Standard Specifications For Road and Bridge
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RAIMUNDO SUHERDINStandard Specifications For Road and Bridge
Uploaded by
RAIMUNDO SUHERDINFLORIDA
DEPARTMENT
OF
TRANSPORTATION
Standard Specifications
for
Road and Bridge
Construction
2013
These Florida Department of Transportation Standard Specifications for Road and Bridge
Construction, 2013, are hereby approved for application on highway and related
construction contracts as referenced in the contract plans or specifications, and they shall
apply as noted and amended by those documents.
Duane F. Brautigam, P.E.
Director, Office of Design
________________________________________________
I hereby certify that these Standard Specifications were prepared by me or under my
responsible charge, compiled from specifications prepared, examined, adopted and
implemented by the Florida Department of Transportation in accordance with established
procedures, and as approved by the Federal Highway Administration.
The official record of this document is the electronic file signed and sealed under Rule
61G15-23.003, F.A.C.
Virgil Y. Tillander III, P.E.
State Specifications Engineer
ii
TABLE OF CONTENTS
DIVISION I General Requirements & Covenants
Section
Page
Definitions and Terms ................................................................................................ 1
Proposal Requirements and Conditions .................................................................... 10
Award and Execution of Contract ............................................................................ 16
Scope of the Work .................................................................................................... 19
Control of the Work .................................................................................................. 31
Control of Materials .................................................................................................. 51
Legal Requirements and Responsibility to the Public .............................................. 55
Prosecution and Progress .......................................................................................... 79
Measurement and Payment ....................................................................................... 92
DIVISION II CONSTRUCTION DETAILS
GENERAL CONSTRUCTION OPERATIONS
100
Construction Equipment - General Requirements ............................................... 103
101
Mobilization ......................................................................................................... 105
102
Maintenance of Traffic ........................................................................................ 106
103
Temporary Work Structures ................................................................................ 123
104
Prevention, Control, and Abatement of Erosion and Water Pollution................. 124
105
Contractor Quality Control General Requirements ............................................. 132
107
Littter Removal and Mowing .............................................................................. 147
CLEARING CONSTRUCTION SITE
110
Clearing and Grubbing......................................................................................... 149
iii
EARTHWORK AND RELATED OPERATIONS
120
Excavation and Embankment .............................................................................. 157
121
Flowable Fill ........................................................................................................ 175
125
Excavation for Structures and Pipe ...................................................................... 177
145
Geosynthetic Reinforcement................................................................................ 186
160
Stabilizing ............................................................................................................ 191
162
Prepared Soil Layer ............................................................................................. 198
175
Cracking and Reseating Existing Concrete Pavement ......................................... 200
BASE COURSES
200
Rock Base ............................................................................................................ 202
204
Graded Aggregate Base ....................................................................................... 208
210
Reworking Limerock Base .................................................................................. 211
230
Limerock Stabilized Base .................................................................................... 213
234
Superpave Asphalt Base ...................................................................................... 215
283
Reclaimed Asphalt Pavement Base ..................................................................... 218
285
Optional Base Course .......................................................................................... 220
286
Turnout Construction ........................................................................................... 223
287
Asphalt Treated Permeable Base ......................................................................... 225
288
Cement Treated Permeable Base ......................................................................... 230
290
Granular Subase ................................................................................................... 234
BITUMINOUS TREATMENTS, SURFACE COURSES AND CONCRETE PAVEMENT
300
Prime and Tack Coats for Base Courses .............................................................. 235
320
Hot Mix Asphalts Plant, Methods, and Equipment .......................................... 240
327
Milling of Existing Asphalt Pavement................................................................. 248
iv
330
Hot Mix Asphalt General Construction Requirements ..................................... 252
334
Superpave Asphalt Concrete ................................................................................ 263
336
Asphalt Rubber Binder ........................................................................................ 280
337
Asphalt Concrete Friction Courses ...................................................................... 284
338
Value Added Asphalt Pavement .......................................................................... 293
339
Miscellaneous Asphalt Pavement ........................................................................ 300
341
Asphalt Rubber Membrane Interlayer ................................................................. 302
346
Portland Cement Concrete ................................................................................... 305
347
Portland Cement Concrete - Class NS ................................................................. 326
350
Cement Concrete Pavement ................................................................................. 329
352
Grinding Concrete Pavement ............................................................................... 342
353
Concrete Pavement Slab Replacement ................................................................ 347
355
Value Added Portland Cement Concrete Pavement ............................................ 352
370
Bridge Approach Expansion Joints...................................................................... 356
STRUCTURES
400
Concrete Structures .............................................................................................. 357
407
Three-Sided Precast Concrete Culvert ................................................................. 396
410
Precast Concrete Box Culvert .............................................................................. 402
411
Epoxy Injection of Cracks in Concrete Structures............................................... 411
413
Sealing Cracks and Concrete Structure Surfaces ................................................. 414
415
Reinforcing Steel ................................................................................................. 421
416
Installation of Post-Installed Anchor Systems and Dowels .......................................
for Structural Applications in Concrete ............................................................... 427
425
Inlets, Manholes, and Junction Boxes ................................................................. 430
v
430
Pipe Culverts ........................................................................................................ 433
431
Pipe Liner ............................................................................................................. 444
435
Structural Plate Pipe and Pipe Arch Culverts ...................................................... 446
436
Trench Drain ........................................................................................................ 447
440
Underdrains .......................................................................................................... 449
443
French Drains ....................................................................................................... 451
446
Edgedrain (Draincrete) ........................................................................................ 453
449
Precast Concrete Drainage Products .................................................................... 455
450
Precast Prestressed Concrete Construction .......................................................... 460
451
Prestressed Soil Anchors ..................................................................................... 489
452
Precast Segmental Bridge Construction .............................................................. 504
453
Epoxy Jointing of Precast Segments .................................................................... 520
455
Structures Foundations ........................................................................................ 526
458
Bridge Deck Joints ............................................................................................... 593
459
Bitumen Coating and Polyethylene Sheeting on Concrete Piles ......................... 597
460
Structural Steel and Miscellaneous Metals .......................................................... 599
461
Multirotational Bearings ......................................................................................461
462
Post Tensioning....................................................................................................630
470
Timber Structures ................................................................................................ 651
471
Plastic Fender System Components ..................................................................... 654
INCIDENTAL CONSTRUCTION
502
Shear Connectors ................................................................................................. 656
504
Steel Grid Floors .................................................................................................. 661
vi
506
Bridge Drainage System ...................................................................................... 663
510
Navigation Lights for Fixed Bridges ................................................................... 664
514
Plastic Filter Fabric (Geotextile).......................................................................... 669
520
Concrete Gutter, Curb Elements and Traffic Separator ....................................... 671
521
Concrete Barriers, Traffic Railing Barriers and Parapets .................................... 674
522
Concrete Sidewalk ............................................................................................... 678
523
Patterned Pavement.............................................................................................. 680
524
Concrete Ditch and Slope Pavement ................................................................... 683
525
Asphalt Concrete Curb......................................................................................... 685
526
Architectural Pavers ............................................................................................. 686
527
Detectable Warnings on Walking Surfaces ......................................................... 688
530
Riprap................................................................................................................... 690
534
Sound Barriers ..................................................................................................... 695
536
Guardrail .............................................................................................................. 698
538
Resetting Guardrail .............................................................................................. 702
544
Crash Cushions .................................................................................................... 703
546
Rumble Strips ...................................................................................................... 704
548
Retaining Wall Systems ....................................................................................... 706
550
Fencing................................................................................................................. 718
555
Directional Bore ................................................................................................... 722
556
Jack and Bore ....................................................................................................... 729
557
Vibratory Plowing................................................................................................ 739
560
Coating New Structural Steel .............................................................................. 743
vii
561
Coating Existing Structural Steel ......................................................................... 749
562
Repair of Galvanized Surfaces ............................................................................ 756
563
Anti-Graffiti Coating System............................................................................... 757
570
Performance Turf ................................................................................................. 759
571
Plastic Erosion Mat .............................................................................................. 764
580
Landscape Installation ......................................................................................... 766
TRAFFIC CONTROL SIGNALS AND DEVICES
603
General Requirements for the Installation and Evaluation of ...................................
Traffic Control Signals and Devices .................................................................... 769
608
Manufacturers Warranties for Traffic Control Signals and Devices .................. 772
611
Acceptance Procedures for Traffic Control and Devices .................................... 773
620
Traffic Control Signal and Device Installation Grounding ................................. 778
630
Conduit................................................................................................................. 780
632
Signal and Interconnect Cable ............................................................................. 785
634
Span Wire Assembly ........................................................................................... 788
635
Pull and Junction Boxes ....................................................................................... 792
639
Electrical Power Service Assemblies .................................................................. 794
641
Prestressed Concrete Poles .................................................................................. 797
649
Galvanized Steel Strain Poles, Mast Arms and Monotube Assemblies .............. 799
650
Vehicular Signal Assemblies ............................................................................... 804
653
Pedestrian Signal Assemblies .............................................................................. 807
660
Inductive Loop Detectors..................................................................................... 809
665
Pedestrian Detector Assembly ............................................................................. 812
670
Traffic Controller Assembly ................................................................................ 814
viii
671
Traffic Controllers ............................................................................................... 815
676
Controller Cabinets .............................................................................................. 816
678
Controller Accessories ......................................................................................... 818
690
Removal of Existing Traffic Control Signal and Devices ................................... 819
699
Internally Illuminated Signs................................................................................. 823
SIGNING, PAVEMENT MARKING AND LIGHTING
700
Highway Signing ................................................................................................. 826
701
Audible and Vibratory Pavement Markings ........................................................ 834
702
Wet Weather Pavement Markings ....................................................................... 838
705
Object Markers and Delineators .......................................................................... 842
706
Raised Retroreflective Pavement Markers and Bituminous Adhesive ................ 843
709
Traffic Stripes and Markings Two Reactive Components................................ 845
710
Painted Pavement Markings ................................................................................ 848
711
Thermoplastic Traffic Stripes and Markings ....................................................... 852
713
Permanent Tape Stripes and Markings ................................................................ 857
715
Highway Lighting System ................................................................................... 860
780
Intelligent Transportation Systems General Requirements .............................. 865
781
Intelligent Transportation Systems Motorist Information Systems .................. 867
782
Intelligent Transportation Systems Video Equipment ...................................... 885
783
Intelligent Transportation Systems Fiber Optic Cable and Interconnect .......... 897
784
Intelligent Transportation Systems Network Systems ...................................... 914
785
Intelligent Transportation Systems Infrastructure ............................................ 924
786
Intelligent Transportation Systems Vehicle Detection and Data Collection .... 946
ix
DIVISION III MATERIALS
AGGREGATES
901
Coarse Aggregate ................................................................................................. 969
902
Fine Aggregate ..................................................................................................... 975
FLEXIBLE-PAVEMENT MATERIALS
(INCLUDING MATERIALS FOR STABILIZING)
911
Limerock Material for Base and Stabilized Base ................................................ 979
913
Shell Material ....................................................................................................... 980
913A Shell Rock Material .......................................................................................... 982
914
Stabilization Materials ......................................................................................... 983
915
Cemented Coquina Shell Material ....................................................................... 984
916
Bituminous Materials ........................................................................................... 985
917
Mineral Filler ....................................................................................................... 996
919
Ground Tire Rubber for Use in Asphalt Rubber Binder ...................................... 997
MATERIALS FOR PORTLAND CEMENT CONCRETE
(STRUCTURAL PAVEMENT AND MISCELLANEOUS)
921
Portland Cement and Blended Cement ................................................................ 999
923
Water for Concrete............................................................................................. 1002
924
Admixtures for Concrete ................................................................................... 1004
925
Curing Materials for Concrete ........................................................................... 1007
926
Epoxy Compounds ............................................................................................. 1009
929
Pozzolans and Slag ............................................................................................ 1015
930
Materials for Concrete Repair............................................................................ 1019
ACCESSORY MATERIALS FOR CONCRETE PAVEMENT
AND CONCRETE STRUCTURES
931
Metal Accessory Materials for Concrete Pavement and Concrete Structures ... 1026
932
Nonmetallic Accessory Materials for Concrete Pavement ........................................
and Concrete Structures ..................................................................................... 1029
933
Prestressing Steel ............................................................................................... 1039
934
Non-Shrink Grout .............................................................................................. 1041
937
Post-Installed Anchor Systems for Structural Applications ......................................
in Concrete Elements ......................................................................................... 1043
938
Posttensioning Grout.......................................................................................... 1045
DRAINAGE MATERIALS
942
Pipe Gaskets ....................................................................................................... 1048
943
Corrugated Steel Pipe and Pipe Arch (Including Underdrain) .......................... 1050
944
Structural Plate Steel Pipe and Pipe Arch .......................................................... 1053
945
Aluminum Pipe, Including Underdrain, Pipe Arch and.............................................
Structural Plate Pipe and Pipe Arch ................................................................... 1055
946
Cast Iron Pipe..................................................................................................... 1057
948
Miscellaneous Types of Pipe ............................................................................. 1058
949
Brick and Concrete Masonary Units for Manholes, ..................................................
Inlets and Other Structures ................................................................................ 1064
TIMBER PRODUCTS AND MATERIALS
951
Inspection of Timber Products ........................................................................... 1065
952
Structural Timber ............................................................................................... 1066
953
Timber Piling (Including Timber Sheet Piling) ................................................. 1067
954
Timber Fence Posts and Braces ......................................................................... 1069
955
Timber Treatment (Including Treating Materials)............................................. 1071
xi
METAL MATERIALS AND FABRICATION DETAILS FOR METAL ITEMS
960
Posttensioning Components ............................................................................... 1073
962
Structural Steel and Miscellaneous Metal Items (Other than Aluminum)......... 1084
965
General Provisions for Aluminum Items (Including Welding) ......................... 1088
967
Rail Elements for Guardrail ............................................................................... 1090
PAVEMENT MARKINGS, COATINGS AND
RECYCLED MATERIAL (MISCELLANEOUS)
970
Materials for Raised Retroreflective Pavement Markers ...........................................
& Bituminous Adhesive..................................................................................... 1091
971
Traffic Marking Materials ................................................................................. 1093
972
Recycled Plastic Products .................................................................................. 1106
973
Structural Plastics .............................................................................................. 1107
975
Structural Coating Materials .............................................................................. 1110
EROSION CONTROL MATERIALS
981
Turf Materials .................................................................................................... 1116
982
Fertilizer ............................................................................................................. 1118
983
Water for Grassing ............................................................................................. 1119
985
Geotextile Fabrics .............................................................................................. 1120
987
Prepared Soil Layer Materials ........................................................................... 1121
TRAFFIC CONTROL MATERIALS
990
Temporary Traffic Control Device Materials .................................................... 1122
992
Highway Lighting Materials .............................................................................. 1133
993
Object Markers and Delineators ........................................................................ 1142
994
Retroreflective and Nonreflective Sheeting for Traffic Control Devices .......... 1146
xii
DIVISION I
General Requirements and Covenants
SECTION 1
DEFINITIONS AND TERMS
1-1 General.
These Specifications are written to the bidder, prior to award of the Contract, and to the
Contractor. Within Divisions I and II of the specifications, sentences that direct the Contractor to
perform work are written in the active voice-imperative mood. These directions to the Contractor
are written as commands. In the imperative mood, the subject the bidder or the Contractor is
understood.
All other requirements to be performed by others, with the exception of the Method of
Measurement and the Basis of Payment Articles, have been written in the active voice, but not in
the imperative mood. Sentences written in the active voice identify the party responsible for
performing the action. For example, The Engineer will determine the density of the compacted
material. Certain requirements of the Contractor may also be written in the active voice, rather
than active voice-imperative mood.
Division III of the Specifications (Materials) is written in the passive voice writing style.
1-2 Abbreviations.
The following abbreviations, when used in the Contract Documents, represent the full
text shown.
AAN
American Association of Nurserymen, Inc.
AASHTO
American Association of State Highway and Transportation Officials
ACI
American Concrete Institute
AGC
The Associated General Contractors of America, Inc.
AGMA
American Gear Manufacturers Association
AIA
American Institute of Architects.
AISI
American Iron and Steel Institute
ANSI
American National Standards Institute, Inc.
AREA
American Railway Engineering Association
ASCE
American Society of Civil Engineers
ASME
American Society of Mechanical Engineers
ASTM
American Society for Testing and Materials
AWG
American Wire Gauge
AWPA
American Wood Preservers Association
AWS
American Welding Society
AWWA
American Water Works Association
CRSI
Concrete Reinforcing Steel Institute
EASA
Electrical Apparatus Service Association
EPA
Environmental Protection Agency of the United States Government
FDOT
Florida Department of Transportation
FHWA
Federal Highway Administration
FSS
Federal Specifications and Standards
IEEE
Institute of Electrical and Electronics Engineers
IES
Illuminating Engineering Society
IPCEA
Insulated Power Cable Engineers Association
ISO
International Organization for Standards
MSTCSD
Minimum Specifications for Traffic Control Signals and Devices
MUTCD
Manual on Uniform Traffic Control Devices
NEC
National Electrical Code
NEMA
National Electrical Manufacturers Association
NFPA
National Fire Protection Association
NIST
National Institute for Standards and Technology
NOAA
National Oceanic and Atmospheric Administration
OSHA
Occupational Safety and Health Administration
SAE
Society of Automotive Engineers
SI
International System of Units
SSPC
Society of Protective Coatings
UL
Underwriters' Laboratories
Each of the above abbreviations, when followed by a number or letter designation, or
combination of numbers and letters, designates a specification, test method, or other code or
recommendation of the particular authority or organization shown.
Use standards, specifications, test methods, or other codes as specified in the current
edition at the time of the bid opening.
1-3 Definitions.
The following terms, when used in the Contract Documents, have the meaning described
Advertisement.
The public announcement, as required by law, inviting bids for work to be performed or
materials to be furnished, usually issued as Notice to Contractors, or Notice to Bidders.
Article.
The numbered prime subdivision of a Section of these Specifications.
Bidder.
An individual, firm, or corporation submitting a proposal for the proposed work.
Bridge.
A structure, including supports, erected over a depression or over an obstruction such as
water, highway or railway, or for elevated roadway, for carrying traffic or other moving loads,
and having a length, measured along the center of the roadway, of more than 20 feet between the
inside faces of end supports. A multiple-span box culvert is considered a bridge, where the
length between the extreme ends of the openings exceeds 20 feet.
Calendar day.
Every day shown on the calendar, ending and beginning at midnight.
Contract.
The term Contract means the entire and integrated agreement between the parties
thereunder and supersedes all prior negotiations, representations, or agreements, either written or
oral. The Contract Documents form the Contract between the Department and the Contractor
setting forth the obligations of the parties thereunder, including, but not limited to, the
performance of the Work and the basis of payment.
Contract Claim (Claim).
A written demand submitted to the Department by the Contractor in compliance with
5-12.3 seeking additional monetary compensation, time, or other adjustments to the Contract, the
entitlement or impact of which is disputed by the Department.
Contract Documents.
The term Contract Documents includes: Advertisement for Proposal, Proposal,
Certification as to Publication and Notice of Advertisement for Proposal, Appointment of Agent
by Nonresident Contractors, Noncollusion Affidavit, Warranty Concerning Solicitation of the
Contract by Others, Resolution of Award of Contract, Executed Form of Contract, Performance
Bond and Payment Bond, Specifications, plans (including revisions thereto issued during
construction), Addenda, or other information mailed or otherwise transmitted to the prospective
bidders prior to the receipt of bids, work orders and supplemental agreements, all of which are to
be treated as one instrument whether or not set forth at length in the form of contract.
Note: As used in Sections 2 and 3 only, Contract Documents do not include work orders,
and supplementary agreements. As used in Section 2 only, Contract Documents also do not
include Resolution of Award of Contract, Executed Form of Contract, and Performance and
Payment Bond.
Contract Bond.
The security furnished by the Contractor and the surety as a guaranty that the Contractor
shall fulfill the terms of the Contract and pay all legal debts pertaining to the construction of the
project.
Contract Letting.
The date that the Department opened the bid proposals.
Contract Time.
The number of calendar days allowed for completion of the Contract work, including
authorized time extensions.
Contractor.
The individual, firm, joint venture, or company contracting with the Department to
perform the work.
Contractors Engineer of Record.
A Professional Engineer registered in the State of Florida, other than the Engineer of
Record or his subcontracted consultant, who undertakes the design and drawing of components
of the permanent structure as part of a redesign or Cost Savings Initiative Proposal, or for repair
designs and details of the permanent work. The Contractors Engineer of Record may also serve
as the Specialty Engineer.
The Contractors Engineer of Record must be an employee of a pre-qualified firm. The
firm shall be pre-qualified in accordance with the Rules of the Department of Transportation,
Chapter 14-75. Any Corporation or Partnership offering engineering services must hold a
Certificate of Authorization from the Florida Department of Business and Professional
Regulation.
As an alternate to being an employee of a pre-qualified firm, the Contractors Engineer of
Record may be a pre-qualified Specialty Engineer. For items of the permanent work declared by
the State Construction Office to be major or structural, the work performed by a prequalified Specialty Engineer must be checked by another pre-qualified Specialty Engineer. An
individual Engineer may become pre-qualified in the work groups listed in the Rules of the
Department of Transportation, Chapter 14-75, if the requirements for the Professional Engineer
are met for the individual work groups. Pre-qualified Specialty Engineers are listed on the State
Construction Website. Pre-qualified Specialty Engineers will not be authorized to perform
redesigns or Cost Savings Initiative Proposal designs of items fully detailed in the plans.
