches of the pipe, to place the backfill evenly on each side of the pipe to retain its vertical axis, and to avoid displacement. The backfill and compaction efforts shall be advanced simultan eously on both sides of the pipe. Box culvert initial backfill material shall be suitable granular material free from particle sizes larger than 1 -½ inch or crushed aggregate. Unless otherwise noted on the plans, it shall be placed to a minimum of twelve (12) inches over the top of box culvert.
604.8.2 -Final Backfill Zone: Unless otherwise noted in the plans, the area above initial backfill zone shall be one of the following:
387 1. Suitable random material with material sized up to three ( 3) inches with no more than 20% retained on the 1 -½ sieve (40mm),
This method of backfilling and compacting shall be followed until the top of the trench is reached.
604.8.3 -Backfill Testing: The quality control testing and acceptance of CLSM shall be in accordance with Section 219. Class B concrete shall be in accordance with Section 601, except that the job site and A -bar testin g are waived. The quality control testing and acceptance for compaction of the random backfill material shall be in accordance with applicable sections of 207 and 716, granular material according to section 716, and crushed aggregate according to section 717, with the following exception: Testing will be conducted on both sides of the pipe and testing within a lot may include tests on both sides of the pipe. For pipe installations in an embankment where existing tests are on file for the adjacent emb ankment material, the target percentage of dry density for the pipe backfill will be equal to the average of the X values for the tests in the adjacent lots of embankment material or a minimum value of 95, whichever is greater. For embankments where no te sts are on file, the target percentage of dry density will be 95. A lot shall have five
For pipes less than sixty ( 60) inches in diameter, a lot will normally consist of the quantity of backfill required for each 75 linear feet of pipe installed. For pipes sixty ( 60) inches in diameter and larger, a lot will normally consist of not more than 5 lifts of backfill. For pipe with lifts of backfill placed for the full length of the pipe, a sublot will normally consist of a lift of backfill placed on both sides for the full length of the pipe. For pipes that are backfilled in segments, a sublot will normally consist of a lift of backfill placed on both sides for the length of each segment of pipe backfilled. Backfill placed outside embankments and roadbed is to be compacted to or better than the average total dry density for the existing soil. An average total dry density will be determined from representative density tests conducted for each existing soil. Quality control testing will normally consist of one test per 100 linear feet of pipe installed, and lot evaluations are not required. The moisture tolerance is not applicable.
604.9 -FIELD PAVING : The Contracto r may pave with Portland cement concrete or use shotcrete. If practicable, such paving shall be delayed until completion of the fill over the structure. Before the placing of the paving, the surface of the plates shall be cleaned. The Portland cement co ncrete or shotcrete, mesh reinforcement, fastening of mesh, and paving dimensions shall be as specified and the minimum thickness over the crest of the corrugations shall be 1 -½ inches. Concrete used shall have a design 28 -day compressive strength of 3,000 psi (equivalent to Class B in 601.3); concrete may be hand mixed and shall be handled and placed as directed by the Engineer. After initial set has taken place, the paving shall be flo oded or kept moist by sprinkling for three days. Liquid membrane -forming compound, conforming to subsection 707.9 may be used for curing at a minimum application rate of one gallon per 150 square feet of concrete surface. Other methods of curing may be u sed if approved by the Engineer. Field paving with shotcrete shall conform to Section 623. When paving with shotcrete, the exposed surface shall be brought to a uniform surface by screeding or troweling. After completion of the shotcrete paving, the reb ound material shall be cleaned from the culvert above the paved