Presentation on theme: "Construction Materials"— Presentation transcript:
1Construction Materials William G. LaSageNYSDOT Region 7 Materials Engineer
2Materials Forms and Manuals Where do I find these documents?https://www.nysdot.gov/divisions/engineering/technical-services/materials-bureau/forms-manualsWhat’s available?MURK Part 2A - Materials Inspection Manual (Materials Acceptance Requirements)Materials Method Plant Inspection of Portland Cement ConcreteMaterials Method Field Inspection of Portland Cement ConcreteMaterials Procedure NY05-04 – Preparing and Processing Fabrication Drawings for Precast ProductsMaterials Procedure Plant Inspection of Hot Mix Asphalt (Superpave)Murk 2A – Referenced by the 700 Section that pertains.MP – What’s required for culvert shop drawings, drainage structures, manholes, special structures. Includes the Fabrication Request Sheet (Standard Sheet or Cut Sheets) and Working Drawing Sheet (Shop Drawings).MP 401 – Replaces MP
4Miscellaneous NYSDOT Publications MURK Part 1B - Construction Inspection Manual (CIM)https://www.nysdot.gov/main/business-center/contractors/construction-division/construction-repository/murk1b_cim_ pdfSteel Construction Manual 3rd Edition (March 2008)https://www.nysdot.gov/divisions/engineering/structures/manuals/scmPrestressed Concrete Construction Manual (September 2000)https://www.nysdot.gov/divisions/engineering/structures/manuals/pccmStandard Sheetshttps://www.nysdot.gov/main/business-center/engineering/cadd-info/drawings/standard-sheetsStandard Specificationshttps://www.nysdot.gov/main/business-center/engineering/specificationsCIM – Provides useful checklists and some forms. Also gives guidance other NYSDOT manuals do not.Deck Machine Setup, PrePour Meeting Topics, etc.SCM – Explains the procedures that are required when working with shop/erection drawings, shop and field inspection, certifications, welding, bolted connections, testing, etc.PCCM - Explains the procedures that are required when working with shop/installation drawings, inspection, materials, testing, acceptance criteria, construction details, etc.Standard Sheets – NYSDOT Standard Drawings and Details referenced by item number to aid in the uniform construction of capital projects.Standard Specifications – For each Standard item, all NYSDOT specifications provide:Description of Work – A general description of what is expected by specifying the item.Materials Requirements – References all the component materials required and the standards they must meet to be found acceptable.Construction Details – Specific details/procedures that need to be done during Construction.Method of Measurement – How the quantities are measured.Basis of Payment – What is included in the payment of the item.
5Materials Certifications Where do I find out what is required?Contract Plans/ProposalNYSDOT Standard SheetsNYSDOT Standard SpecificationsEach Section has a “Materials” narrative (XXX-2) detailing the Materials Acceptance requirements for a given item.MURK Part 2A - Materials Inspection ManualApproved ListAggregateshttps://www.nysdot.gov/divisions/engineering/technical-services/materials-bureau/fine-coarse-aggregatesMaterials and Equipmenthttps://www.nysdot.gov/divisions/engineering/technical-services/materials-bureau/materials-and-equipmentContract Plans/Proposal – Contract specific details.NYSDOT Standard Sheets – Look in the notes for what 700 Materials Specifications are referenced.NYSDOT Standard Specifications – Look up in the required materials for each item, then look up in the 700 Materials Specifications for specific Materials Acceptance DetailsMIM – Provides additional guidance regarding what is required for Materials Acceptance.Approved Lists – Lists of products the department has approved for use in capital projects.All products must minimally meet their appropriate 700 Materials Section requirements.Aggregates are sampled/tested every two years in order to maintain approved status.
6Hot Mix Asphalt Plant Inspection NYSDOT Approved PlantAnnual Inspection90 Day Scale Checks Up-to-DateMix DesignsNYSDOT Regional Materials assigns production status to all Superpave mix designs that have been successfully plant verified.The owner is encouraged to review all Superpave mix designs and make their own determination on acceptability.For all Marshall Mixes, a mix design must be submitted for approval by the owner.Plant InspectionRequired for daily Superpave production >500 TON.Plant may certify quantities of less than 500 TON.NYSDOT Standard Specifications § requires 3:00 PM notification the day before production to arrange for inspection.Contractor must give notification to plant prior to 3:00 PM to ensure scheduling can be accommodated.Approved PlantAnnual Inspection is valid from date it was performed.90 Day Scale checks must be up to date to stay approved.Approved List of HMA plants is not published outside the department.Publicly releasing this information may create an unfair bidding situation.Contact your Regional Local Let Laison to verify approved status.Mix Designs – Owner or their representative needs to approve the use of specific mix designs for their project.Copies of mix designs should be obtained directly from the producer (Proprietary Information).Plant Inspection – Required for Superpave, encouraged for Marshall mix production.3 PM notification is a big problem and needs to be addressed, especially if NYSDOT will be providing inspection (NHS system).