Controlling Work Items.
The activity or work item on the critical path having the least amount of total float. The
controlling item of work will also be referred to as a Critical Activity.
Culverts.
Any structure not classified as a bridge that provides an opening under the roadway.
Delay.
Any unanticipated event, action, force or factor which extends the Contractors time of
performance of any controlling work item under the Contract. The term delay is intended to
cover all such events, actions, forces or factors, whether styled delay, disruption,
interference, impedance, hindrance, or otherwise, which are beyond the control of and not
caused by the Contractor, or the Contractors subcontractors, materialmen, suppliers or other
agents. This term does not include extra work.
Department.
State of Florida Department of Transportation.
Developmental Specification.
See definition for Specifications.
Engineer.
The Director, Office of Construction, acting directly or through duly authorized
representatives; such representatives acting within the scope of the duties and authority assigned
to them.
Note: In order to avoid cumbersome and confusing repetition of expressions in these
Specifications, it is provided that whenever anything is, or is to be done, if, as, or, when, or
where acceptable, accepted, approval, approved, authorized, condemned, considered necessary,
contemplated, deemed necessary, designated, determined, directed, disapproved, established,
given, indicated, insufficient, ordered, permitted, rejected, required, reserved, satisfactory,
specified, sufficient, suitable, suspended, unacceptable, or unsatisfactory, it shall be understood
as if the expression were followed by the words by the Engineer, to the Engineer, or of the
Engineer.
Engineer of Record.
The Professional Engineer or Engineering Firm registered in the State of Florida that
develops the criteria and concept for the project, performs the analysis, and is responsible for the
preparation of the Plans and Specifications. The Engineer of Record may be Departmental inhouse staff or a consultant retained by the Department.
The Contractor shall not employ the Engineer of Record as the Contractors Engineer of
Record or as a Specialty Engineer.
Equipment.
The machinery and equipment, together with the necessary supplies for upkeep and
maintenance thereof, and all other tools and apparatus necessary for the construction and
acceptable completion of the work.
Extra Work.
Any work which is required by the Engineer to be performed and which is not
otherwise covered or included in the project by the existing Contract Documents, whether it be
in the nature of additional work, altered work, deleted work, work due to differing site
conditions, or otherwise. This term does not include a delay.
Highway, Street, or Road.
A general term denoting a public way for purposes of vehicular travel, including the
entire area within the right-of-way.
Holidays.
Days designated by the State Legislature or Cabinet as holidays, which include, but are
not limited to, New Years Day, Martin Luther Kings Birthday, Memorial Day, Independence
Day, Labor Day, Veterans Day, Thanksgiving Day and the following Friday, and Christmas
Day.
Inspector.
An authorized representative of the Engineer, assigned to make official inspections of the
materials furnished and of the work performed by the Contractor.
Laboratory.
The official testing laboratory used by the Department.
Major Item of Work.
Any item of work having an original Contract value in excess of 5% of the original
Contract amount.
Materials.
Any substances to be incorporated in the work under the Contract.
Median.
The portion of a divided highway or street separating the traveled ways for traffic moving
in opposite directions.
Plans.
The approved plans, including reproductions thereof, showing the location, character,
dimensions, and details of the work.
Proposal (Bid, Bid Proposal).
The offer of a bidder, on the prescribed form, to perform the work and to furnish the
labor and materials at the prices quoted.
Proposal Form.
The official form or the expedite program generated bid item sheets on which the
Department requires formal bids to be prepared and submitted for the work.
Proposal Guaranty
The security furnished by the bidder as guaranty that the bidder will enter into the
Contract for the work if the Department accepts the proposal.
Right-of-Way.
The land that the Department has title to, or right of use, for the road and its structures
and appurtenances, and for material pits furnished by the Department.
Roadbed.
The portion of the roadway occupied by the subgrade and shoulders.
Roadway.
The portion of a highway within the limits of construction.
Secretary.
Secretary of Transportation, State of Florida Department of Transportation, acting
directly or through an assistant or other representative authorized by him; the chief officer of the
Department of Transportation.
Section.
A numbered prime division of these Specifications.
Special Event.
Any event, including but not limited to, a festival, fair, run or race, motorcade, parade,
civic activity, cultural activity, charity or fund drive, sporting event, or similar activity
designated in the Contract Documents.
Special Provisions.
See definition for Specifications.
Specialty Engineer.
A Professional Engineer registered in the State of Florida, other than the Engineer of
Record or his subcontracted consultant, who undertakes the design and drawing preparation of
components, systems, or installation methods and equipment for specific temporary portions of
the project work or for special items of the permanent works not fully detailed in the plans and
required to be furnished by the Contractor such as but not limited to pot bearing designs, nonstandard expansion joints, MSE wall designs and other specialty items. The Specialty Engineer
may also provide designs and details for items of the permanent work declared by the State
Construction Office to be minor or non-structural. The Specialty Engineer may be an
employee or officer of the Contractor or a fabricator, an employee or officer of an entity
providing components to a fabricator, or an independent consultant.
For items of work not specifically covered by the Rules of the Department of
Transportation, a Specialty Engineer is qualified if he has the following qualifications:
(1) Registration as a Professional Engineer in the State of Florida.
(2) The education and experience necessary to perform the submitted design as
required by the Florida Department of Business and Professional Regulation.
Specifications.
The directions, provisions, and requirements contained herein, together with all
stipulations contained in the Contract Documents, setting out or relating to the method and
manner of performing the work, or to the quantities and qualities of materials and labor to be
furnished under the Contract.
A. Standard Specifications: Standard Specifications for Road and Bridge
Construction a bound book, applicable to all Department Contracts containing adopted
requirements, setting out or relating to the method or manner of performing work, or to the
quantities and qualities of materials and labor.
B. Supplemental Specifications: Approved additions and revisions to the Standard
Specifications, applicable to all Department Contracts.
C. Special Provisions: Specific clauses adopted by the Department that add to or
revise the Standard Specifications or supplemental specifications, setting forth conditions
varying from or additional to the Standard Specifications applicable to a specific project.
D. Technical Special Provisions: Specifications, of a technical nature, prepared,
signed, and sealed by an Engineer registered in the State of Florida other than the State
Specifications Engineer or his designee, that are made part of the Contract as an attachment to
the Contract Documents.
E. Developmental Specification: A specification developed around a new process,
procedure, or material.
Standard Specifications.
See definition for Specifications.
State.
State of Florida.
Subarticle.
A headed and numbered subdivision of an Article of a Section of these Specifications.
Subgrade.
The portion of the roadbed immediately below the base course or pavement, including
below the curb and gutter, valley gutter, shoulder and driveway pavement. The subgrade limits
ordinarily include those portions of the roadbed shown in the plans to be constructed to a design
bearing value or to be otherwise specially treated. Where no limits are shown in the plans, the
subgrade section extends to a depth of 12 inches below the bottom of the base or pavement and
outward to 6 inches beyond the base, pavement, or curb and gutter.
Substructure.
All of that part of a bridge structure below the bridge seats, including the parapets,
backwalls, and wingwalls of abutments.
Superintendent.
The Contractors authorized representative in responsible charge of the work.
Superstructure.
The entire bridge structure above the substructure, including anchorage and anchor bolts,
but excluding the parapets, backwalls, and wingwalls of abutments.
Supplemental Agreement
A written agreement between the Contractor and the Department, and signed by the
surety, modifying the Contract within the limitations set forth in these Specifications.
Supplemental Specifications
See definition for Specifications.
Surety.
The corporate body that is bound by the Contract Bond with and for the Contractor and
responsible for the performance of the Contract and for payment of all legal debts pertaining
thereto.
Technical Special Provisions.
See definition for Specifications.
Traveled Way.
The portion of the roadway providing for the movement of vehicles, exclusive of
shoulders and auxiliary lanes.
Unilateral Payment.
A payment of money made to the Contractor by the Department pursuant to
Section 337.11(12), Florida Statutes (2009), for sums the Department determines to be due to the
Contractor for work performed on the project, and whereby the Contractor by acceptance of such
payment does not waive any rights the Contractor may otherwise have against the Department
for payment of any additional sums the Contractor claims are due for the work.
Work.
All labor, materials and incidentals required to execute and complete the requirements of
the Contract including superintendence, use of equipment and tools, and all services and
responsibilities prescribed or implied.
Work Order.
A written agreement between the Contractor and the Department modifying the Contract
within the limitations set forth in these Specifications. Funds for this agreement are drawn
against the Initial Contingency Pay Item or a Contingency Supplemental Agreement.Working
Day.
Any calendar day on which the Contractor works or is expected to work in accordance
with the approved work progress schedule.
SECTION 2
PROPOSAL REQUIREMENTS AND CONDITIONS
2-1 Prequalification of Bidders.
Except as noted below, prequalify with the Department to be eligible to bid. The
Department publishes regulations covering prequalification of bidders under separate cover.
The Department does not require the Contractor to be prequalified if bidding construction
contracts of $250,000 or less, or if constructing buildings. In addition, at its sole discretion, the
Department may waive prequalification requirements on contracts of $500,000 or less.
For construction contracts requiring prequalification, file an application for qualification
on forms furnished by the Department, giving detailed information with respect to financial
resources, equipment, past record, personnel, and experience. For qualified applicants, the
Department will issue a certificate fixing the types of work and the aggregate amount of work
that the Department allows the prequalified bidder to have under contract at any one time.
A person or affiliate who has been placed on the convicted vendor list following a
conviction for a public entity crime may not submit the following:
(a) A bid on a contract to provide any goods or services to a public entity.
(b) A bid on a contract with a public entity for the construction or repair of a
public building or public work.
(c) Bids on leases of real property to a public entity.
A person or affiliate who has been placed on the convicted vendor list following a
conviction for a public entity may not be awarded or perform work as a contractor, supplier,
subcontractor, or consultant under a contract with any public entity, and may not transact
business with any public entity in excess of the threshold amount provided in
Section 287.017 F.S., for Category Two. All restrictions apply for a period of 36 months from
the date of placement on the convicted vendor list.
All prequalified Contractors bidding on any Contract must certify their total dollar
amount of Work Underway and submit Form 375-020-39 or a spreadsheet in a similar format
prior to submitting a bid. This information must be submitted at least once during the month the
bid is due via the Work Underway link in the Contractor Pre-Qualification System.
2-2 Proposals.
2-2.1 Obtaining Proposals: Obtain a proposal under the conditions stipulated in the
Advertisement. The proposal states the location and description of the work to be performed; the
estimate of the various quantities (if applicable); the items of work to be performed (if
applicable); the Contract Time; the amount of proposal guaranty; and the date, time, and place of
the opening of proposals.
The Plans, Specifications and other documents designated in the proposal are part
of the proposal, whether attached or not.
Upon receipt of a proposal order, the Department will provide a computer diskette
or CD-ROM for use on a personal computer that is suitable for preparing the bid. This diskette or
CD-ROM contains the Expedite Proposal file to be used by the Contractor to prepare the bid and
print a proposal form for submittal.
The Department is not responsible for loss of or damage to a diskette or CD-ROM
after it has been mailed or delivered to the bidder. If loss or damage occurs, the bidder may order
another diskette or CD-ROM.
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If the bidder requests a replacement diskette or CD-ROM during a seven calendar
day period prior to the letting, the request must be by Internet E-mail as specified in the
Advertisement. The Department will attempt to replace the diskette or CD-ROM by sending
another diskette or CD-ROM by overnight delivery or by electronic transmittal of the files. The
Department will not be held responsible if the bidder cannot complete and submit a bid due to
failure or incomplete delivery of the files.
Unless otherwise indicated in the Advertisement, the Contractor has the option to
submit a bid either as an Internet Bid Submittal in accordance with 2-2.3 or as a Hard Copy Bid
Submittal in accordance with 2-2.4. When an Internet bid submittal is used, the hard copy will
not be considered.
2-2.2 Department Modifications to Contract Documents: Modifications to any
Contract Documents will be posted on the Departments website at the following URL address:
http://www.dot.state.fl.us/cc-admin/addend.htm .
The bidder shall take responsibility for checking and downloading the revised
data from the Departments website upon notification from the Department. The bidder must
provide an e-mail address to the Department for receipt of addenda notification. Contractors
must follow the amendment access instructions provided on the website. If the Departments
website cannot be accessed, contact the Departments Contracts Administration Office Web
Coordinator at (850) 414-4000.
2-2.3 Internet Bid Submittals: Unless otherwise indicated in the Advertisement, the
Contractor may use the Expedite Proposal file to prepare a bid for Internet submittal. The
Department will accept, as the official bid, the set of proposal forms generated from the Expedite
Proposal file along with a complete proposal package, submitted via the Internet in accordance
with 2-5 and 2-8. A Digital ID is required to submit a bid via the Internet. Digital IDs may be
obtained as outlined in the Advertisement.
The Department will not be responsible for any communications or machine
breakdowns, transmission interruptions, delays, or any other problems that interfere with the
receipt of proposals as required above either at the Bidders transmitting location, at the
Departments receiving location, or anywhere between these locations. Receipt or non-receipt of
a proposal will not be considered grounds for a bid protest. The Department will not be held
responsible if the bidder cannot complete and submit a bid due to failure or incomplete delivery
of the files submitted via the Internet.
2-2.4 Hard Copy Bid Submittals: Unless otherwise indicated in the Advertisement, the
Contractor may use the Expedite Proposal file to prepare a bid for hard copy submittal.
Print and submit bid item sheets generated from the Expedite Proposal file on
letter size paper. Ensure that all computer generated sheets are legible. Do not submit computer
generated sheets using a font size smaller than 9 point. The Department prefers 12 point font size
and recommends a minimum of 20 pound paper.
The Department will accept, as the official bid, this set of proposal forms
generated from the Expedite Proposal file along with a complete proposal package, delivered to
the Department in hard copy in accordance with the instructions listed below and the
requirements of 2-5 and 2-8.
Return the Expedite Proposal file used to generate the official bid with the
proposal on the diskette furnished by the Department, or on another diskette labeled with the
Contractors Name, Vendor Number, Letting Date, Revision Date (if applicable) and the
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Proposal ID. Failure to follow proper diskette-handling and shipping procedures could result in
the Department being unable to process the diskette and cause the bid to be declared irregular.
In case of a discrepancy between the unit or lump sum prices submitted on the
program-printed proposal form and those contained on the diskette returned to the Department,
the Department will use the unit or lump sum prices submitted on the program-printed proposal
form.
2-3 Interpretation of Estimated Quantities.
2-3.1 Lump Sum Contracts: The bidder is responsible for the determination of the
quantities for those items constructed within the authorized plan limits or dimensions.
The Department does not assume any responsibility for any incidental information
in bid documents that may be construed as a quantity of work and/or materials.
2-3.2 Contracts other than Lump Sum: For those items constructed within authorized
plan limits or dimensions, use the quantities shown in the Plans and in the proposal form as the
basis of the bid. The Department will also use these quantities for final payment as limited by the
provisions for the individual items. For those items having variable final pay quantities that are
dependent on actual field conditions, use and measurement, the quantities shown in the Plans and
in the proposal form are approximate and provide only a basis for calculating the bid upon which
the Department will award the Contract. Where items are listed for payment as lump sum units
and the Plans show estimates of component quantities, the Department is responsible for the
accuracy of those quantities limited to the provisions of 9-3.3. Where items are listed for
payment as lump sum units and the Plans do not show estimates of component quantities, the
Contractor is solely responsible for his own estimates of such quantities.
The Department may increase, decrease, or omit the estimated quantities of work
to be done or materials to be furnished.
2-4 Examination of Plans, Specifications, Special Provisions and Site of Work.
Examine the Contract Documents and the site of the proposed work carefully before
submitting a proposal for the work contemplated. Investigate the conditions to be encountered, as
to the character, quality, and quantities of work to be performed and materials to be furnished
and as to the requirements of all Contract Documents.
The Department does not guarantee the details pertaining to borings, as shown in the
Plans, to be more than a general indication of the materials likely to be found adjacent to holes
bored at the site of the work, approximately at the locations indicated. The Contractor shall
examine boring data, where available, and make his own interpretation of the subsoil
investigations and other preliminary data, and shall base his bid on his own opinion of the
conditions likely to be encountered.
The bidders submission of a proposal is prima facie evidence that the bidder has made
an examination as described in this Article.
2-5 Preparation of Proposals.
2-5.1 General: Submit proposals on the form described in 2-2. Any pay item that will be
provided free or at no cost to the Department shall be indicated as free or $.00. If the pay
item is left blank or n/a is used, the bid may be declared irregular. Show the total of the bid on
the face of the proposal.
2-5.2 Internet Bid Submittals: The bidder shall execute the proposal under the bidders
Digital ID and enter the firms bidding office street address on the Bidders Information Tab in
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the Expedite Bidding Program. This Digital ID represents the firm as an individual, partnership,
corporation, limited liability company, or joint venture. By entering and submitting the Digital
ID the authorized parties obligate the firm to the bid. Internet Bid Submittals must acknowledge,
on behalf of, the person, firm, association, or corporation submitting the bid certifying that such
person, firm, association, or corporation has not, either directly or indirectly, entered into any
agreement, participated in any collusion, or otherwise taken any action in restraint of free
competitive bidding in connection with the submitted bid, by indicating such in the Expedite
Proposal File. The Department will not consider any bid unless such acknowledgement is
included.
2-5.3 Hard Copy Bid Submittals: If the proposal is made by an individual, either in the
bidders own proper person or under a trade or firm name, the bidder shall execute the proposal
under the bidders signature and enter the firms bidding office street address. If made by a
partnership, execute the proposal by setting out in full the names of the partners, the firm name
of the partnership, if any, have two or more of the general partners sign the proposal and enter
the firms bidding office street address. If made by a corporation, execute the proposal by setting
out in full the corporate name and have the president or other legally authorized corporate officer
or agent sign the proposal, affix the corporate seal and enter the corporations bidding office
street address. If made by a limited liability company, execute the proposal by setting out the
company name, have the manager or authorized member sign the proposal and enter the
companys bidding office address. If made by a joint venture, execute the proposal by setting out
the joint venture name, have the authorized parties sign the proposal and enter the bidding
offices street address. File with the Department Form 375-020-08, contained in the proposal,
which includes an unsworn statement executed by, or on behalf of, the person, firm, association,
or corporation submitting the bid certifying that such person, firm, association, or corporation
has not, either directly or indirectly, entered into any agreement, participated in any collusion, or
otherwise taken any action in restraint of free competitive bidding in connection with the
submitted bid. The Department will not consider any bid unless such form is properly completed
in accordance with the requirements shown thereon.
2-6 Rejection of Irregular Proposals.
A proposal is irregular and the Department may reject it if it shows omissions, alterations
of form, additions not specified or required, conditional or unauthorized alternate bids, or
irregularities of any kind; or if the unit prices are obviously unbalanced, or if the cost is in excess
of or below the reasonable cost analysis values.
When the Department provides for alternate bids in the proposal form and the bidder
submits non-computer-generated proposal form sheets, make only one entry in each design
group. A proposal that provides for alternative bids is irregular and the Department may reject it
if the bidder makes entries for more than one alternate.
2-7 Guaranty to Accompany Proposals.
The Department will not consider any proposal unless it is accompanied by a proposal
guaranty of the character and amount indicated in the Advertisement, and unless it is made
payable to the Florida Department of Transportation. Submit proposals with the understanding
that the successful bidder shall furnish a Contract Bond pursuant to the requirements of 3-5.
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2-8 Delivery of Proposals.
2-8.1 Internet Bid Submittals: Unless otherwise indicated in the Advertisement, bids
may be submitted via the Internet. The Department will not accept responsibility for Internet bids
not meeting the time requirement stipulated in the Advertisement.
2-8.2 Hard Copy Bid Submittals: Unless otherwise indicated in the Advertisement, bids
may be submitted via hard copy. Submit all bids in sealed envelopes, bearing on the outside the
name of the bidder, the bidders address, and the Proposal ID of the project for which the bidder
submitted the bid. For proposals that are submitted by mail, enclose the proposal in a sealed
envelope, marked as directed above. Enclose the sealed envelope in a second outer envelope
addressed to the Department, at the place designated in the Advertisement. For a proposal that is
not submitted by mail, deliver it to the Contracts Office of the Department, or to the place as
designated in the Advertisement. The Department will not consider proposals received after the
time set for opening bids. The Department will retain these proposals unopened.
2-9 Withdrawal or Revision of Proposals.
2-9.1 Internet Bid Submittals: A bidder may withdraw a proposal any time prior to the
bid submittal deadline specified in the Advertisement. The resubmission of any proposal so
withdrawn must be made as a complete proposal, subject to the provisions of 2-8.
A bidder may revise a proposal any time prior to the bid submittal deadline
specified in the Advertisement. Revisions may be made via Internet in accordance with 2-8.1 or
by fax in accordance with 2-9.2.
The Department will not be responsible for any communications or machine
breakdowns, transmission interruptions, delays, or any other problems that interfere with the
receipt of revisions to proposals as required above either at the Bidders transmitting location, at
the Departments receiving location, or anywhere between these locations. Receipt or nonreceipt of revisions to a proposal will not be considered grounds for a bid protest. The
Department will not be held responsible if the bidder cannot complete and submit revisions to a
bid due to failure or incomplete delivery of the files submitted via the Internet.
2-9.2 Hard Copy Bid Submittals: A bidder may withdraw or revise a proposal after
submitting it, provided the Department receives a written request to withdraw or revise the
proposal prior to the time set for opening of bids. The resubmission of any proposal withdrawn
under this provision is subject to the provisions of 2-8.
Legible facsimile (FAX) proposal changes will be accepted if received in full at the fax
number listed in the Bid Solicitation Notice by the time proposals are due on the day of the
letting and provided that all of the following conditions are met:
1. The Bidders name is the same on the faxed proposal change as shown on the
original proposal.
2. The proposal change includes the following:
The correct Proposal ID.
The correct bid item number being changed and the respective unit price
change.
The correct revised total per item.
The revised total bid amount.
The signature of the President or Vice President of the Company.
Faxed proposal changes failing to meet all of these requirements will not be considered
and will not change the original bid.
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The Department will not be responsible for any communications or fax machine
breakdowns, transmission interruptions, delays, or any other problems that interfere with the
receipt of faxed proposal changes as required above either at the Bidders fax location, at the
Departments fax location, or anywhere between these locations. Receipt or non-receipt of a
faxed proposal change will not be considered grounds for a bid protest.
2-10 Opening of Proposals.
The Department will open and publicly announce proposals at the time and place
indicated in the Advertisement. The Department invites bidders, their authorized agents, and
other interested parties to attend.
2-11 Disqualification of Bidders.
The Department may disqualify any bidder and reject the bidders proposal or proposals
for any of the following reasons:
(a) The submission of more than one proposal for the same work from an
individual, firm, or corporation under the same or a different name.
(b) Evidence that one bidder has a financial interest in the firm of another bidder
for the same work.
(c) Evidence of collusion among bidders. The Department will not recognize a
participant in such collusion as a bidder for any future work of the Department until the
Department reinstates such participant as a qualified bidder.
(d) Failure to qualify in accordance with 2-1.
(e) Uncompleted work on other projects that, in the judgment of the Department,
could hinder or prevent the prompt completion of the proposed work.
(f) Failure to pay or satisfactorily settle all bills due for labor and material on
other contracts in force at the time of advertisement for bids.
(g) Default under a previous contract.
(h) Employment of unauthorized aliens in violation of Section 274A (e) of the
Immigration and Nationality Act.
(i) Falsification on any form required by the Department.
(j) The submission of a proposal that was not issued by the Department.
2-12 Material, Samples and Statement.
The Department may require that the bidder furnish a statement of the origin,
composition, and manufacture of any and all materials to be used in the construction of the work,
together with samples that may be subjected to the tests provided for in these Specifications to
determine the materials quality and fitness for the work.
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SECTION 3
AWARD AND EXECUTION OF CONTRACT
3-1 Consideration of Bids.
For the purpose of award, after opening and reading the proposals, the Department will
consider as the bid the correct summation of each unit bid price multiplied by estimated
quantities shown in the proposal. On this basis, the Department will compare the amounts of
each bid and make the results of such comparison available to the public. Until the actual award
of the Contract, however, the Department reserves the right to reject any or all proposals and to
waive technical errors that the Department may deem best for the interest of the State.
The Department reserves the right to delete the bid portion of the utility relocation work
from the Contract. When the Department deletes utility relocation work from the Contract, the
Department will recalculate the Contract bid tabulations based on the remaining project
quantities.
In the event that the Department deletes utility relocation work from the Contract, the
utility owner will relocate such utilities in accordance with the utility Relocation Schedule
attached to the Specifications Package.
3-2 Award of Contract.
3-2.1 General: If the Department decides to award the Contract, the Department will
award the Contract to the lowest responsible bidder whose proposal complies with all the
Contract Document requirements. If awarded, the Department will award the Contract within
50 days after the opening of the proposals, unless the Special Provisions change this time limit or
the bidder and the Department extend the time period by mutual consent.
Prior to award of the Contract by the Department, a contractor must provide proof
of authorization to do business in the State of Florida.
3-2.2 Bids Exceeding Contractors Rating: The Department will address bids
exceeding a Contractors rating, and the resulting impact on the Contractors qualification to bid,
in accordance with Florida Administrative Code Rules 14-22.003 and 14-22.009.
The bidders proposal guaranties are binding for all projects awarded to the
Contractor pursuant to the provisions of this Subarticle.
3-3 Cancellation of Award.
The Department reserves the right to cancel the award of any contract at any time before
the execution of the contract by all parties, with no compensation due any of the bidders.
3-4 Release of Proposal Guaranty.
The Department will release all proposal guaranties except those of the two lowest
bidders immediately following the opening and checking of the proposals. The Department will
immediately release the proposal guaranties of the two lowest bidders after the successful bidder
delivers the executed contract and a satisfactory bond to the Department, except that the
Department will not retain the proposal guaranty of the next-to-lowest bidder longer than 50 days
after the opening of the proposals unless the Department awards the contract to the next lowest
bidder prior to the expiration of this time limit.
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3-5 Contract Bond Required.
3-5.1 General Requirements of the Bond: Upon award, furnish to the Department, and
maintain in effect throughout the life of the Contract, an acceptable surety bond in a sum at least
equal to the amount of the Contract. Execute such bond on the form furnished by the
Department. Obtain a surety that has a resident agent in the State of Florida, meets all of the
requirements of the laws of Florida and the regulations of the Department, and has the
Departments approval. Ensure that the suretys resident agents name, address, and telephone
number is clearly stated on the face of the Contract Bond.
On contracts of $250,000 or less, the Department may waive the requirement for
all or a portion of a surety bond if it determines that the project is of a noncritical nature and
nonperformance will not endanger the public health, safety, or property. The Department may
require alternate means of security if it waives the requirement for a surety bond.
3-5.2 Continued Acceptability of Surety: Provide a surety bond that remains acceptable
to the Department throughout the life of the Contract. In the event that the surety executing the
bond, although acceptable to the Department at the time of execution of the Contract,
subsequently becomes insolvent or bankrupt, or becomes unreliable or otherwise unsatisfactory
due to any cause that becomes apparent after the Departments initial approval of the company,
then the Department may require that the Contractor immediately replace the surety bond with a
similar bond drawn on a surety company that is reliable and acceptable to the Department. In
such an event, the Department will bear all costs of the premium for the new bond, after
deducting any amounts that are returned to the Contractor from his payment of premium on the
original bond.
3-5.3 Default by Contractor: In case of default on the part of the Contractor, the
Department will charge against the bond all expenses for services incidental to ascertaining and
collecting losses under the bond, including accounting, engineering, and legal services, together
with any and all costs incurred in connection with renegotiation of the Contract.
3-5.4 Surety to Furnish Legal Defense as to Payment and Performance Claims or
Suits: The surety company shall indemnify and provide defense for the Department when called
upon to do so for all claims or suits against the Department, by third parties, pertaining to
Contractor payment or performance issues arising out of the Contract where the Contractor has
failed to timely do so. It is expressly understood that the monetary limitation on the extent of the
indemnification shall be the approved Contract amount, which shall be the original Contract
amount as may be increased by subsequent Supplemental Agreements.
3-5.5 Liability for Wrongful or Criminal Act by Contractor: The principal and surety
executing the bond shall be liable to the State in any civil action that might be instituted by the
Department or any officer of the State authorized in such cases, for double any amount in money
or property the State might lose, or be overcharged, or otherwise be defrauded of by any
wrongful or criminal act of the Contractor, his agent or his employees.
3-6 Execution of Contract and Bond.
Within 10 calendar days, excluding Saturdays, Sundays and state holidays, after receipt
of the Contract award, execute the necessary agreements to enter into a contract with the
Department and return the agreement along with a satisfactory surety bond and documentation
evidencing all insurance required by 7-13 to the Departments Contracts Office that awarded the
Contract. For each calendar day that the successful bidder is late in delivering to the
Departments Contracts Office all required documents in properly executed form, the
Department will deduct one day from the allowable Contract Time as specified in 8-7.1. The
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Department will not be bound by any proposal until it executes the associated Contract. The
Department will execute the Contract and bond in the manner stipulated in 3-5.1.
The Department will execute the Contract within 5 calendar days, excluding Saturdays,
Sundays and state holidays, after receipt of the necessary agreements and bond from the
Contractor.
3-7 Failure by Contractor to Execute Contract and Furnish Bond.
In the event that the bidder fails to execute the awarded Contract and to file an acceptable
bond, as prescribed in 3-5 and 3-6, within 10 calendar days, excluding Saturdays, Sundays and
state holidays, of receipt of the Contract award, the Department may annul the award, causing
the bidder to forfeit the proposal guaranty to the Department; not as a penalty but in liquidation
of damages sustained. The Department may then award the Contract to the next lowest
responsible bidder, re-advertise, or accomplish the work using day labor.
3-8 Audit of Contractors Records.
Upon execution of the Contract, the Department reserves the right to conduct an audit of
the Contractors records pertaining to the project. The Department or its representatives may
conduct an audit, or audits, at any time prior to final payment, or thereafter pursuant to 5-13. The
Department may also require submittal of the records from either the prime contractor, the
subcontractor, or both. As the Department deems necessary, records include all books of
account, supporting documents, and papers pertaining to the cost of performance of the project
work.
Retain all records pertaining to the Contract for a period of not less than three years from
the date of the Engineers final acceptance of the project, unless a longer minimum period is
otherwise specified. Upon request, make all such records available to the Department or its
representative(s). For the purpose of this Article, records include but are not limited to all books
of account, supporting documents, and papers that the Department deems necessary to ensure
compliance with the Contract provisions.
If the Contractor fails to comply with these requirements, the Department may disqualify
or suspend the Contractor from bidding on or working as a subcontractor on future Contracts.
Ensure that the subcontractors provide access to their records pertaining to the project
upon request by the Department.
3-9 Public Records.
Allow public access to all documents, papers, letters, or other material subject to the
provisions of Chapter 119, Florida Statutes, made or received by the Contractor in conjunction
with this Contract. Failure to grant such public access will be grounds for immediate termination
of this Contract by the Department pursuant to 8-9.1.
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SECTION 4
SCOPE OF THE WORK
4-1 Intent of Contract.
The intent of the Contract is to provide for the construction and completion in every
detail of the work described in the Contract. Furnish all labor, materials, equipment, tools,
transportation, and supplies required to complete the work in accordance with the Contract
Documents.
4-2 Work not covered by Standard Specifications.
Proposed construction and any contractual requirements not covered by these Standard
Specifications may be covered by Contract Plan notes or by Supplemental Specifications or
Special Provisions for the Contract, and all requirements of such Supplemental Specifications or
Special Provisions shall be considered as a part of these Specifications.
4-3 Alteration of Plans or of Character of Work.
4-3.1 General: The Engineer reserves the right to make, at any time prior to or during the
progress of the work, such increases or decreases in quantities, whether a significant change or
not, and such alterations in the details of construction, whether a substantial change or not,
including but not limited to alterations in the grade or alignment of the road or structure or both,
as may be found necessary or desirable by the Engineer. Such increases, decreases or alterations
shall not constitute a breach of Contract, shall not invalidate the Contract, nor release the Surety
from any liability arising out of this Contract or the Surety bond. The Contractor agrees to
perform the work, as altered, the same as if it had been a part of the original Contract.
The term significant change applies only when:
(a) The Engineer determines that the character of the work as altered
differs materially in kind or nature from that involved or included in the original proposed
construction, or
(b) A major item of work, as defined in 1-3, is increased in excess of
125% or decreased below 75% of the original Contract quantity. The Department will apply any
price adjustment for an increase in quantity only to that portion in excess of 125% of the original
Contract item quantity in accordance with 4-3.2 below. In the case of a decrease below 75% the
Department will only apply a price adjustment for the additional costs that are a direct result of
the reduction in quantity.
In (a) above, the determination by the Engineer shall be conclusive. If the
determination is challenged by the Contractor in any proceeding, the Contractor must establish
by clear and convincing proof that the determination by the Engineer was without any reasonable
basis.
4-3.2 Increase, Decrease or Alteration in the Work: The Engineer reserves the right to
make alterations in the character of the work which involve a substantial change in the nature of
the design or in the type of construction or which materially increases or decreases the cost or
time of performance. Such alteration shall not constitute a breach of Contract, shall not
invalidate the Contract or release the Surety.
Notwithstanding that the Contractor shall have no formal right whatsoever to any
extra compensation or time extension deemed due by the Contractor for any cause unless and
until the Contractor follows the procedures set forth in 5-12.2 for preservation, presentation and
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resolution of the claim, the Contractor may at any time, after having otherwise timely provided a
notice of intent to claim or preliminary time extension request pursuant to 5-12.2 and 8-7.3.2,
submit to the Department a request for equitable adjustment of compensation or time or other
dispute resolution proposal. The Contractor shall in any request for equitable adjustment of
compensation, time, or other dispute resolution proposal certify under oath and in writing, in
accordance with the formalities required by Florida law, that the request is made in good faith,
that any supportive data provided are accurate and complete to the Contractors best knowledge
and belief, and that the amount of the request accurately reflects what the Contractor in good
faith believes to be the Departments responsibility. Such certification must be made by an
officer or director of the Contractor with the authority to bind the Contractor. Any such certified
statements of entitlement and costs shall be subject to the audit provisions set forth in 5-12.14.
While the submittal or review of a duly certified request for equitable adjustment shall neither
create, modify, nor activate any legal rights or obligations as to the Contractor or the
Department, the Department will review the content of any duly certified request for equitable
adjustment or other dispute resolution proposal, with any further action or inaction by the
Department thereafter being in its sole discretion. Any request for equitable adjustment that fails
to fully comply with the certification requirements will not be reviewed by the Department.
The monetary compensation provided for below constitutes full and complete
payment for such additional work and the Contractor shall have no right to any additional
monetary compensation for any direct or indirect costs or profit for any such additional work
beyond that expressly provided below. The Contractor shall be entitled to a time extension only
to the extent that the performance of any portion of the additional work is a controlling work
item and the performance of such controlling work item actually extends completion of the
project due to no fault of the Contractor. All time related costs for actual performance of such
additional work are included in the compensation already provided below and any time
extension entitlement hereunder will be without additional monetary compensation. The
Contractor shall have no right to any monetary compensation or damages whatsoever for any
direct or indirect delay to a controlling work item arising out of or in any way related to the
circumstances leading up to or resulting from additional work (but not relating to the actual
performance of the additional work, which is paid for as otherwise provided herein), except only
as provided for under 5-12.6.2.1.
4-3.2.1 Allowable Costs for Extra Work: The Engineer may direct in writing
that extra work be done and, at the Engineers sole discretion, the Contractor will be paid
pursuant to an agreed Supplemental Agreement or in the following manner:
(a) Labor and Burden: The Contractor will receive payment for actual
costs of direct labor and burden for the additional or unforeseen work. Labor includes foremen
actually engaged in the work; and will not include project supervisory personnel nor necessary
on-site clerical staff, except when the additional or unforeseen work is a controlling work item
and the performance of such controlling work item actually extends completion of the project
due to no fault of the Contractor. Compensation for project supervisory personnel, but in no case
higher than a Project Managers position, shall only be for the pro-rata time such supervisory
personnel spent on the contract. In no case shall an officer or director of the Company, nor those
persons who own more than 1% of the Company, be considered as project supervisory
personnel, direct labor or foremen hereunder.
Payment for burden shall be limited solely to the following:
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Table 4-3.2.1
Item
FICA
FUTA/SUTA
Medical Insurance
Holidays, Sick & Vacation
benefits
Retirement benefits
Rate
Rate established by Law
Rate established by Law
Actual
Actual
Actual
Rates based on the National Council on Compensation Insurance
basic rate tables adjusted by Contractors actual experience
Workers Compensation
modification factor in effect at the time of the additional work or
unforeseen work.
Per Diem
Actual but not to exceed State of Floridas rate
Insurance*
Actual
*Compensation for Insurance is limited solely to General Liability Coverage and does not
include any other insurance coverage (such as, but not limited to, Umbrella Coverage,
Automobile Insurance, etc.).
following:
At the Pre-construction conference, certify to the Engineer the
(1) A listing of on-site clerical staff, supervisory personnel
and their pro-rated time assigned to the contract,
(2) Actual Rate for items listed in Table 4-3.2.1,
(3) Existence of employee benefit plan for Holiday, Sick
and Vacation benefits and a Retirement Plan, and,
(4) Payment of Per Diem is a company practice for
instances when compensation for Per Diem is requested.
Such certification must be made by an officer or director of the
Contractor with authority to bind the Contractor. Timely certification is a condition precedent to
any right of the Contractor to recover compensations for such costs, and failure to timely submit
the certification will constitute a full, complete, absolute and irrevocable waiver by the
Contractor of any right to recover such costs. Any subsequent changes shall be certified to the
Engineer as part of the cost proposal or seven calendar days in advance of performing such extra
work.
(b) Materials and Supplies: For materials accepted by the Engineer and
used on the project, the Contractor will receive the actual cost of such materials incorporated
into the work, including Contractor paid transportation charges (exclusive of equipment as
hereinafter set forth). For supplies reasonably needed for performing the work, the Contractor
will receive the actual cost of such supplies.
(c) Equipment: For any machinery or special equipment (other than small
tools), including fuel and lubricant, the Contractor will receive 100% of the Rental Rate Blue
Book for the actual time that such equipment is in operation on the work, and 50% of the
Rental Rate Blue Book for the time the equipment is directed to standby and remain on the
project site, to be calculated as indicated below. The equipment rates will be based on the latest
edition (as of the date the work to be performed begins) of the Rental Rate Blue Book for
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Construction Equipment or the Rental Rate Blue Book for Older Construction Equipment,
whichever is applicable, as published by Machinery Information Division of PRIMEDIA
Information, Inc. (version current at the time of bid), using all instructions and adjustments
contained therein and as modified below. On all projects, the Engineer will adjust the rates using
regional adjustments and Rate Adjustment Tables according to the instructions in the Blue Book.
Allowable Equipment Rates will be established as set out below:
(1) Allowable Hourly Equipment Rate = Monthly Rate/176
x Adjustment Factors x 100%.
(2) Allowable Hourly Operating Cost = Hourly Operating
Cost x 100%.
(3) Allowable Rate Per Hour = Allowable Hourly
Equipment Rate + Allowable Hourly Operating Cost.
(4) Standby Rate = Allowable Hourly Equipment
Rate x 50%.
The Monthly Rate is The Basic Machine Rate Plus Any
Attachments. Standby rates will apply when equipment is not in operation and is directed by the
Engineer to standby at the project site when needed again to complete work and the cost of
moving the equipment will exceed the accumulated standby cost. Standby rates will not apply on
any day the equipment operates for eight or more hours. Standby payment will be limited to only
that number of hours which, when added to the operating time for that day equals eight hours.
Standby payment will not be made on days that are not normally considered work days on the
project.
The Department will allow for the cost of transporting the
equipment to and from the location at which it will be used. If the equipment requires assembly
or disassembly for transport, the Department will pay for the time to perform this work at the
rate for standby equipment.
Equipment may include vehicles utilized only by Labor, as defined
above.
(d) Indirect Costs, Expenses, and Profit: Compensation for all indirect
costs, expenses, and profit of the Contractor, including but not limited to overhead of any kind,
whether jobsite, field office, division office, regional office, home office, or otherwise, is
expressly limited to the greater of either (1) or (2) below:
above.
(1) Solely a mark-up of 17.5% on the payments in (a) through (c),
(i) Bond: The Contractor will receive compensation for any
premium for acquiring a bond for such additional or unforeseen work at the original Contract
bond rate paid by the Contractor. No compensation for bond premium will be allowed for
additional or unforeseen work paid by the Department via initial contingency pay item.
(ii) The Contractor will be allowed a markup of 10% on the first $50,000 and a markup of 5% on
any amount over $50,000 on any subcontract directly related to the additional or unforeseen
work. Any such subcontractor mark-up will be allowed only by the prime Contractor and a first
tier subcontractor, and the Contractor must elect the markup for any eligible first tier
subcontractor to do so.
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(2) Solely the formula set forth below and only as applied solely as
to such number of calendar days of entitlement that are in excess of ten cumulative calendar days
as defined below.
D=
AC
B
Where A = Original Contract Amount
B = Original Contract Time
C = 8%
D = Average Overhead Per Day
Cumulative Calendar Days is defined as the combined total
number of calendar days granted as time extensions due to either extra work, excluding overruns
to existing contract items, that extend the duration of the project or delay of a controlling work
item caused solely by the Department, or the combined total number of calendar days for which
a claim of entitlement to a time extension due to delay of a controlling work item caused solely
by the Department is otherwise ultimately determined to be in favor of the Contractor.
Further, in the event there are concurrent delays to one or
more controlling work items, one or more being caused by the Department and one or more
being caused by the Contractor, the Contractor shall be entitled to a time extension for each day
that a controlling work item is delayed by the Department but shall have no right to nor receive
any monetary compensation for any indirect costs for any days of concurrent delay. No
compensation, whatsoever, will be paid to the Contractor for any jobsite overhead and other
indirect impacts when the total number of calendar days granted for time extension due to delay
of a controlling work item caused solely by the Department is, or the total number of calendar
days for which entitlement to a time extension due to delay of a controlling work item caused
solely by the Department is otherwise ultimately determined in favor of the Contractor to be,
equal to or less than ten calendar days and the Contractor also fully assumes all monetary risk of
any and all partial or single calendar day delay periods, due to delay of a controlling work item
caused solely by the Department, that when combined together are equal to or less than ten
calendar days and regardless of whether monetary compensation is otherwise provided for
hereunder for one or more calendar days of time extension entitlement for each calendar day
exceeding ten calendar days. All calculations under this provision shall exclude weather days,
Holidays, and Special Events.