7Hot Mix Asphalt Plant Inspection Quality Assurance/Quality Control Certification Program (Alfred Certification)Inspector must possess current certification.Recertification is required every 5 years.Superpave (NYSDOT Standard Specifications §402)Inspection progressed as per NYSDOT Materials Procedure 401.Daily production for each mix is broken into 1000 TON Sublots.Independent QC and QA aggregate and hot mix asphalt samples are taken within each Sublot.Samples are tested for Gradation, Bulk Specific Gravity, Maximum Specific Gravity, and % Air Voids.A Plant Production Quality Adjustment Factor (QAF) is calculated based upon the results of these tests.The inspector also completes all required paperwork, records in the Hot Mix Asphalt Daily Diary pertinent/required information pertaining to the day’s production, and prepares the BR 343 – Daily Hot Mix Asphalt Authorized Shipments.QC/QA Certification – A photo ID card is issued by Alfred as proof of certification.For each Superpave project, a binder is placed in the plant lab for use only on that project.All project related tests/paperwork/records need to be filed in that binder.The project binder is setup exactly the same as the NYSDOT binder.
8Hot Mix Asphalt Plant Inspection Marshall Mix (NYSDOT Standard Specifications §403)Section Construction Details assigns responsibility to the Contractor for production Quality Control.Unless otherwise specified, a Quality Control Technician is not required to be present during production.Typically the Quality Control Technician will monitor and verify mix production via automation.Owners are encouraged to perform Quality Assurance Testing to ensure the quality of the hot mix asphalt being produced.Asphalt content verified via automation.AASHTO T27 – Sieve Analysis of Fine and Coarse AggregatesAASHTO T245 - Standard Method of Test for Resistance to Plastic Flow of Bituminous Mixtures Using Marshall ApparatusAASHTO T166 – Bulk Specific Gravity of Compacted MixturesAASHTO T209 – Theoretical Maximum Specific Gravity of Bituminous Paving MixturesAASHTO T269 – Percent Air Voids in Compacted Dense and Open Bituminous Paving MixturesMonitor and VerifyVerify the %AC via the tickets or 5 minute printouts.Look at the mix as it is being loaded into the trucks.Verify aggregate is being coated sufficiently.Verify the top looks like top.Verify the temperature.Most likely little to no sampling is being done.QA VerificationVerify gradations are not varying throughout the day’s production.Verify the actual air voids at which the mix is being produced at.Reduce the chances of bleeding, raveling, etc.
9Hot Mix Asphalt Field Inspection Compaction MethodsMarshall MixNYSDOT Standard Specification Tables (Similar to 80 Series)Superpave 80 SeriesNumber of PassesNYSDOT Standard Specification Table 402-5Superpave 70 Series - Nuclear/Non-Nuclear Density Gauge Monitoring“Peak the Gauge”NYSDOT Standard Specification § CEIC’s must obtain a copy of the Nuclear Gauge Operators Associated General Contractors, New York State, Density Gauge Inspector Certification for the project records.Superpave 60 Series – Coring of Test Strip with Nuclear/Non-Nuclear Density Gauge MonitoringNYSDOT Standard Specification § BMarshall vs. 80 Series80 Series requires more passes to be done when compared to Marshall Mix.Peak the GaugeEIC randomly selects 3 random locations within the area between the first feet of mainline paving.Gauge readings are taken after each roller pass.Gauge readings are taken until the average of 4 gauge reading at that location does not change by more than 2 pcf.The PTD is then based upon 96% of the average of highest reading at location.60 SeriesTest Strip = Area between the first linear feet of mainline paving.Calibrates the gauge to the mix and laydown/compaction equipment.A Project Target Density is established based upon the actual core density and nuclear gauge readings.Each nuclear gauge is also assigned a correction factor based on the difference between the reading and the actual core density.Establish a rolling pattern that can be followed to achieve consistent results.If there is a significant change in the mix or equipment, multiple test strips may be required.