4-3.2.2 Subcontracted Work: Compensation for the additional or unforeseen
work performed by a subcontractor shall be limited solely to that provided for in 4-3.2.1 (a), (b),
(c) and (d)(1). In addition, the Contractor compensation is expressly limited to the greater of the
total provided in either 4-3.2.1(d)(1) or (d)(2), except that the Average Overhead Per-Day
calculation is as follows:
Ds =
As C
B
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Subcontract amounts(s)*
Where As = Original Contract Amount minus Original
B = Original Contract Time
C = 8%
Ds = Average Overhead Per-Day
* deduct Original Subcontract Amount(s) of
subcontractor(s) performing the work
The subcontractor may receive compensation for any premium for acquiring a bond for the
additional or unforeseen work; provided, however, that such payment for additional
subcontractor bond will only be paid upon presentment to the Department of clear and
convincing proof that the subcontractor has actually provided and paid for separate bond
premiums for such additional or unforeseen work in such amount and that the subcontractor was
required by the Contractor to acquire a bond.
The Contractor shall require the subcontractor to provide a certification, in
accordance with 4-3.2.1 (a), as part of the cost proposal and provide such to the Engineer. Such
certification must be made by an officer or director of the subcontractor with authority to bind
the subcontractor. Timely certification is a condition precedent to any right of the Contractor to
recover compensation for such subcontractor costs, and failure to timely submit the certification
will constitute a full, complete, absolute and irrevocable waiver by the Contractor of any right to
recover such subcontractor costs.
of any right to recover such subcontractor costs.
4-3.3 No Waiver of Contract: Changes made by the Engineer will not be considered to
waive any of the provisions of the Contract, nor may the Contractor make any claim for loss of
anticipated profits because of the changes, or by reason of any variation between the
approximate quantities and the quantities of work actually performed. All work shall be
performed as directed by the Engineer and in accordance with the Contract Documents.
4-3.4 Conditions Requiring a Supplemental Agreement or Unilateral Payment: A
Supplemental Agreement or Unilateral Payment will be used to clarify the Plans and
Specifications of the Contract; to provide for unforeseen work, grade changes, or alterations in
the Plans which could not reasonably have been contemplated or foreseen in the original Plans
and Specifications; to change the limits of construction to meet field conditions; to provide a safe
and functional connection to an existing pavement; to settle documented Contract claims; to
make the project functionally operational in accordance with the intent of the original Contract
and subsequent amendments thereto.
A Supplemental Agreement or Unilateral Payment may be used to expand the
physical limits of the project only to the extent necessary to make the project functionally
operational in accordance with the intent of the original Contract. The cost of any such
agreement extending the physical limits of the project shall not exceed $100,000 or 10% of the
original Contract price, whichever is greater.
Perform no work to be covered by a Supplemental Agreement or Unilateral
Payment before written authorization is received from the Engineer. The Engineers written
authorization will set forth sufficient work information to allow the work to begin. The work
activities, terms and conditions will be reduced to written Supplemental Agreement or Unilateral
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Payment form promptly thereafter. No payment will be made on a Supplemental Agreement or
Unilateral Payment prior to the Departments approval of the document.
4-3.5 Extra Work: Extra work authorized in writing by the Engineer will be paid in
accordance with the formula in 4-3.2. Such payment will be the full extent of all monetary
compensation entitlement due to the Contractor for such extra work. Any entitlement to a time
extension due to extra work will be limited solely to that provided for in 4-3.2 for additional
work.
4-3.6 Connections to Existing Pavement, Drives and Walks: Generally adhere to the
limits of construction at the beginning and end of the project as detailed in the Plans. However, if
the Engineer determines that it is necessary to extend the construction in order to make suitable
connections to existing pavement, the Engineer will authorize such a change in writing.
For necessary connections to existing walks and drives that are not indicated in
the Plans, the Engineer will provide direction regarding the proper connections in accordance
with the Design Standards.
4-3.7 Differing Site Conditions: During the progress of the work, if subsurface or latent
physical conditions are encountered at the site differing materially from those indicated in the
Contract, or if unknown physical conditions of an unusual nature differing materially from those
ordinarily encountered and generally recognized as inherent in the work provided for in the
Contract are encountered at the site, the party discovering such conditions shall promptly notify
the other party in writing of the specific differing conditions before the Contractor disturbs the
conditions or performs the affected work.
Upon receipt of written notification of differing site conditions from the
Contractor, the Engineer will investigate the conditions, and if it is determined that the
conditions materially differ and cause an increase or decrease in the cost or time required for the
performance of any work under the Contract, an adjustment will be made, excluding loss of
anticipated profits, and the Contract will be modified in writing accordingly. The Engineer will
notify the Contractor whether or not an adjustment of the Contract is warranted.
The Engineer will not allow a Contract adjustment for a differing site condition
unless the Contractor has provided the required written notice.
The Engineer will not allow a Contract adjustment under this clause for any
effects caused to any other Department or non-Department projects on which the Contractor may
be working.
4-3.8 Changes Affecting Utilities: The Contractor shall be responsible for identifying
and assessing any potential impacts to a utility that may be caused by the changes proposed by
the Contractor, and the Contractor shall at the time of making the request for a change notify the
Department in writing of any such potential impacts to utilities.
Department approval of a Contractor proposed change does not relieve the
Contractor of sole responsibility for all utility impacts, costs, delays or damages, whether direct
or indirect, resulting from Contractor initiated changes in the design or construction activities
from those in the original Contract Specifications, design plans (including traffic control plans)
or other Contract Documents and which effect a change in utility work different from that shown
in the utility plans, joint project agreements or utility relocation schedules.
4-3.9 Cost Savings Initiative Proposal:
4-3.9.1 Intent and Objective:
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4-3.9.1 Intent and Objective:
(1) This Subarticle applies to any cost reduction proposal (hereinafter
referred to as a Proposal) that the Contractor initiates and develops for the purpose of refining
the Contract to increase cost effectiveness or significantly improve the quality of the end result.
A mandatory Cost Savings Initiative Workshop will be held prior to Contract Time beginning for
the Contractor and Department to discuss potential Proposals. This Subarticle does not, however,
apply to any such proposal unless the Contractor identifies it at the time of its submission to the
Department as a proposal submitted pursuant to this Subarticle.
(2) The Department will consider Proposals that would result in net
savings to the Department by providing a decrease in the cost of the Contract. Proposals must
result in savings without impairing essential functions and characteristics such as safety, service,
life, reliability, economy of operation, ease of maintenance, aesthetics and necessary standard
design features. However, nothing herein prohibits the Contractor from submitting Proposals
when the required functions and characteristics can be combined, reduced or eliminated because
they are nonessential or excessive. The Department will not recognize the Contractors
correction of plan errors that result in a cost reduction, as a Proposal.
(3) The Department reserves the right to reject at its discretion any
Proposal submitted that proposes a change in the design of the pavement system or that would
require additional right-of-way. Pending the Departments execution of a formal supplemental
agreement implementing an approved Proposal, the Contractor shall remain obligated to perform
the work in accordance with the terms of the existing Contract. The Department may grant time
extensions to allow for the time required to develop and review a Proposal.
(4) For potential Proposals not discussed at the Cost Savings Initiative
Workshop, a mandatory concept meeting will be held for the Contractor and Department to
discuss the potential Proposal prior to development of the Proposal.
4-3.9.2 Subcontractors: The Department encourages the Contractor to include
the provisions of this Subarticle in Contracts with subcontractors and to encourage submission of
Proposals from subcontractors. However, it is not mandatory to submit Proposals to the
Department or to accept or transmit subcontractor proposed Proposals to the Department.
4-3.9.3 Data Requirements: As a minimum, submit the following information
with each Proposal:
(1) a description of the difference between the existing Contract
requirement, including any time extension request, and the proposed change, and the
comparative advantages and disadvantages.
(2) separate detailed cost estimates for both the existing Contract
requirement and the proposed change. Break down the cost estimates by pay item numbers
indicating quantity increases or decreases and deleted pay items. Identify additional proposed
work not covered by pay items within the Contract, by using pay item numbers in the Basis of
Estimates Manual. In preparing the estimates, include overhead, profit, and bond within pay
items in the Contract. Separate pay item(s) for the cost of overhead, profit, and bond will not be
allowed.
(3) an itemization of the changes, deletions or additions to plan details,
plan sheets, design standards and Specifications that are required to implement the Proposal if
the Department adopts it. Provide preliminary plan drawings sufficient to describe the proposed
changes.
26
(4) engineering or other analysis in sufficient detail to identify and
describe specific features of the Contract that must be changed if the Department accepts the
Proposal with a proposal as to how these changes can be accomplished and an assessment of
their effect on other project elements. The Department may require that engineering analyses be
performed by a prequalified consultant in the applicable class of work. Support all design
changes that result from the Proposal with prints of drawings and computations signed and
sealed by the Contractors Engineer of Record. Written documentation or drawings will be
provided clearly delineating the responsibility of the Contractors Engineer of Record.
(5) the date by which the Department must approve the Proposal to obtain
the total estimated cost reduction during the remainder of the Contract, noting any effect on the
Contract completion time or delivery schedule.
(6) a revised project schedule that would be followed upon approval of the
Proposal. This schedule would include submittal dates and review time for the Department and
Peer reviews.
4-3.9.4 Processing Procedures: Submit two copies of each Proposal to the
Engineer or his duly authorized representative. The Department will process Proposals
expeditiously; however, the Department is not liable for any delay in acting upon a Proposal
submitted pursuant to this Subarticle. The Contractor may withdraw, in whole or in part, a
Proposal not accepted by the Department within the period specified in the Proposal. The
Department is not liable for any Proposal development cost in the case where the Department
rejects or the Contractor withdraws a Proposal.
The Engineer is the sole judge of the acceptability of a Proposal and of the
estimated net savings in construction costs from the adoption of all or any part of such proposal.
In determining the estimated net savings, the Department reserves the right to disregard the
Contract bid prices if, in the judgment of the Engineer, such prices do not represent a fair
measure of the value of work to be performed or to be deleted.
Prior to approval, the Engineer may modify a Proposal, with the
concurrence of the Contractor, to make it acceptable. If any modification increases or decreases
the net savings resulting from the Proposal, the Department will determine the Contractors fair
share upon the basis of the Proposal as modified and upon the final quantities. The Department
will compute the net savings by subtracting the revised total cost of all bid items affected by the
Proposal from the total cost of the same bid items as represented in the original Contract.
Prior to approval of the Proposal that initiates the supplemental
agreement, provide acceptable Contract-quality plan sheets revised to show all details consistent
with the Proposal design.
4-3.9.5 Computations for Change in Contract Cost of Performance: If the
Proposal is adopted, the Contractors share of the net savings as defined hereinafter represents
full compensation to the Contractor for the Proposal.
The Department will not include its costs to process and implement a
Proposal in the estimate. However, the Department reserves the right, where it deems such action
appropriate, to require the Contractor to pay the Department's cost of investigating and
implementing a Proposal as a condition of considering such proposal. When the Department
imposes such a condition, the Contractor shall accept this condition in writing, authorizing the
Department to deduct amounts payable to the Department from any monies due or that may
become due to the Contractor under the Contract.
27
4-3.9.6 Conditions of Acceptance for Major Design Modifications of
Category 2 Bridges: A Proposal that proposes major design modifications of a category 2
bridge, as determined by the Engineer, shall have the following conditions of acceptance:
All bridge plans relating to the Proposal shall undergo an independent
peer review conducted by a single independent engineering firm referred to for the purposes of
this article as the Independent Review Engineer who is not the originator of the Proposal design,
and is pre-qualified by the Department in accordance with Rule 14-75, Florida Administrative
Code. The independent peer review is intended to be a comprehensive, thorough verification of
the original work, giving assurance that the design is in compliance with all Department
requirements. The Independent Review Engineers comments, along with the resolution of each
comment, shall be submitted to the Department. The Independent Review Engineer shall sign
and seal the submittal cover letter stating that all comments have been adequately addressed and
the design is in compliance with the Department requirements. If there are any unresolved
comments the Independent Review Engineer shall specifically list all unresolved issues in the
signed and sealed cover letter.
The Contractor shall designate a primary engineer responsible for the
Proposal design and as such will be designated as the Contractors Engineer of Record for the
Proposal design. The Department reserves the right to require the Contractors Engineer of
Record to assume responsibility for design of the entire structure.
New designs and independent peer reviews shall be in compliance with all
applicable Department, FHWA and AASHTO criteria requirements including bridge load
ratings.
4-3.9.7 Sharing Arrangements: If the Department approves a Proposal, the
Contractor shall receive 50% of the net reduction in the cost of performance of the Contract as
determined by the final negotiated agreement between the Contractor and the Department. The
net reduction will be determined by subtracting from the savings of the construction costs the
reasonable documented engineering costs incurred by the contractor to design and develop a
Proposal. The reasonable documented engineering costs will be paid by the Department.
Engineering costs will be based on the consultants certified invoice and may include the costs of
the Independent Review Engineer in 4-3.9.6. The total engineering costs to be subtracted from
the savings to determine the net reduction will be limited to 25% of the construction savings and
shall not include any markup by the Contractor or the costs for engineering services performed
by the Contractor.
4-3.9.8 Notice of Intellectual Property Interests and Departments Future
Rights to a Proposal:
4-3.9.8.1 Notice of Intellectual Property Interests: The Contractors
Proposal submittal shall identify with specificity any and all forms of intellectual property rights
that either the Contractor or any officer, shareholder, employee, consultant, or affiliate, of the
Contractor, or any other entity who contributed in any measure to the substance of the
Contractors Proposal development, have or may have that are in whole or in part implicated in
the Proposal. Such required intellectual property rights notice includes, but is not limited to,
disclosure of any: issued patents, copyrights, or licenses; pending patent, copyright or license
applications; and any intellectual property rights that though not yet issued, applied for or
intended to be pursued, could nevertheless otherwise be subsequently the subject of patent,
copyright or license protection by the Contractor or others in the future. This notice requirement
does not extend to intellectual property rights as to stand-alone or integral components of the
28
Proposal that are already on the Departments QPL or design standard indexes, or are otherwise
generally known in the industry as being subject to patent or copyright protection.
4-3.9.8.2 Departments Future Rights to a Proposal: Notwithstanding
7-3 nor any other provision of the Standard Specifications, upon acceptance of a Proposal, the
Contractor hereby grants to the Department and its contractors (such grant being expressly
limited solely to any and all existing or future Department construction projects and any other
Department projects that are partially or wholly funded by or for the Department) a royalty-free
and perpetual license under all forms of intellectual property rights to manufacture, to use, to
design, to construct, to disclose, to reproduce, to prepare and fully utilize derivative works, to
distribute, display and publish, in whole or in part, and to permit others to do any of the above,
and to otherwise in any manner and for any purpose whatsoever do anything reasonably
necessary to fully utilize any and all aspects of such Proposal on any and all existing and future
construction projects and any other Department projects.
Contractor shall hold harmless, indemnify and defend the
Department and its contractors and others in privity therewith from and against any and all
claims, liabilities, other obligations or losses, and reasonable expenses related thereto (including
reasonable attorneys fees), which are incurred or are suffered by any breach of the foregoing
grants, and regardless of whether such intellectual property rights were or were not disclosed by
the Contractor pursuant to 4-3.9.8.1, unless the Department has by express written exception in
the Proposal acceptance process specifically released the Contractor from such obligation to hold
harmless, indemnify and defend as to one or more disclosed intellectual property rights.
4-4 Unforeseeable Work.
When the Department requires work that is not covered by a price in the Contract and
such work does not constitute a Significant Change as defined in 4-3.1, and the Department
finds that such work is essential to the satisfactory completion of the Contract within its intended
scope, the Department will make an adjustment to the Contract. The Engineer will determine the
basis of payment for such an adjustment in a fair and equitable amount.
4-5 Rights in and Use of Materials Found on the Site of the Work.
4-5.1 Ownership and Disposal of Existing Materials: Take ownership and dispose of
all materials that are not designated as the property of other parties, in both roadway and
structures, found on the right-of-way, and all material in structures designated for removal. Such
materials do not include earth or other excavated material required for the construction of the
project. During construction, the Contractor may use materials from existing structures that are
required to be removed and that are designated to remain the property of the Department. Do not
cut or otherwise damage such material during removal unless the Engineer gives permission to
do so. Store material in an accessible location as the Engineer directs. The Department is not
responsible for the quality or quantity of any material salvaged.
4-5.2 Ornamental Trees and Shrubs: Take ownership of all ornamental trees or shrubs
existing in the right-of-way that are required to be removed for the construction operations and
which are not specifically designated on the Plans to be reset, or to be removed by others prior to
the construction operations.
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4-6 Final Cleaning Up of Right-of-Way.
Upon completion of the work, and before the Department accepts the work and makes
final payment, remove from the right-of-way and adjacent property all falsework, equipment,
surplus and discarded materials, rubbish and temporary structures; restore in an acceptable
manner all property, both public and private, that has been damaged during the prosecution of
the work; and leave the waterways unobstructed and the roadway in a neat and presentable
condition throughout the entire length of the work under Contract. Do not dispose of materials of
any character, rubbish or equipment, on abutting property, with or without the consent of the
property owners. The Engineer will allow the Contractor to temporarily store equipment, surplus
materials, usable forms, etc., on a well-kept site owned or leased by the Contractor, adjacent to
the project. However, do not place or store discarded equipment, materials, or rubbish on such a
site.
Shape and dress areas adjacent to the project right-of-way that were used as plant sites,
materials storage areas or equipment yards when they are no longer needed for such purposes.
Restore these areas in accordance with 7-11.1 and 7-11.2. Grass these areas when the Engineer
directs.
30
SECTION 5
CONTROL OF THE WORK
5-1 Plans and Working Drawings.
5-1.1 Contract Documents: The Contractor may purchase copies of the Standard
Specifications and Design Standards from the Department or access them from the Departments
website. Have available on the worksite, at all times, one copy of the Contract Documents.
5-1.2 Departments Plans: Plans consist of general drawings showing such details as are
necessary to give a comprehensive idea of the construction contemplated. In general, roadway
plans will show alignment, profile grades, typical cross-sections and general cross-sections. In
general, structure plans will show in detail all dimensions of the work contemplated. When the
structure plans do not show the dimensions in detail, they will show general features and such
details as are necessary to give a comprehensive idea of the structure.
Grades shown are finished grades, and B.M. Datum is North American Vertical
Datum 1988 (NAVD-1988) National Geodetic Vertical Datum of 1929 (NGVD-1929) or other
datum as noted in the plans.
5-1.3 Alterations in Plans: The Department will issue, in writing, all authorized
alterations affecting the requirements and information given on the approved plans.
5-1.4 Shop Drawings:
5-1.4.1. Definitions:
(a) Shop Drawings: All working, shop and erection drawings, associated
trade literature, calculations, schedules, manuals and similar documents submitted by the
Contractor to define some portion of the project work. The type of work includes both permanent
and temporary works as appropriate to the project.
(b) Permanent Works: All the permanent structures and parts thereof
required of the completed Contract.
(c) Temporary Works: Any temporary construction work necessary for the
construction of the permanent works. This includes but is not limited to bracing, falsework,
formwork, scaffolding, shoring, temporary earthworks, sheeting, cofferdams, and special
erection equipment.
(d) Construction Affecting Public Safety: Construction that may
jeopardize public safety such as structures spanning functioning vehicular roadways, pedestrian
walkways, railroads, navigation channels of navigable waterways and walls or other structure
foundations located in embankments immediately adjacent to functioning roadways. It does not
apply to those areas of the site under the Contractors control and outside the limits of normal
public access.
(e) Major and Unusual Structures: Bridges of complex geometry and/or
complex design. Generally, this includes the following types of structures:
1. Bridges with an individual span longer than 300 feet.
2. Structurally continuous superstructures with spans over 150 feet.
3. Steel box and plate girder bridges.
4. Steel truss bridges.
5. Concrete segmental and longitudinally post-tensioned
continuous girder bridges.
6. Cable stayed or suspension bridges.
7. Arch bridges.
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8. Tunnels.
9. Movable bridges (specifically electrical and mechanical
components).
10. Rehabilitation, widening, or lengthening of any of the above.
(f) Special Erection Equipment includes launching gantries, beam and
winch equipment, form travelers, stability towers, strong-backs, erection trusses, launching noses
or similar items made purposely for construction of the structure. It does not apply to commonly
available proprietary construction equipment such as cranes.
(g) Falsework includes any temporary construction work used to support
the permanent structure until it becomes self-supporting. Falsework includes steel or timber
beams, girders, columns, piles and foundations, and any proprietary equipment including
modular shoring frames, post shores, and adjustable horizontal shoring.
(h) Formwork includes any structure or mold used to retain plastic or fluid
concrete in its designated shape until it hardens. Formwork comprises common materials such as
wood or metal sheets, battens, soldiers and walers, ties, proprietary forming systems such as
stay-in-place metal forms, and proprietary supporting bolts, hangers and brackets. Formwork
may be either permanent formwork requiring a shop drawing submittal such as stay-in-place
metal or concrete forms, or may be temporary formwork which requires certification by the
Specialty Engineer for Construction Affecting Public Safety and for Major and Unusual
Structures.
(i) Scaffolding is an elevated work platform used to support workmen,
materials and equipment, but not intended to support the structure.
(j) Shoring is a component of falsework such as horizontal, vertical or
inclined support members. In this Section, this term is interchangeable with falsework.
(k) Bracing is a temporary structural member(s) placed between beams,
girders, piles columns, etc. to provide stability during construction activities.
(l) Contractor Originated Designs: Items which the Contract Documents
require the Contractor to design, detail and incorporate into the permanent works.
5-1.4.2 Work Items Requiring Shop Drawings: In general, the Department
requires shop drawings for items of work not fully detailed in the plans which require additional
drawings and coordination prior to constructing the item, including but not limited to:
(a) Bridge components not fully detailed in the plans, i.e. segments, steel
girder details, post-tensioning details, handrails, etc.
(b) Retaining Wall Systems
(c) Precast Box Culverts
(d) Non-standard lighting, signalization and signing structures and
components
(e) Building structures
(f) Drainage structures, attenuators, and other nonstructural items
(g) Design and structural details furnished by the Contractor in
compliance with the Contract
(h) Temporary Works affecting public safety
Additional clarification for certain types of bridge structures is provided in
5-1.4.7. Other provisions of the Contract Documents may waive the requirement for submittals
for certain items; i.e., items constructed from standard drawings or those complying with
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alternate details for prestressed members under Section 450. Review the Contract Documents to
determine the submittals required.
5-1.4.3 Schedule of Submittals: Prepare and submit a schedule of submittals that
identifies the work for which shop drawings apply. For each planned submittal, define the type,
and approximate number of drawings or other documents that are included and the planned
submittal date, considering the processing requirements herein. Submit the schedule of
submittals to the Departments Shop Drawing Review Office and the Engineer of Record within
60 days of the start of the Contract, and prior to the submission of any shop drawings.
Coordinate subsequent submittals with construction schedules to allow
sufficient time for review, approval, and re-submittal as necessary.
5-1.4.4 Style, Numbering, and Material of Submittals:
5-1.4.4.1 Drawings: Furnish two clearly legible photographic or
xerographic copies of all shop drawings that are necessary to complete the structure in
compliance with the design shown on the plans. Prepare all shop drawings using the same units
of measure as those used in the Departments plans. Use sheets no larger than 11 by 17 inches.
Consecutively number each sheet in the submittal series, and indicate the total number in the
series (i.e., 1 of 12, 2 of 12, . . ., 12 of 12). Include on each sheet the following items as a
minimum requirement: the complete Financial Project Identification Number, Bridge Number(s),
drawing title and number, a title block showing the names of the fabricator or producer and the
Contractor for which the work is being done, the initials of the person(s) responsible for the
drawing, the date on which the drawing was prepared, the location of the item(s) within the
project, the Contractors approval stamp with date and initials, and, when applicable, the
documents shall be signed and sealed by the Specialty Engineer or Contractors Engineer of
Record, as appropriate. A re-submittal will be requested when any of the required information is
not included.
5-1.4.4.2 Other Documents: Provide four sets of original documents or
clearly legible photographic or xerographic copies of documents other than drawings, such as
trade literature, catalogue information, calculations, and manuals. Provide sheets no larger than
11 by 17 inches. Clearly label and number each sheet in the submittal to indicate the total
number of sheets in the series (i.e., 1 of 12, 2 of 12, . . ., 12 of 12). Provide an additional three
sets of documentation for items involved with precast prestressed components. Provide an
additional two sets of documentation for items involving structural steel components.
Prepare all documents using the same units of measure as those
used in the Departments plans. Bind and submit all documents with a Table of Contents cover
sheet. List on the cover sheet the total number of pages and appendices, and include the complete
Financial Project Identification Number, a title referencing the submittal item(s), the name of the
firm and person(s) responsible for the preparation of the document, the Contractors approval
stamp with date and initials, and, when applicable, the documents shall be signed and sealed by
the Specialty Engineer or Contractors Engineer of Record, as appropriate.
Submit appropriately prepared and checked calculations and
manuals that clearly outline the design criteria. Include on the internal sheets the complete
Financial Project Identification Number and the initials of the person(s) responsible for preparing
and checking the document.
Clearly label trade literature and catalogue information on the front
cover with the title, Financial Project Identification Number, date and name of the firm and
person(s) responsible for that document.
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5-1.4.5 Submittal Paths and Copies:
5-1.4.5.1 General: Shop drawings are not required for prequalified items.
For non-prequalified items, determine the submittal path to be followed based upon the identity
of the Engineer of Record as shown adjacent to the title block on the structural plan sheets, and
on the key sheets of roadway plans, signing, and pavement marking plans, and/or lighting plans.
At the preconstruction conference, the Department will notify the Contractor of any changes in
the submittal path and whether the Departments or the Consultants red-ink review stamp will
signify an officially reviewed shop drawing.
(a) When the Florida Department of Transportation is the Engineer
of Record, submit shop drawings to the appropriate Department Shop Drawing Review Office
with a copy of the letter of transmittal sent to the Resident Engineer. For work requiring other
information (e.g., catalog data, procedure manuals, fabrication/welding procedures, and
maintenance and operating procedures), submit the required number of copies to the appropriate
Department Shop Drawing Review Office. If not shown on the plans, the Department will
furnish the mailing address of the appropriate Department Shop Drawing Review Office. Provide
copies of material certifications and material tests to the Resident Engineer.
(b) When the Engineer of Record is a consultant hired by the
Department, submit shop drawings to the consultant with a copy of the letter of transmittal sent
to the Resident Engineer and, when requested, to the appropriate Department Shop Drawing
Review Office. For work requiring other documentation (e.g., catalog data, procedure manuals,
fabrication/welding procedures, and maintenance and operating manuals), submit the required
number of copies with the prints. If not shown on the plans, the Department will furnish the
mailing address of the Consulting Engineer of Record. Provide copies of material certifications
and material tests to the Resident Engineer.
5-1.4.5.2 Building Structures: Submit working, shop and erection
drawings, and all correspondence related to building structures, such as Rest Area Pavilions,
Office Buildings, and Maintenance Warehouses, to the Architect of Record for review and
approval. Send a copy of the transmittal to the Resident Engineer.
5-1.4.5.3 Contractor-Originated Design: Submit shop drawings and
applicable calculations to the Engineer of Record for review. Ensure that each sheet of the shop
drawings and the cover sheet of the calculations are signed and sealed by the Specialty Engineer
or the Contractors Engineer of Record. Transmit the submittal and copies of the transmittal
letters in accordance with the requirements of 5-1.4.5.1 through 5-1.4.5.3, as appropriate.
5-1.4.5.4 Temporary Works: For Construction Affecting Public Safety,
submit to the Engineer of Record shop drawings and the applicable calculations for the design of
special erection equipment, bracing, falsework, scaffolding, etc. Ensure that each sheet of the
shop drawings and the cover sheet of the applicable calculations is signed and sealed by the
Specialty Engineer. Transmit the submittal and copies of the transmittal letters in accordance
with the requirements of 5-1.4.5.1 through 5-1.4.5.3, as appropriate.
5-1.4.5.5 Falsework Founded on Shallow Foundations: When vertical
displacement limits are provided in the Plans for falsework founded on shallow foundations such
as spread footings and mats, submit to the Engineer of Record shop drawings and applicable
calculations of the falsework system including subsurface conditions and settlement estimates.
Ensure that each sheet of the shop drawings and the cover sheet of the applicable calculations is
signed and sealed by the Specialty Engineer. Transmit the submittal and copies of the
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transmitted letters in accordance with the requirements of 5-1.4.5.1 through 5-1.4.5.3, as
appropriate.
5-1.4.5.6 Formwork and Scaffolding: The Contractor is solely
responsible for the safe installation and use of all formwork and scaffolding. The Department
does not require any formwork or scaffolding submittals unless such work would be classified as
Construction Affecting Public Safety.
5-1.4.5.7 Beam and Girder Temporary Bracing: The Contractor is
solely responsible for ensuring stability of beams and girders during all handling, storage,
shipping and erection. Adequately brace beams and girders to resist wind, weight of forms and
other temporary loads, especially those eccentric to the vertical axis of the products, considering
actual beam geometry and support conditions during all stages of erection and deck construction.
Develop the required designs following the AASHTO Guide Design Specifications for Bridge
Temporary Works and Construction Handbook for Bridge Temporary Works and the Contract
Documents.
For Construction Affecting Public Safety, submit signed and
sealed calculations for stability for all beams and girders.
5-1.4.5.8 Erection Plan: Submit, for the Engineers review, an Erection
Plan that meets the specific requirements of Sections 450, 452 and 460 and this section. Refer to
Index 600 for construction activities not permitted over traffic.
5-1.4.5.9 Other Miscellaneous Design and Structural Details
Furnished by the Contractor in Compliance with the Contract: Submit to the Engineer of
Record shop drawings and the applicable calculations. Ensure that each sheet of the shop
drawings and the cover sheet of the applicable calculations is signed and sealed by the Specialty
Engineer. Transmit the submittal and copies of the transmittal letters in accordance with the
requirements of 5-1.4.5.1 through 5-1.4.5.3, as appropriate.
5-1.4.6 Processing of Shop Drawings:
5-1.4.6.1 Contractor Responsibility for Accuracy and Coordination of
Shop Drawings: Coordinate, schedule, and control all submittals, with a regard for the required
priority, including those of the various subcontractors, suppliers, and engineers, to provide for an
orderly and balanced distribution of the work.
Coordinate, review, date, stamp, approve and sign all shop
drawings prepared by the Contractor or agents (subcontractor, fabricator, supplier, etc.) prior to
submitting them to the Engineer of Record for review. Submittal of the drawings confirms
verification of the work requirements, units of measurement, field measurements, construction
criteria, sequence of assembly and erection, access and clearances, catalog numbers, and other
similar data. Indicate on each series of drawings the specification section and page or drawing
number of the Contract plans to which the submission applies. Indicate on the shop drawings all
deviations from the Contract drawings and itemize all deviations in the letter of transmittal.
Likewise, whenever a submittal does not deviate from the Contract plans, clearly state so in the
transmittal letter.
Schedule the submission of shop drawings to allow for a 45 day
review period. The review period commences upon the Engineer of Records receipt of the valid
submittal or valid re-submittal and terminates upon the transmittal of the submittal back to the
Contractor. A valid submittal includes all the minimum requirements outlined in 5-1.4.4.
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Submit shop drawings to facilitate expeditious review. The
Contractor is discouraged from transmitting voluminous submittals of shop drawings at one time.
For submittals transmitted in this manner, allow for the additional review time that may result.
Only shop drawings distributed with the red ink stamps are valid
and all work that the Contractor performs in advance of approval will be at the Contractors risk.
5-1.4.6.2 Scope of Review by Engineer: The Engineer of Records
review of the shop drawings is for conformity to the requirements of the Contract Documents
and to the intent of the design. The Engineer of Records review of shop drawings which include
means, methods, techniques, sequences, and construction procedures are limited to the effects on
the permanent works. The Engineer of Records review of submittals which include means,
methods, techniques, sequences, and construction procedures does not include an in-depth check
for the ability to perform the work in a safe or efficient manner. Review by the Engineer of
Record does not relieve the Contractor of responsibility for dimensional accuracy to ensure field
fit and for conformity of the various components and details.
5-1.4.6.3 Special Review by Engineer of Shop Drawings for
Construction Affecting Public Safety: For Construction Affecting Public Safety, the Engineer
of Record, or other Engineer as the Department appoints for this purpose, will make an
independent review of all relevant shop drawings and similar documents. Do not proceed with
construction of the permanent works until receiving the Engineer of Records approval. The
review of these shop drawings is for overall structural adequacy of the item to support the
imposed loads and does not include a check for economy, efficiency or ease of construction.
5-1.4.7 Other Requirements for Shop Drawings for Bridges:
5-1.4.7.1 Shop Drawings for Structural Steel and Miscellaneous
Metals: Furnish shop drawings for structural steel and miscellaneous metals. Shop drawings
shall consist of working, shop, and erection drawings, welding procedures, and other working
plans, showing details, dimensions, sizes of material, and other information necessary for the
complete fabrication and erection of the metal work.
5-1.4.7.2 Shop Drawings for Concrete Structures: Furnish shop
drawings for concrete components that are not cast-in-place and are not otherwise exempted
from submittal requirements. Also, furnish shop drawings for all details that are required for the
effective prosecution of the concrete work and are not included in the Contract Documents such
as: special erection equipment, masonry layout diagrams, and diagrams for bending reinforcing
steel, in addition to any details required for concrete components for the permanent work.
5-1.4.7.3 Shop Drawings for Major and Unusual Structures: In
addition to any other requirements, within 60 days from the Notice to Proceed, submit
information to the Engineer outlining the integration of the Major and Unusual Structure into the
overall approach to the project. Where applicable to the project, include, but do not limit this
information to:
(1) The overall construction program for the duration of the
Contract. Clearly show the Milestone dates. (For example, the need to open a structure by a
certain time for traffic operations.)
(2) The overall construction sequence. The order in which
individual structures are to be built, the sequence in which individual spans of girders or
cantilevers are erected, and the sequence in which spans are to be made continuous.
(3) The general location of any physical obstacles to construction
that might impose restraints or otherwise affect the construction, and an outline of how to deal
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with such obstacles while building the structure(s). (For example, obstacles might include road,
rail and waterway clearances, temporary diversions, transmission lines, utilities, property, and
the Contractors own temporary works, such as haul roads, cofferdams, plant clearances and the
like.)
(4) The approximate location of any special lifting equipment in
relation to the structure, including clearances required for the operation of the equipment. (For
example, crane positions, operating radii and the like.)
(5) The approximate location of any temporary falsework, and the
conceptual outline of any special erection equipment. Provide the precise locations and details of
attachments, fixing devices, loads, etc. in later detailed submittals.
(6) An outline of the handling, transportation, and storage of
fabricated components, such as girders or concrete segments. Provide the precise details in later
detailed submittals.
(7) Any other information pertinent to the proposed scheme or
intended approach.
Clearly and concisely present the above information on as few
drawings as possible in order to provide an overall, integrated summary of the intended approach
to the project. The Department will use these drawings for information, review planning, and to
assess the Contractors approach in relation to the intent of the original design. The delivery to
and receipt by the Engineer does not constitute any Department acceptance or approval of the
proposals shown thereon. Include the details of such proposals on subsequent detailed shop
drawing submittals. Submit timely revisions and re-submittals for all variations from these
overall scheme proposals.
5-1.4.8 Modifications for Construction: Where the Engineer allows the
Contractor to make modifications to the permanent works for the purposes of expediting the
Contractors chosen construction methods, the Contractor shall submit proposals to the Engineer
of Record for review and approval prior to modifying the works. Submit proposals for minor
modifications under the shop drawing process. Indicate on all drawings the deviations from the
Contract Documents and itemize all deviations in the letter of transmittal. The Department will
require additional submittals and/or submittal under a Value Engineering Change Proposal for
major modifications.
Minor modifications are those items that, in the opinion of the Engineer,
do not significantly affect the quantity of measured work, or the integrity or maintainability of
the structure or its components. (For example, adjusting concrete dimensions, substituting steel
plate sizes, changing reinforcing bar size and spacing, etc., all within the acceptable limits of the
design.)
Major modifications are any modifications that, in the opinion of the
Engineer, significantly affect the quantity of measured work, or the integrity or maintainability
of the structure or its components. (For example, substituting alternative beam sizes and
spacings, changing material strength or type, and the like.)
Provide signed and sealed revised sheets to the Engineer for any required
revisions to the Contract plans prior to submitting shop drawings.
The Engineers decision on the delineation between a minor and a major
modification and the disposition of a proposal is final.
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5-1.4.9 Cost of Shop Drawings: Include the cost of furnishing shop and working
drawings in the Contract prices for the work requiring the shop and working drawings. The
Department will not pay the Contractor additional compensation for such drawings.
5-1.5 Certifications:
5-1.5.1 Special Erection Equipment: Prior to its use, ensure that the Specialty
Engineer personally inspects the special erection equipment and certifies to the Engineer in
writing that the equipment has been fabricated in accordance with the submitted drawings and
calculations. In addition, after assembly, ensure that the Specialty Engineer observes the
equipment in use and certifies to the Engineer in writing that it is being used as intended and in
accordance with the submitted drawings and calculations. In each case, ensure that the Specialty
Engineer also signs and seals the letter of certification.
5-1.5.2 Falsework and Shoring Requiring Shop Drawings: After its erection or
installation but prior to the application of any superimposed load, ensure that the Specialty
Engineer personally inspects the falsework and certifies to the Engineer in writing that the
falsework has been constructed in accordance with the materials and details shown on the
submitted drawings and calculations. Ensure that the Specialty Engineer also signs and seals the
letter of certification.
5-1.5.3 Temporary Formwork: For Construction Affecting Public Safety and
for Major and Unusual Structures, prior to the placement of any concrete, ensure that the
Specialty Engineer inspects the formwork and certifies to the Engineer in writing that the
formwork has been constructed to safely withstand the superimposed loads to which it will be
subjected. Ensure that the Specialty Engineer signs and seals the letter of certification.
5-1.5.4 Erection: For Construction Affecting Public Safety, submit an erection
plan signed and sealed by the Specialty Engineer to the Engineer at least four (4) weeks prior to
erection commencing. Include as part of this submittal signed and sealed calculations and details
for any falsework, bracing or other connection(s) supporting the structural elements shown in the
erection plan.
At least two (2) weeks prior to beginning erection, conduct a Pre-erection
meeting with the Specialty Engineer and Engineer to review details of the plan.
After erection of the elements but prior to opening of the roadway below
the structure, ensure that a Specialty Engineer has personally inspected the erected member(s)
and certified to the Engineer that the structure has been erected in accordance with the signed
and sealed erection plan.
Perform daily inspections of the erected structural systems. For structures
without temporary supports but with temporary girder bracing systems, perform inspections until
all the diaphragms and cross frames are in place. For structures with temporary supports,
perform inspections until the temporary supports are no longer needed as indicated in the
erection plans. Provide written documentation of the inspections to the Engineer within 24 hours
of the inspection.
5-1.6 Corrections for Construction Errors: For work that the Contractor constructs
incorrectly or does not meet the requirements of the Contract Documents, the Contractor has the
prerogative to submit an acceptance proposal to the Engineer for review and disposition. The
acceptance proposal shall describe the error or defect and either describe remedial action for its
correction or propose a method for its acceptance. In either case, the acceptance proposal shall
address structural integrity, aesthetics, maintainability, and the effect on Contract Time. The
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Department will judge any such proposal for its effect on these criteria and also for its effect on
Contract Administration.
When the Engineer judges that a proposal infringes on the structural integrity or
maintainability of the structure, the Contractors Engineer of Record will perform a technical
assessment and submit it to the Engineer for approval. Do not take any corrective action without
the Engineers approval.
Carry out all approved corrective construction measures at no expense to the
Department.
Notwithstanding any disposition of the compensation aspects of the defective
work, the Engineers decision on the technical merits of a proposal is final.
5-2 Coordination of Contract Documents.
These Specifications, the Plans, Special Provisions, and all supplementary documents are
integral parts of the Contract; a requirement occurring in one is as binding as though occurring in
all. All parts of the Contract are complementary and describe and provide for a complete work.
In addition to the work and materials specified in the Specifications as being included in any
specific pay item, include in such pay items additional, incidental work, not specifically
mentioned, when so shown in the plans, or if indicated, or obvious and apparent, as being
necessary for the proper completion of the work under such pay item and not stipulated as being
covered under other pay items.
In cases of discrepancy, the governing order of the documents is as follows:
1. Special Provisions.
2. Technical Special Provisions.
3. Plans.
4. Design Standards.
5. Developmental Specifications.
6. Supplemental Specifications.
7. Standard Specifications.
Computed dimensions govern over scaled dimensions.
5-3 Conformity of Work with Contract Documents.
Perform all work and furnish all materials in reasonably close conformity with the lines,
grades, cross-sections, dimensions, and material requirements, including tolerances, as specified
in the Contract Documents.
In the event that the Engineer finds that the Contractor has used material or produced a
finished product that is not in reasonably close conformity with the Contract Documents, but that
the Contractor has produced reasonably acceptable work, the Engineer will determine if the
Department will accept the work in place. In this event, the Engineer will document the basis of
acceptance by Contract modification, which provides for an appropriate reduction in the
Contract price for such work or materials included in the accepted work as deemed necessary to
conform to the determination based on engineering judgment.
In the event that the Engineer finds that the Contractor has used material or produced a
finished product that is not in reasonably close conformity with the Contract Documents, and
that the Contractor has produced an inferior or unsatisfactory product, the Contractor shall
remove and replace or otherwise correct the work or materials at no expense to the Department.
39
For base and surface courses, the Department will allow the finished grade to vary as
much as 0.1 foot from the grade shown in the plans, provided that the Contractors work meets
all templates and straightedge requirements and contains suitable transitions.
5-4 Errors or Omissions in Contract Documents.