10Hot Mix Asphalt Field Inspection Temperature Readings, Yields and Depth ChecksMust be done on a regular basis and recorded.Tack CoatTack TrucksNYSDOT Standard Specifications § EquipmentSelf-Certification and Annual Calibration (ASTM D 2995) must be provided prior to use on the project.Application Rates as per NYSDOT Standard Specifications TableSampling & TestingSampling as per NYSDOT Materials Method Asphalt Emulsion Quality Assurance.Emulsion must meet requirements of NYSDOT Standard Specifications Table
11Hot Mix Asphalt Paperwork/Certifications Plant CertificationsBR 307 – Region 7 Quality Control Hot Mix Asphalt CertificationGenerated by the Plant for all Marshall Mix or non-testable quantities of Hot Mix Asphalt.BR 343a – Daily Hot Mix Asphalt Authorized ShipmentsGenerated by the Plant Inspector.Certifies Type of Material, Quantity, and Quality Adjustment Factor.Delivery TicketsMust conform to NYSDOT Standard Specifications §401-4 Method of Measurement.Verify Mix Codes (09F32YB) using NYSDOT Standard Specification TableDensity MonitoringNuclear Gauge = BR 340 & BR 341 – Hot Mix Asphalt In-Place Pavement Density DataNon-Nuclear Gauge = BR 66, BR 68 & BR 69 – Hot Mix Asphalt In-Place Pavement Density DataCoring = BR Test Section Nuclear Gauge Test DataNon-nuclear gauges are the PQI = Pavement Quality Indicator or Pave Tracker
12Concrete Plant Inspection NYSDOT Approved PlantAnnual Inspection90 Day Scale Checks Up-to-DateNYSDOT Inspected Transit Mixers (Inspection Sticker)Barrel/Fin ConditionCounter FunctionWater Tank CalibrationMix DesignsAnnually or when updates are necessary, Regional Materials provides the producer with mix designs for all NYSDOT concrete classes (A, D, J, H, etc.).For all non-NYSDOT mixes, a mix design must be submitted for approval by the owner.Plant InspectionRequired for all concrete production of 25+ CY.Plant may certify quantities of less than 25 CY.NYSDOT Standard Specifications § requires 3:00 PM notification the day before production to arrange for inspection.Contractor must give notification to plant prior to 3:00 PM to ensure scheduling can be accommodated.Approved PlantAnnual Inspection is valid from date it was performed.90 Day Scale checks must be up to date to stay approved.Approved List of concrete plants is not published outside the department.Publicly releasing this information may create an unfair bidding situation.Contact your Regional Local Let Laison to verify approved status.Transit TrucksInspection expires at the end of the calendar year.Inspection is performed annually or when complaints arise during the production season.Hatches are pulled and fins checked for wear, counters are checked for function, and water tank is checked for calibration.Mix Designs – Owner or their representative needs to approve the use of specific mix designs for their project.Copies of mix designs should be obtained directly from the producer (Proprietary Information).Plant Inspection – Required for all production over 25 CY.3 PM notification is a big problem and needs to be addressed, especially if NYSDOT will be providing inspection (NHS system).
13Concrete Plant Inspection NYSDOT Concrete Batch Plant Inspector Certification ProgramInspector must possess current certification.Recertification is required every 5 years.Inspection progressed as per Materials Method Plant Inspection of Portland Cement Concrete.Each production day, aggregates are sampled and tested for gradation and moisture content.For HP concrete, moisture corrections are calculated to determine the required hold back water.Cement, flyash, and microsilica samples are obtained and sent for testing, as appropriate.Frequent sampling is encouraged to ensure the quality of the materials incorporated in the batch.Verify the correct mix design is being batched under automation, in spec, using approved materials, and being transported in an approved truck.The inspector records in the Concrete Daily Diary all pertinent/required information pertaining to the day’s production and prepares the BR 316 – Daily Concrete Batch Plant Report.Batch Plant Inspector CertificationTraining must be given by a NYSDOT certified trainer.Just because you are certified doesn’t allow you to become a trainer.After training is completed, a written test is administered by NYSDOT at the Regional Materials Office.SamplingRepresentative samples are encouraged to be taken on a regular basis.The owner is responsible for supplying their own sampling containers and performing the tests on the samples.
14Concrete Field Inspection Certifications.ACI Concrete Field Testing Technician Grade INYSDOT Field Testing Technician ProgramNICET Level II Construction Materials Testing TechnicianInspection as per Materials Method Field Inspection of Portland Cement Concrete.Slump/Air Tests at a minimum of every 50 CY.Slump/Air/Temperature/6” x 12” Concrete Cylinders at a minimum of every 200 CY.A minimum of 2-28 Day Cylinders must be cast for each structural element.No more than 8 Cylinders should be cast for any structural element.All samples must not be obtained from the first or last 10% of the load.Cylinder samples must come from the middle third of the load.Additional slump/air testing and fabrication of cylinders may be necessary, if mix quality problems are encountered.To limit the potential risk of out of spec material being incorporated into the work, placement should be halted while the concrete is being tested.
15Concrete Field Inspection If the material begins to test marginally,Inform your Contractor.The contractor should then contact the plant to request corrective action.Increase testing frequency until you have confidence the material has improved.Communication, communication, communication!If you encounter out of spec test results,Resample and Retest.If the retest fails, reject the load.Increase testing frequency until you have confidence the material quality has improved.Out of Spec Material CANNOT be accepted!Cylinder CuringNYSDOT Standard Specification Table 555-4Notes 1 & 3 require “Early Open” cylinders to be cured in the same manner as the structural element they represent.Cylinders should also be protected from freezing or excessive heat (baking in the sun).
16Concrete Paperwork/Certifications Plant CertificationsBR 316 – Daily Concrete Batch Plant ReportGenerated by the Plant InspectorBR 342 – Portland Cement Concrete Materials CertificationProducer Certification of Concrete (<25 CY)Other PaperworkBatch TicketsMust conform to NYSDOT Standard Specifications § D - Delivery Tickets.Record the water added onsite on the delivery ticket.Record the Begin/End Discharge times.BR 300 – Concrete Cylinder ReportOne form per cylinder set (2 cylinders) is required.