Do not take advantage of any apparent error or omission discovered in the Contract
Documents, but immediately notify the Engineer of such discovery. The Engineer will then make
such corrections and interpretations as necessary to reflect the actual spirit and intent of the
Contract Documents.
5-5 Authority of the Engineer.
Perform all work to the satisfaction of the Engineer.
The Director, Office of Construction will decide all questions, difficulties, and disputes,
of whatever nature, that may arise relative to the interpretation of the plans, construction,
prosecution, and fulfillment of the Contract, and as to the character, quality, amount, and value
of any work done, and materials furnished, under or by reason of the Contract.
5-6 Authority and Duties of Engineers Assistants.
The Director, Office of Construction may appoint such assistants and representatives as
he desires. These assistants and representatives are authorized to inspect all work done and all
materials furnished. Such inspection may extend to all or any part of the work and to the
manufacture, preparation, or fabrication of the materials to be used. Such assistants and
representatives are not authorized to revoke, alter, or waive any requirement of these
Specifications. Rather, they are authorized to call to the attention of the Contractor any failure of
the work or materials to meet the Contract Documents, and have the authority to reject materials
or suspend the work until any questions at issue can be referred to and decided by the Engineer.
The Engineer will immediately notify the Contractor in writing of any such suspension of the
work, stating in detail the reasons for the suspension. The presence of the inspector or other
assistant in no way lessens the responsibility of the Contractor.
5-7 Engineering and Layout.
5-7.1 Control Points Furnished by the Department: The Engineer will provide
centerline control points (Begin Project, End Project, PIs, PTs, etc.) and bench marks at
appropriate intervals along the line of the project to facilitate the proper layout of the work.
Normally, the Engineer will furnish only one bench mark for water crossings. Preserve all
reference points and bench marks that the Department furnishes.
As an exception to the above, for projects where the plans do not show a
centerline or other survey control line for construction of the work (e.g., resurfacing, safety
modifications, etc.) the Engineer will provide only points marking the beginning and ending of
the project, and all exceptions.
5-7.2 Furnishing of Stake Materials: Furnish all stakes, templates, and other materials
necessary for establishing and maintaining the lines and grades necessary for control and
construction of the work.
5-7.3 Layout of Work: Utilizing the control points furnished by the Department in
accordance with 5-7.1, establish all horizontal and vertical controls necessary to construct the
work in conformity to the Contract Documents. Perform all calculations required, and set all
40
stakes needed such as grade stakes, offset stakes, reference point stakes, slope stakes, and other
reference marks or points necessary to provide lines and grades for construction of all roadway,
bridge, and miscellaneous items.
When performing utility construction as part of the project, establish all
horizontal and vertical controls necessary to carry out such work.
5-7.4 Specific Staking Requirements: When performing new base construction as part
of the project, set stakes to establish lines and grades for subgrade, base, curb, and related items
at intervals along the line of the work no greater than 50 feet on tangents and 25 feet on curves.
Set grade stakes at locations that the Engineer directs to facilitate checking of subgrade, base,
and pavement elevations in crossovers, intersections, and irregular shaped areas.
For bridge construction stakes and other control, set references at sufficiently
frequent intervals to ensure construction of all components of a structure in accordance with the
lines and grades shown in the plans.
For projects where the plans do not show a centerline or other survey control line
for construction of the work (resurfacing, safety modifications, etc.), provide only such stakes as
necessary for horizontal and vertical control of work items.
For resurfacing and resurfacing-widening type projects, establish horizontal
controls adequate to ensure that the asphalt mix added matches with the existing pavement. In
tangent sections, set horizontal control points at 100 foot intervals by an instrument survey. In
curve sections, set horizontal control points at 25 foot intervals by locating and referencing the
centerline of the existing pavement.
Establish by an instrument survey, and mark on the surface of the finished
pavement at 25 foot intervals, the points necessary for striping of the finished roadway. As an
exception, for resurfacing and resurfacing/widening projects, establish these points in the same
manner as used for horizontal control of paving operations. Mark the pavement with white paint.
If performing striping, the Engineer may approve an alternate method for layout of striping
provided that the Contractor achieves an alignment equal to or better than the alignment that
would be achieved using an instrument survey.
For projects that include temporary or permanent striping of no passing zones,
provide the location and length of these zones as shown in the plans, except projects where the
vertical or horizontal alignment is new or altered from preconstruction alignment. For projects
that consist of new or altered vertical or horizontal alignment, the Department will provide the
location and length of the "no passing zones" during construction. For these projects, notify the
Engineer not less than 21 calendar days prior to beginning striping.
For all projects, set a station identification stake at each right-of-way line at
100 foot intervals and at all locations where a change in right-of-way width occurs. Mark each of
these stakes with painted numerals, of a size readable from the roadway, corresponding to the
project station at which it is located. As an exception to the above, for projects where plans do
not show right-of-way lines, set station identification stakes at locations and intervals appropriate
to the type of work being done. For resurfacing and resurfacing/widening projects, set station
identification stakes at 200 foot intervals.
5-7.5 Personnel, Equipment, and Record Requirements: Employ only competent
personnel and use only suitable equipment in performing layout work. Do not engage the
services of any person or persons in the employ of the Department for performance of layout
work.
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Keep adequate field notes and records while performing as layout work. Make
these field notes and records available for the Engineers review as the work progresses, and
furnish copies to the Engineer at the time of completion of the project. The Engineers
inspection, checking, or acceptance of the Contractors field notes or layout work does not
relieve the Contractor of his responsibility to achieve the lines, grades, and dimensions shown in
the Contract Documents.
Prior to final acceptance of the project, mark, in a permanent manner on the
surface of the completed work, all horizontal control points originally furnished by the
Department.
5-7.6 Payment: Include the cost of performing layout work as described above in the
Contract unit prices for the various items of work that require layout.
5-8 Contractors Supervision.
5-8.1 Prosecution of Work: Give the work the constant attention necessary to ensure the
scheduled progress, and cooperate fully with the Engineer and with other contractors at work in
the vicinity.
5-8.2 Contractors Superintendent: Maintain a competent superintendent at the site at
all times while work is in progress to act as the Contractors agent. Provide a superintendent who
is a competent superintendent capable of properly interpreting the Contract Documents and is
thoroughly experienced in the type of work being performed. Provide a superintendent with the
full authority to receive instructions from the Engineer and to execute the orders or directions of
the Engineer, including promptly supplying any materials, tools, equipment, labor, and
incidentals that may be required. Furnish such superintendence regardless of the amount of work
sublet.
Provide a superintendent who speaks and understands English, and maintain at
least one other responsible person who speaks and understands English, on the project during all
working hours.
5-8.3 Supervision for Emergencies: Provide a responsible person, who speaks and
understands English, and who is available at or reasonably near the worksite on a 24 hour basis,
seven days a week. Designate this person as the point of contact for emergencies and in cases
that require immediate action to maintain traffic or to resolve any other problem that might arise.
Submit, by certified mail, the phone numbers and names of personnel designated to be contacted
in cases of emergencies, along with a description of the project location, to the Florida Highway
Patrol and all other local law enforcement agencies.
5-9 General Inspection Requirements.
5-9.1 Cooperation by Contractor: Do not perform work or furnish materials without
obtaining inspection by the Engineer or his representative. Furnish the Engineer with every
reasonable facility for ascertaining whether the work performed and materials used are in
accordance with the requirements and intent of the Contract Documents. If the Engineer so
requests at any time before final acceptance of the work, remove or uncover such portions of the
finished work as directed. After examination, restore the uncovered portions of the work to the
standard required by the Contract Documents. If the Engineer determines that the work so
exposed or examined is unacceptable, perform the uncovering or removal, and the replacing of
the covering or making good of the parts removed, at no expense to the Department. However, if
the Engineer determines that the work thus exposed or examined is acceptable, the Department
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will pay for the uncovering or removing, and the replacing of the covering or making good of the
parts removed in accordance with Section 4-4.
5-9.2 Failure of Engineer to Reject Work During Construction: If, during or prior to
construction operations, the Engineer fails to reject defective work or materials, whether from
lack of discovery of such defect or for any other reason, such initial failure to reject in no way
prevents the later rejection when such defect is discovered, or obligates the Department to final
acceptance. The Department is not responsible for losses suffered due to any necessary removals
or repairs of such defects.
5-9.3 Failure to Remove and Renew Defective Materials and Work: If the Contractor
fails or refuses to remove and renew any defective materials used or work performed, or to make
any necessary repairs in an acceptable manner and in accordance with the requirements of the
Contract within the time indicated in writing, the Engineer has the authority to repair, remove, or
renew the unacceptable or defective materials or work as necessary, all at the Contractors
expense. The Department will obtain payment for any expense it incurs in making these repairs,
removals, or renewals, that the Contractor fails or refuses to make, by deducting such expenses
from any moneys due or which may become due the Contractor, or by charging such amounts
against the Contract bond.
5-9.4 Inspection by Federal Government: When the United States Government pays a
portion of the cost of construction, its representatives may inspect the construction work as they
deem necessary. However, such inspection will in no way make the Federal Government a party
to the Contract.
5-10 Final Inspection.
5-10.1 Maintenance until Acceptance: Maintain all Work until the Engineer has given
final acceptance in accordance with 5-11.
5-10.2 Inspection for Acceptance: Upon notification that all Contract Work, or all
Contract Work on the portion of the Contract scheduled for acceptance, has been completed, the
Engineer will make an inspection for acceptance. The inspection will be made within seven days
of the notification. If the Engineer finds that all work has been satisfactorily completed, the
Department will consider such inspection as the final inspection. If any or all of the Work is
found to be unsatisfactory, the Engineer will detail the remedial work required to achieve
acceptance. Immediately perform such remedial work. Subsequent inspections will be made on
the remedial work until the Engineer accepts all Work.
Upon satisfactory completion of the Work, the Department will provide written
notice of acceptance, either partial or final, to the Contractor.
Until final acceptance in accordance with 5-11, replace or repair any damage to
the accepted Work. Payment of such work will be as provided in 7-14.
5-10.3 Partial Acceptance: At the Engineers sole discretion, the Engineer may accept
any portion of the Work under the provisions of 5-10.2.
5-10.4 Conditional Acceptance: The Engineer will not make, or consider requests for
conditional acceptance of a project.
5-11 Final Acceptance.
When, upon completion of the final construction inspection of the entire project, the
Engineer determines that the Contractor has satisfactorily completed the work, the Engineer will
give the Contractor written notice of final acceptance.
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5-12 Claims by Contractor.
5-12.1 General: When the Contractor deems that extra compensation or a time extension
is due beyond that agreed to by the Engineer, whether due to delay, additional work, altered
work, differing site conditions, breach of Contract, or for any other cause, the Contractor shall
follow the procedures set forth herein for preservation, presentation and resolution of the claim.
Submission of timely notice of intent to file a claim, preliminary time extension
request, time extension request, and the certified written claim, together with full and complete
claim documentation, are each a condition precedent to the Contractor bringing any circuit court,
arbitration, or other formal claims resolution proceeding against the Department for the items
and for the sums or time set forth in the Contractors certified written claim. The failure to
provide such notice of intent, preliminary time extension request, time extension request,
certified written claim and full and complete claim documentation within the time required shall
constitute a full, complete, absolute and irrevocable waiver by the Contractor of any right to
additional compensation or a time extension for such claim.
5-12.2 Notice of Claim:
5-12.2.1 Claims For Extra Work: Where the Contractor deems that additional
compensation or a time extension is due for work or materials not expressly provided for in the
Contract or which is by written directive expressly ordered by the Engineer pursuant to 4-3, the
Contractor shall notify the Engineer in writing of the intention to make a claim for additional
compensation before beginning the work on which the claim is based, and if seeking a time
extension, the Contractor shall also submit a preliminary request for time extension pursuant to
8-7.3.2 within ten calendar days after commencement of a delay and a request for Contract Time
extension pursuant to 8-7.3.2 within thirty calendar days after the elimination of the delay. If
such notification is not given and the Engineer is not afforded the opportunity for keeping strict
account of actual labor, material, equipment, and time, the Contractor waives the claim for
additional compensation or a time extension. Such notice by the Contractor, and the fact that the
Engineer has kept account of the labor, materials and equipment, and time, shall not in any way
be construed as establishing the validity of the claim or method for computing any compensation
or time extension for such claim. On projects with an original Contract amount of $3,000,000 or
less within 90 calendar days after final acceptance of the project in accordance with 5-11, and on
projects with an original Contract amount greater than $3,000,000 within 180 calendar days after
final acceptance of the project in accordance with 5-11, the Contractor shall submit full and
complete claim documentation as described in 5-12.3 and duly certified pursuant to 5-12.9.
However, for any claim or part of a claim that pertains solely to final estimate quantities disputes
the Contractor shall submit full and complete claim documentation as described in 5-12.3 and
duly certified pursuant to 5-12.9, as to such final estimate claim dispute issues, within 90 or
180 calendar days, respectively, of the Contractors receipt of the Departments final estimate.
If the Contractor fails to submit a certificate of claim as described in 512.9, the Department will so notify the Contractor in writing. The Contractor shall have ten
calendar days from receipt of the notice to resubmit the claim documentation, without change,
with a certificate of claim as described in 5-12.9, without regard to whether the resubmission is
within the applicable 90 or 180 calendar day deadline for submission of full and complete claim
documentation. Failure by the Contractor to comply with the ten calendar day notice shall
constitute a waiver of the claim.
5-12.2.2 Claims For Delay: Where the Contractor deems that additional
compensation or a time extension is due on account of delay, differing site conditions, breach of
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Contract, or any other cause other than for work or materials not expressly provided for in the
Contract (Extra Work) or which is by written directive of the Engineer expressly ordered by the
Engineer pursuant to 4-3, the Contractor shall submit a written notice of intent to the Engineer
within ten days after commencement of a delay to a controlling work item expressly notifying
the Engineer that the Contractor intends to seek additional compensation, and if seeking a time
extension, the Contractor shall also submit a preliminary request for time extension pursuant to
8-7.3.2 within ten calendar days after commencement of a delay to a controlling work item, as to
such delay and providing a reasonably complete description as to the cause and nature of the
delay and the possible impacts to the Contractors work by such delay, and a request for Contract
Time extension pursuant to 8-7.3.2 within thirty calendar days after the elimination of the delay.
On projects with an original Contract amount of $3,000,000 or less within 90 calendar days after
final acceptance of the project in accordance with 5-11, and on projects with an original Contract
amount greater than $3,000,000 within 180 calendar days after final acceptance of the project in
accordance with 5-11, the Contractor shall submit full and complete documentation as described
in 5-12.3 and duly certified pursuant to 5-12.9.
If the Contractor fails to submit a certificate of claim as described in 512.9, the Department will so notify the Contractor in writing. The Contractor shall have ten
calendar days from receipt of the notice to resubmit the claim documentation, without change,
with a certificate of claim as described in 5-12.9, without regard to whether the resubmission is
within the applicable 90 or 180 calendar day deadline for submission of full and complete claim
documentation. Failure by the Contractor to comply with the ten calendar day notice shall
constitute a waiver of the claim.
There shall be no Contractor entitlement to any monetary compensation or
time extension for any delays or delay impacts, whatsoever, that are not to a controlling work
item, and then as to any such delay to a controlling work item entitlement to any monetary
compensation or time extension shall only be to the extent such is otherwise provided for
expressly under 4-3 or 5-12, except that in the instance of delay to a non-controlling item of
work the Contractor may be compensated for the direct costs of idle labor or equipment only, at
the rates set forth in 4-3.2.1(c), and then only to the extent the Contractor could not reasonably
mitigate such idleness.
5-12.3 Content of Written Claim: As a condition precedent to the Contractor being
entitled to additional compensation or a time extension under the Contract, for any claim, the
Contractor shall submit a certified written claim to the Department which will include for each
individual claim, at a minimum, the following information:
(a) A detailed factual statement of the claim providing all necessary dates,
locations, and items of work affected and included in each claim;
(b) The date or dates on which actions resulting in the claim occurred or
conditions resulting in the claim became evident;
(c) Identification of all pertinent documents and the substance of any material oral
communications relating to such claim and the name of the persons making such material oral
communications;
(d) Identification of the provisions of the Contract which support the claim and a
statement of the reasons why such provisions support the claim, or alternatively, the provisions
of the Contract which allegedly have been breached and the actions constituting such breach;
(e) A detailed compilation of the amount of additional compensation sought and a
breakdown of the amount sought as follows:
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(1) documented additional job site labor expenses;
(2) documented additional cost of materials and supplies;
(3) a list of additional equipment costs claimed, including each piece of
equipment and the rental rate claimed for each;
(4) any other additional direct costs or damages and the documents in
support thereof;
(5) any additional indirect costs or damages and all documentation in
support thereof.
(f) A detailed compilation of the specific dates and the exact number of calendar
days sought for a time extension, the basis for entitlement to time for each day, all
documentation of the delay, and a breakout of the number of days claimed for each identified
event, circumstance or occurrence.
Further, the Contractor shall be prohibited from amending either the bases of
entitlement or the amount of any compensation or time stated for any and all issues claimed in
the Contractors written claim submitted hereunder, and any circuit court, arbitration, or other
formal claims resolution proceeding shall be limited solely to the bases of entitlement and the
amount of any compensation or time stated for any and all issues claimed in the Contractors
written claim submitted hereunder. This shall not, however, preclude a Contractor from
withdrawing or reducing any of the bases of entitlement and the amount of any compensation or
time stated for any and all issues claimed in the Contractors written claim submitted hereunder
at any time.
5-12.4 Action on Claim: The Engineer will respond on projects with an original
Contract amount of $3,000,000 or less within 90 calendar days of receipt of a complete claim
submitted by a Contractor in compliance with 5-12.3, and on projects with an original Contract
amount greater than $3,000,000 within 120 calendar days of receipt of a complete claim
submitted by a Contractor in compliance with 5-12.3. Failure by the Engineer to respond to a
claim within 90 or 120 days, respectively, after receipt of a complete claim in compliance with
5-12.3 constitutes a denial of the claim by the Engineer. If the Engineer finds the claim or any
part thereof to be valid, such partial or whole claim will be allowed and paid for to the extent
deemed valid and any time extension granted, if applicable, as provided in the Contract. No
circuit court or arbitration proceedings on any claim, or a part thereof, may be filed until after
final acceptance per 5-11 of all Contract work by the Department or denial hereunder, whichever
occurs last.
5-12.5 Pre-Settlement and Pre-Judgment Interest: Entitlement to any pre-settlement
or pre-judgment interest on any claim amount determined to be valid subsequent to the
Departments receipt of a certified written claim in full compliance with 5-12.3, whether
determined by a settlement or a final ruling in formal proceedings, the Department shall pay to
the Contractor simple interest calculated at the Prime Rate (as reported by the Wall Street
Journal as the base rate on corporate loans posted by at least 75% of the nations 30 largest
banks) as of the 60th calendar day following the Departments receipt of a certified written claim
in full compliance with 5-12.3, such interest to accrue beginning 60 calendar days following the
Departments receipt of a certified written claim in full compliance with 5-12.3 and ending on
the date of final settlement or formal ruling.
5-12.6 Compensation for Extra Work or Delay:
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5-12.6.1 Compensation for Extra Work: Notwithstanding anything to the
contrary contained in the Contract Documents, the Contractor shall not be entitled to any
compensation beyond that provided for in 4-3.2.
5-12.6.2 Compensation for Delay: Notwithstanding anything to the contrary
contained in the Contract Documents, the additional compensation set forth in 5-12.6.2.1 shall be
the Contractors sole monetary remedy for any delay other than to perform extra work caused by
the Department unless the delay shall have been caused by acts constituting willful or intentional
interference by the Department with the Contractors performance of the work and then only
where such acts continue after Contractors written notice to the Department of such
interference. The parties anticipate that delays may be caused by or arise from any number of
events during the term of the Contract, including, but not limited to, work performed, work
deleted, change orders, supplemental agreements, disruptions, differing site conditions, utility
conflicts, design changes or defects, time extensions, extra work, right-of-way issues, permitting
issues, actions of suppliers, subcontractors or other contractors, actions by third parties,
suspensions of work by the Engineer pursuant to 8-6.1, shop drawing approval process delays,
expansion of the physical limits of the project to make it functional, weather, weekends,
holidays, special events, suspension of Contract time, or other events, forces or factors
sometimes experienced in construction work. Such delays or events and their potential impacts
on the performance by the Contractor are specifically contemplated and acknowledged by the
parties in entering into this Contract, and shall not be deemed to constitute willful or intentional
interference with the Contractors performance of the work without clear and convincing proof
that they were the result of a deliberate act, without reasonable and good-faith basis, and
specifically intended to disrupt the Contractors performance.
5-12.6.2.1 Compensation for Direct Costs, Indirect Costs, Expenses,
and Profit thereon, of or from Delay: For any delay claim, the Contractor shall be entitled to
monetary compensation for the actual idle labor and equipment, and indirect costs, expenses, and
profit thereon, as provided for in 4-3.2.1(d) and solely for costs incurred beyond what reasonable
mitigation thereof the Contractor could have undertaken.
5-12.7 Mandatory Claim Records: After giving the Engineer notice of intent to file a
claim for extra work or delay, the Contractor must keep daily records of all labor, material and
equipment costs incurred for operations affected by the extra work or delay. These daily records
must identify each operation affected by the extra work or delay and the specific locations where
work is affected by the extra work or delay, as nearly as possible. The Engineer may also keep
records of all labor, material and equipment used on the operations affected by the extra work or
delay. The Contractor shall, once a notice of intent to claim has been timely filed, and not less
than weekly thereafter as long as appropriate, provide the Engineer a copy of the Contractors
daily records and be likewise entitled to receive a copy of the Departments daily records. The
copies of daily records to be provided hereunder shall be provided at no cost to the recipient.
5-12.8 Claims For Acceleration: The Department shall have no liability for any
constructive acceleration of the work, nor shall the Contractor have any right to make any claim
for constructive acceleration nor include the same as an element of any claim the Contractor may
otherwise submit under this Contract. If the Engineer gives express written direction for the
Contractor to accelerate its efforts, such written direction will set forth the prices and other
pertinent information and will be reduced to a written Contract Document promptly. No payment
will be made on a Supplemental Agreement for acceleration prior to the Departments approval
of the documents.
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5-12.9 Certificate of Claim: When submitting any claim, the Contractor shall certify
under oath and in writing, in accordance with the formalities required by Florida law, that the
claim is made in good faith, that the supportive data are accurate and complete to the
Contractors best knowledge and belief, and that the amount of the claim accurately reflects what
the Contractor in good faith believes to be the Departments liability. Such certification must be
made by an officer or director of the Contractor with the authority to bind the Contractor.
5-12.10 Non-Recoverable Items: The parties agree that for any claim the Department
will not have liability for the following items of damages or expense:
a. Loss of profit, incentives or bonuses;
b. Any claim for other than extra work or delay;
c. Consequential damages, including, but not limited to, loss of bonding capacity,
loss of bidding opportunities, loss of credit standing, cost of financing, interest paid, loss of other
work or insolvency;
d. Acceleration costs and expenses, except where the Department has expressly
and specifically directed the Contractor in writing to accelerate at the Departments expense;
nor
e. Attorney fees, claims preparation expenses and costs of litigation.
5-12.11 Exclusive Remedies: Notwithstanding any other provision of this Contract, the
parties agree that the Department shall have no liability to the Contractor for expenses, costs, or
items of damages other than those which are specifically identified as payable under 5-12. In the
event any legal action for additional compensation, whether on account of delay, acceleration,
breach of contract, or otherwise, the Contractor agrees that the Departments liability will be
limited to those items which are specifically identified as payable in 5-12.
5-12.12 Settlement Discussions: The content of any discussions or meetings held
between the Department and the Contractor to settle or resolve any claims submitted by the
Contractor against the Department shall be inadmissible in any legal, equitable, arbitration or
administrative proceedings brought by the Contractor against the Department for payment of
such claim. Dispute Resolution Board, State Arbitration Board and Claim Review Committee
proceedings are not settlement discussions, for purposes of this provision.
5-12.13 Personal Liability of Public Officials: In carrying out any of the provisions of
the Contract or in exercising any power or authority granted to the Secretary of Transportation,
Engineer or any of their respective employees or agents, there shall be no liability on behalf of
any employee, officer or official of the Department for which such individual is responsible,
either personally or as officials or representatives of the Department. It is understood that in all
such matters such individuals act solely as agents and representatives of the Department.
5-12.14 Auditing of Claims: All claims filed against the Department shall be subject to
audit at any time following the filing of the claim, whether or not such claim is part of a suit
pending in the Courts of this State. The audit may be performed, at the Departments sole
discretion, by employees of the Department or by any independent auditor appointed by the
Department, or both. The audit may begin after ten days written notice to the Contractor,
subcontractor, or supplier. The Contractor, subcontractor, or supplier shall make a good faith
effort to cooperate with the auditors. As a condition precedent to recovery on any claim, the
Contractor, subcontractor, or supplier must retain sufficient records, and provide full and
reasonable access to such records, to allow the Departments auditors to verify the claim and
failure to retain sufficient records of the claim or failure to provide full and reasonable access to
such records shall constitute a waiver of that portion of such claim that cannot be verified and
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shall bar recovery thereunder. Further, and in addition to such audit access, upon the Contractor
submitting a written claim, the Department shall have the right to request and receive, and the
Contractor shall have the affirmative obligation to provide to the Department, copies of any and
all documents in the possession of the Contractor or its subcontractors, materialmen or suppliers
as may be deemed relevant by the Department in its review of the basis, validity or value of the
Contractors claim.
Without limiting the generality of the foregoing, the Contractor shall upon written
request of the Department make available to the Departments auditors, or upon the
Departments written request for copies provide copies at the Departments expense, any or all
of the following documents:
1. Daily time sheets and foremans daily reports and diaries;
2. Insurance, welfare and benefits records;
3. Payroll register;
4. Earnings records;
5. Payroll tax return;
6. Material invoices, purchase orders, and all material and supply
acquisition contracts;
7. Material cost distribution worksheet;
8. Equipment records (list of company owned, rented or other equipment
used);
9. Vendor rental agreements and subcontractor invoices;
10. Subcontractor payment certificates;
11. Canceled checks for the project, including, payroll and vendors;
12. Job cost report;
13. Job payroll ledger;
14. General ledger, general journal, (if used) and all subsidiary ledgers and
journals together with all supporting documentation pertinent to entries made in these ledgers
and journals;
15. Cash disbursements journal;
16. Financial statements for all years reflecting the operations on this
project;
17. Income tax returns for all years reflecting the operations on this
project;
18. All documents which reflect the Contractors actual profit and
overhead during the years this Contract was being performed and for each of the five years prior
to the commencement of this Contract;
19. All documents related to the preparation of the Contractors bid
including the final calculations on which the bid was based;
20. All documents which relate to each and every claim together with all
documents which support the amount of damages as to each claim;
21. Worksheets used to prepare the claim establishing the cost components
for items of the claim including, but not limited to, labor, benefits and insurance, materials,
equipment, subcontractors, and all documents that establish which time periods and individuals
were involved, and the hours and rates for such individuals.
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5-13 Recovery Rights, Subsequent to Final Payment.
The Department reserves the right, if it discovers an error in the partial or final estimates,
or if it discovers that the Contractor performed defective work or used defective materials, after
the final payment has been made, to claim and recover from the Contractor or his surety, or both,
by process of law, such sums as may be sufficient to correct the error or make good the defects
in the work and materials.
Retain all records pertaining to the project for a period of three years from the date of the
Engineers final acceptance of the project. Upon request, make all such records available to the
Department or its representative. For the purpose of this Article, records include all books of
account, supporting documents, and papers that the Department deems necessary to ensure
compliance with the Contract provisions.
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SECTION 6
CONTROL OF MATERIALS
6-1 Acceptance Criteria.
6-1.1 General: Acceptance of materials is based on the following criteria. All
requirements may not apply to all materials. Use only materials in the work that meet the
requirements of these Specifications. The Engineer may inspect and test any material, at points
of production, distribution and use.
6-1.2 Sampling and Testing: Use the Departments current sample identification and
tracking system to provide related information and attach the information to each sample.
Restore immediately any site from which material has been removed for sampling purposes to
the pre-sampled condition with materials and construction methods used in the initial
construction, at no additional cost to the Department.
Ensure when a material is delivered to the location as described in the Contract
Documents, there is enough material delivered to take samples, at no expense to the Department.
6-1.2.1 Pretest by Manufacturers: Submit certified manufacturers test results to
the Engineer for qualification and use on Department projects. Testing will be as specified in the
Contract Documents. The Department may require that manufacturers submit samples of
materials for independent verification purposes.
6-1.2.2 Point of Production Test: Test the material during production as
specified in the Contract Documents.
6-1.2.3 Point of Distribution Test: Test the material at Distribution facilities as
specified in the Contract Documents.
6-1.2.4 Point of Use Test: Test the material immediately following placement as
specified in the Specifications. After delivery to the project, the Department may require the
retesting of materials that have been tested and accepted at the source of supply, or may require
the testing of materials that are to be accepted by Producer Certification. The Department may
reject all materials that, when retested, do not meet the requirements of these Specifications.
6-1.3 Certification:
6-1.3.1 Producer Certification: Provide complete certifications for materials as
required. Furnish to the Engineer for approval, Producer Certifications for all products listed on
the Qualified Products List and when required by the applicable material Specification(s). Do not
incorporate any manufactured products or materials into the project without approval from the
Engineer. Materials will not be considered for payment when not accompanied by Producer
Certification. Producers may obtain sample certification forms through the Departments
website. Ensure that the certification is provided on the producers letterhead and is signed by a
legally responsible person from the producer and notarized.
6-1.3.1.1 Qualified Products List: The Product Evaluation Section in the
State Specifications and Estimates Office publishes and maintains a Qualified Products List. This
list provides assurance to Contractors, consultants, designers, and Department personnel that
specific products and materials are approved for use on Department facilities. The Department
will limit the Contractors use of products and materials that require pre-approval to items listed
on the Qualified Products List effective at the time of placement.
Manufacturers seeking evaluation in accordance with
Departmental procedures of an item must submit a Product Evaluation Application, available on
the Departments website
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http://www.dot.state.fl.us/specificationsoffice/ProductEvaluation/QPL/SubmittalProcess.shtm ,
with supporting documentation as defined and detailed by the applicable Specifications and
Standards. This may include certified test reports from an independent test laboratory,
certification that the material meets all applicable specifications, signed and sealed drawings and
calculations, quality control plans, samples, infrared scans, or other technical data.
Manufacturers successfully completing the Departments
evaluation are eligible for inclusion on the Qualified Products List. The Department will consider
any marked variations from original test values for a material or any evidence of inadequate field
performance of a material as sufficient evidence that the properties of the material have changed,
and the Department will remove the material from the Qualified Products List.
6-1.3.1.2 Approved Products List: The State Traffic Operations Office
maintains the Approved Products List of Traffic Control Signal Devices. Traffic Monitoring Site
Equipment and Materials are also included on the Approved Products List. This list provides
assurance to Maintaining Agencies, Contractors, consultants, designers, and Department
personnel that the specific items listed are approved for use on Department facilities. The
Department will limit the Contractors procurement and use of Traffic Control Signal Devices,
and Traffic Monitoring Site equipment and materials to only those items listed on the Approved
Products List that is effective at the time of procurement, except as provided in Section 603.
The approval process is described in detail on the State Traffic
Operation website, http://www.dot.state.fl.us/trafficoperations/Traf_Sys/terl/apl2.shtm .
Manufacturers seeking evaluation of a specific device must submit an application which can be
obtained from the State Traffic Operations Office.
6-1.3.2 Contractor Installation Certification: Provide installation certifications
as required by the Contract Documents.
6-2 Applicable Documented Authorities Other Than Specifications.
6-2.1 General: Details on individual materials are identified in various material specific
Sections of the Specifications that may refer to other documented authorities for requirements.
When specified, meet the requirements as defined in such references.
6-2.2 Test Methods: Methods of sampling and testing materials are in accordance with
the Florida Methods (FM). If a Florida Method does not exist for a particular test, perform the
testing in accordance with the method specified in the Specification. When test methods or other
standards are referenced in the Specifications without identification of the specific time of
issuance, use the most current issuance, including interims or addendums thereto, at the time of
bid opening.
6-2.3 Construction Aggregates: Aggregates used on Department projects must be in
accordance with Rule 14-103, FAC.
6-3 Storage of Materials and Samples.
6-3.1 Method of Storage: Store materials in such a manner as to preserve their quality
and fitness for the work, to facilitate prompt inspection, and to minimize noise impacts on
sensitive receivers. More detailed specifications concerning the storage of specific materials are
prescribed under the applicable Specifications. The Department may reject improperly stored
materials.
6-3.2 Use of Right-of-Way for Storage: If the Engineer allows, the Contractor may use
a portion of the right-of-way for storage purposes and for placing the Contractors plant and
equipment. Use only the portion of the right-of-way that is outside the clear zone, which is the
52
portion not required for public vehicular or pedestrian travel. When used, restore the
right-of-way to pre-construction condition at no additional cost to the Department or as specified
in the Contract Documents. Provide any additional space required at no expense to the
Department.
6-3.3 Responsibility for Stored Materials: Accept responsibility for the protection of
stored materials. The Department is not liable for any loss of materials, by theft or otherwise, or
for any damage to the stored materials.
6-3.4 Storage Facilities for Samples: Provide facilities for storage of samples as
described in the Contract Documents and warranted by the test methods and Specifications.
6-4 Defective Materials.
Materials not meeting the requirements of these Specifications will be considered
defective. The Engineer will reject all such materials, whether in place or not. Remove all
rejected material immediately from the site of the work and from storage areas, at no expense to
the Department.
Do not use material that has been rejected and the defects corrected, until the Engineer
has approved the materials use. Upon failure to comply promptly with any order of the Engineer
made under the provisions of this Article, the Engineer has the authority to have the defective
material removed and replaced by other forces and deduct the cost of removal and replacement
from any moneys due or to become due the Contractor.
As an exception to the above, within 30 calendar days of the termination of the LOT or
rejection of the material, the Contractor may submit a proposed scope of work to the Engineer
for an engineering or independent laboratory (as approved by the Engineer) analysis to
determine the disposition of the material. A Specialty Engineer, who is an independent
consultant, or the Contractors Engineer of Record as stated within each individual Section shall
perform any such analysis. Upon the Engineers approval of the scope of work submitted by the
Contractor, the engineering analysis must be completed and the report must be submitted to the
Engineer within 45 calendar days, or other time frame as approved by the Engineer. The report
must be signed and sealed by the Specialty Engineer. The Engineer will determine the final
disposition of the material after review of the information submitted by the Contractor. No
additional monetary compensation or time extension will be granted for the impact of any such
analysis or review.
6-5 Products and Source of Supply.
6-5.1 Source of SupplyConvict Labor (Federal-Aid Contracts Only): Do not use
materials that were produced after July 1, 1991, by convict labor for Federal-aid highway
construction projects unless the prison facility has been producing convict-made materials for
Federal-aid highway construction projects before July 1, 1987.
Use materials that were produced prior to July 2, 1991, by convicts on Federal-aid
highway construction projects free from the restrictions placed on the use of these materials by
23 U.S.C. 114. The Department will limit the use of materials produced by convict labor for use
in Federal-aid highway construction projects to:
1. materials produced by convicts on parole, supervised release, or
probation from a prison or,
2. materials produced in a qualified prison facility.
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The amount of such materials produced for Federal-aid highway construction
during any 12-month period shall not exceed the amount produced in such facility for use in such
construction during the 12-month period ending July 1, 1987.
6-5.2 Source of Supply-Steel (Federal-Aid Contracts Only): For Federal-aid
Contracts, only use steel and iron produced in the United States, in accordance with the Buy
America provisions of 23 CFR 635.410, as amended. Ensure that all manufacturing processes for
this material occur in the United States. As used in this specification, a manufacturing process is
any process that modifies the chemical content, physical shape or size, or final finish of a
product, beginning with the initial melding and mixing and continuing through the bending and
coating stages. A manufactured steel or iron product is complete only when all grinding, drilling,
welding, finishing and coating have been completed. If a domestic product is taken outside the
United States for any process, it becomes foreign source material. When using steel and iron as a
component of any manufactured product incorporated into the project (e.g., concrete pipe,
prestressed beams, corrugated steel pipe, etc.), these same provisions apply, except that the
manufacturer may use minimal quantities of foreign steel and iron when the cost of such foreign
materials does not exceed 0.1% of the total Contract amount or $2,500, whichever is greater.
These requirements are applicable to all steel and iron materials incorporated into the finished
work, but are not applicable to steel and iron items that the Contractor uses but does not
incorporate into the finished work. Provide a certification from the producer of steel or iron, or
any product containing steel or iron as a component, stating that all steel or iron furnished or
incorporated into the furnished product was manufactured in the United States in accordance
with the requirements of this specification and the Buy America provisions of 23 CFR 635.410,
as amended. Such certification shall also include (1) a statement that the product was produced
entirely within the United States, or (2) a statement that the product was produced within the
United States except for minimal quantities of foreign steel and iron valued at $ (actual value).
Furnish each such certification to the Engineer prior to incorporating the material into the
project. When FHWA allows the use of foreign steel on a project, furnish invoices to document
the cost of such material, and obtain the Engineers written approval prior to incorporating the
material into the project.
6-5.3 Contaminated, Unfit, Hazardous, and Dangerous Materials: Do not use any
material that, after approval and/or placement, has in any way become unfit for use. Do not use
materials containing any substance that has been determined to be hazardous by the State of
Florida Department of Environmental Protection or the U.S. Department of Environmental
Protection. Provide workplaces free from serious recognized hazards and to comply with
occupational safety and health standards, as determined by the U.S. Department of Labor
Occupational Safety and Health Administration.
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SECTION 7
LEGAL REQUIREMENTS AND
RESPONSIBILITY TO THE PUBLIC
7-1 Laws to be Observed.
7-1.1 General: Become familiar with and comply with all Federal, State, county, and city
laws, by-laws, ordinances, and regulations that control the action or operation of those engaged
or employed in the work or that affect materials used. Pay particular attention called to the safety
regulations promulgated by the U.S. Department of Labor, Occupational Safety and Health
Administration (OSHA). In addition, comply with Chapter 403, of the Florida Statutes, regarding
control of air pollution. Direct special attention to that portion of Chapter 17-5 of the Rules and
Regulations, pertaining to open burning in land clearing operations. Where work or structures
included in the Contract are in Navigable Waters of the U.S., (reference 33 of the Code of
Federal Regulations, Part 329); Waters of the U.S., (reference 33 of the Code of Federal
Regulations, Parts 323 and 328); or Waters of the State, (reference Part 4, Chapters 253 and
373 of the Florida Statutes and Section 62-340 of the Florida Administrative Code); comply with
the regulatory provisions of Section 404 of the Federal Clean Water Act of 1977; Sections 9 and
10 of the Federal River and Harbor Act of 1899; Chapter 161 of the Florida Statutes; and any
local authority having jurisdiction over such waters.
Comply with Part IV, Chapter 378, of the Florida Statutes regarding land
reclamation. Direct special attention to Chapters 62c-36 and 62c-39 of the Florida
Administrative Code. Submit the Notice of Intent to Mine to:
Department of Environmental Protection
Collins Building
2051 East Dirac Drive
Tallahassee, Florida 32310-3760
with a copy to the Engineer. The Engineer will determine consistency with the environmental
documents prior to commencement of mining.
Obtain certification from the Construction Industry Licensing Board as required
by Part I, Chapter 489, of the Florida Statutes, regardless of exemptions allowed by
Section 489.103, prior to removing underground pollutant storage tanks. Dispose of tanks and
pollutants in accordance with the requirements and regulations of any Federal, State, or local,
agency having jurisdiction.
Prior to building construction or renovation, provide copies of current
registrations or certifications issued by the Florida Construction Industry Licensing Board in
accordance with Chapter 489, for the appropriate category of construction.
Corporations must be registered with the State of Florida, Department of State,
Division of Corporations, and hold a current State Corporate Charter Number in accordance with
Chapter 607, Florida Statutes.
The Contractor or the authorized subcontractor applying the roofing material must
be licensed or be an approved dealer and applicator of the proposed roofing material.
Indemnify, defend, and save harmless the Department and all of its officers,
agents, and employees, in the amount of the Contract price, against all claims or liability arising
from or based on the violation of any such laws, by-laws, ordinances, regulations, order, or
decrees; whether by himself or his employees.
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The Contractor shall comply with all environmental permits, including measures
identified in the National Pollutant Discharge Elimination System (NPDES) Stormwater
Pollution Prevention Plan and Sediment and Erosion Control Plan for the work.
The Contractor shall exert every reasonable and diligent effort to ensure that all
labor employed by the Contractor and his subcontractors for work on the project work
harmoniously and compatibly with all labor used by other building and construction contractors
now or hereafter on the site of the work covered by this Contract. Include this provision in all
subcontracts, and require all subcontractors to include it in their subcontracts with others.
However, do not interpret or enforce this provision so as to deny or abridge, on account of
membership or non-membership in any labor union or labor organization, the right of any person
to work as guaranteed by Article I, Section 6 of the Florida Constitution.
Comply with Chapter 556 of the Florida Statutes during the performance of
excavation or demolition operations.
The Executive Order 11246 Electronic version, dated September 24, 1965 is
posted on the Departments website at the following URL address:
www.dot.state.fl.us/specificationsoffice/federal/deo11246.pdf . Take responsibility to obtain the
information posted on this website up through five calendar days before the opening of bids and
comply with the provisions contained in Executive Order 11246.
If the Departments website cannot be accessed, contact the Departments
Specifications Office Web Coordinator at (850) 414-4101.
7-1.2 Plant Quarantine Regulations: The U.S. Department of Agriculture and the
Florida Department of Agriculture and Consumer Services have issued quarantine regulations
pertaining to control of the nematodes of citrus, Rule 5B-44, Florida Administrative Code, and
other plant pests. Contact the local (or other available) representatives of the Animal and Plant
Health Inspection Service of the U.S. Department of Agriculture, and the Division of Plant
Industry of the Florida Department of Agriculture and Consumer Services to ascertain all current
restrictions regarding plant pests that are imposed by these agencies. Keep advised of current
quarantine boundary lines throughout the construction period.
These restrictions may affect operations in connection with such items as clearing
and grubbing, earthwork, grassing and mulching, sodding, landscaping, and other items which
might involve the movement of materials containing plant pests across quarantine lines.
Obtain quarantine regulations and related information from the following:
Animal and Plant Health Inspection Service
U.S. Department of Agriculture
3029 Lake Alfred Road
Winter Haven, Florida 33881
Director, Division of Plant Industry
Florida Department of Agriculture and Consumer Services
Post Office Box 147100
Gainesville, Florida 32614-7100
7-1.3 Introduction or Release of Prohibited Aquatic Plants, Plant Pests, or Noxious
Weeds: Do not introduce or release prohibited aquatic plants, plant pests, or noxious weeds into
the project limits as a result of clearing and grubbing, earthwork, grassing and mulching,
sodding, landscaping, or other such activities. Immediately notify the Engineer upon discovery
56
of all prohibited aquatic plants, plant pests, or noxious weeds within the project limits. Do not
move prohibited aquatic plants, plant pests, or noxious weeds within the project limits or to
locations outside of the project limits without the Engineers permission. Maintain all borrow
material brought onto the project site free of prohibited aquatic plants, plant pests, noxious
weeds, and their reproductive parts. Refer to Rule 16C-52 and Rule 5B-57, of the Florida
Administrative Code for the definition of prohibited aquatic plants, plant pests, and noxious
weeds.
7-1.4 Compliance with Federal Endangered Species Act and other Wildlife
Regulations: The Federal Endangered Species Act requires that the Department investigate the
potential impact to a threatened or endangered species prior to initiating an activity performed in
conjunction with a highway construction project. If the Departments investigation determines
that there is a potential impact to a protected, threatened or an endangered species, the
Department will conduct an evaluation to determine what measures may be necessary to mitigate
such impact. When mitigation measures and/or special conditions are necessary, these measures
and conditions will be addressed on the plans or in permits as identified in 7-2.1.
In addition, in cases where certain protected, threatened or endangered species are
found or appear within close proximity to the project boundaries, the Department has established
guidelines that will apply when interaction with certain species occurs, absent of any special
mitigation measures or permit conditions otherwise identified for the project.
These guidelines are posted at the following URL address:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/endangeredwildli
feguidelines.pdf .
Take responsibility to obtain this information and take all actions and precautions
necessary to comply with the conditions of these guidelines during all project activities.
Prior to establishing any off-project activity in conjunction with a project, notify
the Engineer of the proposed activity. Covered activities include but are not necessarily limited
to borrow pits, concrete or asphalt plant sites, disposal sites, field offices, and material or
equipment storage sites. Include in the notification the Financial Project ID, a description of the
activity, the location of the site by township, range, section, county, and city, a site location map
including the access route, the name of the property owner, and a person to contact to arrange a
site inspection. Provide this notification sufficiently in advance of planned commencement of the
off-site activity, to allow a reasonable period of time for the Engineer to conduct an investigation
without delaying job progress.
Do not perform any off-project activity without obtaining written clearance from
the Engineer. In the event the Departments investigation determines a potential impact to a
protected, threatened or endangered species and mitigation measures or permits are necessary,
coordinate with the appropriate resource agencies for clearance, obtain permits and perform
mitigation measures as necessary. Immediately notify the Engineer in writing of the results of
this coordination with the appropriate resource agencies. Additional compensation or time will
not be allowed for permitting or mitigation, associated with Contractor initiated off-project
activities.
7-1.5 Occupational Safety and Health Requirements: The Contractor shall take all
precautions necessary for the protection of life, health, and general occupational welfare of all
persons, including employees of both the Contractor and the Department, until the Contractor
has completed the work required under the Contract as provided in 5-10 and 5-11.
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Comply at all times with applicable Federal, State, and local laws, provisions, and
policies governing safety and health, including 29 CFR 1926, including all subsequent revisions
and updates.
7-1.6 Discovery of an Unmarked Human Burial: When an unmarked human burial is
discovered, immediately cease all activity that may disturb the unmarked human burial and
notify the Engineer. Do not resume activity until specifically authorized by the Engineer.
7-1.7 Insecticides and Herbicides: Use products found on the following website,
www.flpesticide.us/ , approved by the Florida Department of Agriculture for the State of Florida.
The use of restricted products is prohibited. Do not use any products in the sulfonylurea family
of chemicals. Herbicide application by broadcast spraying is not allowed.
Procure any necessary licenses, pay all charges and fees, and give all notices
necessary for lawful performance of the work.
Ensure that all employees applying insecticides and herbicides possess a current
Florida Department of Agriculture Commercial Applicator license with the categories of
licensure in Right-of-Way Pest Control and Aquatic Pest Control. Provide a copy of current
certificates upon request, to the Engineer.
Ensure that employees who work with herbicides comply with all applicable
Federal, State, and local regulations.
Comply with all regulations and permits issued by any regulatory agency within
whose jurisdiction work is being performed. Post all permit placards in a protected, conspicuous
location at the work site.
Acquire any permits required for work performed on the rights-of-way within the
jurisdiction of National Forests in Florida. Contact the Local National Forest Ranger District, or
the United States Department of Agriculture (USDA) office for the proper permits and
subsequent approval.
Acquire all permits required for aquatic plant control as outlined in Chapter
62C-20, Florida Administrative Code, Rules of the Florida Department of Environmental
Protection. Contact the Regional Field Office of Bureau of Invasive Plant Management of the
Florida Department of Environmental Protection for proper permits and subsequent approval. If
application of synthetic organo-auxin herbicides is necessary, meet the requirements of
Chapter 5E-2, Florida Administrative Code.
7-1.8 Compliance with Section 4(f) of the USDOT Act: Section 4(f) of the USDOT Act
prohibits the U. S. Secretary of Transportation from approving a project which requires the use
of publicly owned land of a public park, recreation area or a wildlife and waterfowl refuge, or of
any historic site of national, state, or local significance unless there is no prudent or feasible
alternative to using that land and the program or project includes all possible planning to
minimize the harm to the site resulting from the use.
Before undertaking any off-project activity associated with any federally assisted
undertaking, ensure that the proposed site does not represent a public park, recreation area,
wildlife or waterfowl refuge, or a historic site (according to the results of the Cultural Resources
Survey discussed in 120-6.2). If such a site is proposed, notify the Engineer and provide a
description of the proposed off-site activity, the Financial Project ID, the location of the site by
township, range, section, a county or city map showing the site location and including the access
route and the name of the property. It is the Contractors responsibility to provide justification
for use of Section 4(f) property that is sufficient for the Florida Department of Transportation
and the Federal Highway Administration to make a Section 4(f) determination. Provide this
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notification sufficiently in advance of planned commencement of the off-site activity to allow a
reasonable time for the Engineer to conduct an investigation without delaying job progress. Do
not begin any off-project activity without obtaining written clearance from the Engineer.
7-1.9 Florida Minority Business Loan Mobilization Program:
The Loan Mobilization Program is established by Section 288.706 of the Florida
Statutes, and has as its goal to assist minority business enterprises by facilitating working capital
loans to those eligible businesses that are Contractors or subcontractors on Department contracts.
The limits of such advances under this program shall be as specified in
Section 288.706 of the Florida Statutes. In the case of a subcontractor, the amount of the advance
will be based on the subcontract unit prices, not the contract unit prices.
All prime Contractor vendors shall be required to incorporate the designated loan
mobilization payment procedures in subcontract agreements with minority business enterprise
vendors participating in this program and to cooperate in the release of designated loan
mobilization payments to achieve the objective of providing working capital for minority
business enterprise subcontract vendors.
When the Contract has been awarded or, in the case of a subcontractor, a
subcontract has been signed with the prime Contractor, application for participation in this
program will be made in writing to the Engineer. Such application must be made prior to
commencement of the work. If the application is made on behalf of a subcontractor, it shall be
considered incomplete if not accompanied by a copy of the subcontract with the unit prices of
the work clearly delineated.
When all applicable conditions have been met, approval for participation will be
made by the Office of the Comptroller and the applicant will be notified of the approval action
taken.
Once approval has been obtained and the Notice to Proceed has been issued,
disbursement of the monies will be made at the request of the applicant. The designated loan
mobilization payment may be paid prior to the commencement of work on the Contract.
However, if the work on the Contract has not commenced and the payment has not been made,
then the Contract Time may not commence until the payment is made. All designated loan
mobilization payments will be made payable jointly to the prime Contractor and the participating
financial institution. When a subcontractor is the participant in the program, such payments shall
be paid to the participant within 10 business days after receipt of the funds from the Department.
Repayment of monies advanced through this program will be made after the value
of the work accomplished by the participant reaches 50 percent. Contractors are encouraged to
make weekly or bi-weekly payments to subcontractors participating in this program.
7-2 Permits and Licenses.
7-2.1 General: Except for permits procured by the Department, as incorporated by
Special Provision expanding this Subarticle, if any, procure all permits and licenses, pay all
charges and fees, and give all notices necessary and incidental to the due and lawful prosecution
of the work.
The Department will also acquire any modifications or revisions to an original
permit incorporated by Special Provision to this Subarticle when the Contractor requires such
modifications or revisions to complete the construction operations specified in the plans or
Special Provisions and within the right-of-way limits.
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Acquire all permits for work performed outside the right-of-way or easements for
the project.
In carrying out the work in the Contract, when under the jurisdiction of any
environmental regulatory agency, comply with all regulations issued by such agencies and with
all general, special, and particular conditions relating to construction activities of all permits
issued to the Department as though such conditions were issued to the Contractor. Post all permit
placards in a protected location at the worksite.
In case of a discrepancy between any permit condition and other Contract
Documents, the more stringent condition shall prevail.
7-2.2 Work or Structures in Navigable Waters of the U.S., Waters of the U.S., and
Waters of the State: In general, one or more governmental agencies will exercise regulatory
authority over work or structures, including related construction operations, in all tidal areas
(Channelward of the mean high water lines on the Atlantic and Gulf Coast); in the ocean and
gulf waters to the outer limits of the continental shelf; in all rivers, streams, and lakes to the
ordinary high water line; in marshes and shallows that are periodically inundated and normally
characterized by aquatic vegetation capable of growth and reproduction; in all artificially created
channels and canals used for recreational, navigational, or other purposes that are connected to
navigable waters; and in all tributaries of navigable waters up to their headwaters.
Whenever the work under or incidental to the Contract requires structures or
dredge/fill/construction activities in Navigable Waters of the U.S., Waters of the U.S., and
Waters of the State, the Federal, State, county, and local regulatory agencies may require the
Department to obtain a permit. For such dredge/fill /construction specified in the plans to be
accomplished within the limits of the project, or for any dredge/fill/construction within the limits
of Department-furnished borrow areas, the Department will procure the necessary permits prior
to advertising for bids.
7-2.3 As-Built Drawings and Certified Surveys
7-2.3.1 Surface Water Management Systems for Water Management
Districts: As a condition precedent to final acceptance of the project, submit to the Engineer
three copies of as-built drawings and a certified survey verifying the as-built conditions for all
installed and constructed surface water management systems. The as-built drawings and certified
survey must satisfy all the requirements and special conditions listed in the Water Management
Districts Environmental Resource Permit (ERP) and any applicable local permit. The as-built
drawings and certified survey must be signed and sealed by an appropriately licensed
professional registered in the State of Florida.
If the ERP does not contain specific requirements, provide as-built
drawings with the following information as a minimum:
1. Discharge structures: structure identification number, type,
locations (latitude and longitude), dimensions and elevations of all, including weirs, bleeders,
orifices, gates, pumps, pipes, and oil and grease skimmers.
2. Side bank and underdrain filters, or exfiltration trenches:
locations, dimensions and elevations of all, including clean-outs, pipes, connections to control
structures and points of discharge to receiving waters.
3. Storage areas for treatment and attenuation: storage area
identification number, dimensions, elevations, contours or cross-sections of all, sufficient to
determine stage-storage relationships of the storage area and the permanent pool depth and
volume below the control elevation for normally wet systems.
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4. System grading: dimensions, elevations, contours, final grades
or cross-sections to determine contributing drainage areas, flow directions and conveyance of
runoff to the system discharge points.
5. Conveyance: dimensions, elevations, contours, final grades or
cross-sections of systems utilized to divert off-site runoff around or through the new system.
6. Water levels: existing water elevations and the date determined.
7. Benchmarks: location and description (minimum of one per
major water control structure).
7-2.3.2 Bridge Clearances for Projects under the Authority of a U.S. Coast
Guard Permit: As a condition precedent to final acceptance of the project, submit to the
Engineer a certified survey verifying the as-built clearances described in the U.S. Coast Guard
Owners Certification of Bridge Completion. The certified survey must be signed and sealed by
a Professional Engineer or Professional Surveyor and Mapper registered in the State of Florida.
7-2.3.3 Projects Under the Authority of a U.S. Army Corps of Engineers
Permit: As a condition precedent to final acceptance of the project, submit to the Engineer three
copies of as-built drawings and a certified survey verifying the as-built conditions. The as-built
drawings and certified survey must satisfy all of the requirements and special conditions listed in
the U.S. Army Corps of Engineers permit. The as-built drawings and certified survey must be
signed and sealed by a Professional Engineer or Professional Surveyor and Mapper registered in
the State of Florida.
7-3 Patented Devices, Materials and Processes.
Include all royalties and costs arising from patents, trademarks, and copyrights, in any
way involved in the work in the Contract price. Whenever using any design, device, material, or
process covered by letters patent or copyright, obtain the right for such use by suitable legal
agreement with the patentee or owner of the copyright. File a copy of such agreement with the
Engineer. However, whether or not such agreement is made or filed as noted, the Contractor and
the surety in all cases shall indemnify, defend, and save harmless, the Department from all
claims for infringement by reason of the use of any such patented design, device, material, or
process on work under the Contract, and shall indemnify the Department for all costs, expenses,
and damages that it may be obliged to pay by reason of any such infringement, at any time
during the prosecution or after the completion of the work.
7-4 Right-of-Way Furnished by the Department.
Except as otherwise stipulated in these Specifications or as shown in the plans, the
Department will furnish all rights-of-way necessary for the proper completion of the work at no
expense to the Contractor.
Should Department-furnished areas for obtaining borrow material, contain limerock
material do not remove such material from the pit unless the Engineer gives specific approval.
Use of Department owned right-of-way for the purpose of equipment or material storage,
lay-down facilities, pre-cast material fabrication sites, batch plants for the production of asphalt,
concrete or other construction related materials, or other similar activities, shall require advance
written approval by the Department prior to making use of said Department owned right of way.
Use of Department owned right of way for these purposes is expressly limited to storage of
equipment and materials for the Project or production of materials or products for the Project.
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7-5 Restoration of Surfaces Opened by Permit.
Upon the presentation of a duly authorized and satisfactory permit that provides that all
necessary repair work will be paid for by the party holding such permit, the Engineer may
authorize the Contractor to allow parties bearing such permits to make openings in the highway.
Upon the Engineers written order, perform, in an acceptable manner, all necessary repairs due
to such openings, and such necessary work that the Engineer orders, subject to the same
conditions as the original work performed. The Department will pay the Contractor for such
work either under applicable Contract items or in accordance with 4-4 when Contract items are
not applicable.
7-6 Sanitary Provisions.
The Contractor shall provide and maintain, in a neat and sanitary condition, such
accommodations for the use of his employees as are necessary to comply with the requirements
and regulations of the State and local boards of health. Commit no public nuisance.
7-7 Control of the Contractors Equipment.
7-7.1 Traffic Interference: Do not allow equipment, while it is on or traversing a road
or street, to unreasonably interfere with traffic.
7-7.2 Overloaded Equipment: Do not operate on any road or street any hauling unit or
equipment loaded in excess of (1) the maximum weights specified in the Florida Uniform Traffic
Control Law, or (2) lower weights legally established for any section of road or bridge by the
Department or local authorities. The governmental unit having jurisdiction over a particular road
or bridge may provide exceptions by special permit under the provisions of 7-7.3. This
restriction applies to all roads and bridges inside and outside the Contract limits as long as these
roads and bridges are open for public use. The Contractor may overload roads and bridges which
are to be demolished after they are permanently closed to the public. The Contractor is
responsible for all loss or damages resulting from equipment operated on a structure permanently
closed to the public.
7-7.3 Crossings: Where it is necessary to cross an existing road or street, including
specifically the existing traveled lanes of a divided highway within the limits of the project,
obtain permits from the Department, for crossing overloaded or oversized equipment. Cross
existing roads or streets only at Engineer-designated points. The Engineer may require the
Contractor to protect the pavement or Roadway at the crossing by using lumber, planks, or fill.
Provide flagging and watchman service, or approved signal devices, for the protection of traffic
at all such crossings, in accordance with an approved written plan for that activity.
7-7.4 Protection from Damage by Tractor-Type Equipment: Take positive measures
to ensure that tractor-type equipment does not damage the road. If any such damage should
occur, repair it without delay, at no expense to the Department and subject to the Engineers
approval.
7-7.5 Contractors Equipment on Bridge Structures: The Contractors Engineer of
Record shall analyze the effect of imposed loads on bridge structures, within the limits of a
construction contract, resulting from the following operations:
(1) Overloaded Equipment as defined in 7-7.2:
(a) Operating on or crossing over completed bridge structures.
(b) Operating on or crossing over partially completed bridge structures.
(2) Equipment within legal load limits:
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(a) Operating on or crossing over partially completed bridge structures.
(3) Construction cranes:
(a) Operating on completed bridge structures.
(b) Operating on partially completed bridge structures.
Any pipe culvert(s) or box culvert(s) qualifying as a bridge under 1-3 is excluded
from the requirements above.
A completed bridge structure is a bridge structure in which all elemental
components comprising the load carrying assembly have been completed, assembled, and
connected in their final position. The components to be considered shall also include any related
members transferring load to any bridge structure.
The Contractors Engineer of Record shall determine the effect that equipment
loads have on the bridge structure and develop the procedures for using the loaded equipment
without exceeding the structures design load capacity.
Submit to the Department for approval eight copies of design calculations, layout
drawings, and erection drawings showing how the equipment is to be used so that the bridge
structure will not be overstressed. The Contractors Engineer of Record shall sign and seal one
set of the eight copies of the drawings and the cover sheet of one of the eight copies of the
calculations for the Departments Record Set.
7-7.6 Posting of the Legal Gross Vehicular Weight: Display the maximum legal gross
weight, as specified in the Florida Uniform Traffic Code, in a permanent manner on each side of
any dump truck or dump type tractor-trailer unit hauling embankment material, construction
aggregates, road base material, or hot bituminous mixture to the project over any public road or
street. Display the weight in a location clearly visible to the scale operator, in numbers that
contrast in color with the background and that are readily visible and readable from a distance of
50 feet.
7-8 Structures over Navigable Waters.
7-8.1 Compliance with Federal and Other Regulations: Where erecting structures in,
adjacent to, or over, navigable waters, observe all regulations and instructions of Federal and
other authorities having control over such waters. Do not obstruct navigation channels without
permission from the proper authority, and provide and maintain navigation lights and signals in
accordance with the Federal requirements for the protection of the structure, of false work, and
of navigation.
In the event of accidental blocking of the navigation channel, immediately notify
the U.S. Coast Guard of the blockage and upon removal of the blockage.
When work platforms are indicated in the permit for construction, submit work
platform construction plans to the appropriate Coast Guard District for approval. Obtain
approval prior to beginning construction on the platform.
7-8.2 Maintenance of Channel: Where the work includes the excavation of a channel or
other underwater areas to a required section, maintain the section from shoaling or other
encroachment until final acceptance of the project.
7-9 Use of Explosives.
When using explosives for the prosecution of the work, exercise the utmost care not to
endanger life or property, including new work. The Contractor is responsible for all damage
resulting from the use of explosives.
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Store all explosives in a secure manner in compliance with all laws and ordinances, and
clearly mark all such storage places with the words: DANGEROUS - EXPLOSIVES. Place
such storage in the care of a competent watchman. Where no local laws or ordinances apply,
provide storage satisfactory to the Engineer and, in general, not closer than 1,000 feet from the
road or from any building, camping area, or place of human occupancy.
Notify each public utility company having structures in proximity to the site of the work
of the intention to use explosives. Give such notice sufficiently in advance to enable the
companies to take precautionary steps to protect their property from injury.
7-10 Forest Protection.
7-10.1 Compliance with State and Federal Regulations: In carrying out work within or
adjacent to State or National forests or parks, comply with all of the regulations of the State or
Federal authority having jurisdiction, governing the protection of and the carrying out of work in
forests or parks, and observe all sanitary laws and regulations with respect to the performance of
work in these areas. Keep the areas in an orderly condition, dispose of all refuse, and obtain
permits for the construction, installation, and maintenance of any construction camps, living
quarters, stores, warehouses, sanitary facilities, and other structures; all in accordance with the
requirements of the forest or park official.
7-10.2 Prevention and Suppression of Forest Fires: Take all reasonable precautions to
prevent and suppress forest fires. Require employees and subcontractors, both independently and
at the request of forest officials, to do all reasonably within their power to prevent and suppress
forest fires. Assist in preventing and suppressing forest fires, and make every possible effort to
notify a forest official at the earliest possible moment of the location and extent of all fires.
Extinguish the fire if practicable.
7-11 Preservation of Property.
7-11.1 General: Preserve from damage all property which is in the vicinity of or is in
any way affected by the work, the removal or destruction of which is not specified in the plans.
This applies to public and private property, public and private utilities (except as modified by the
provisions of 7-11.6), trees, shrubs, crops, signs, monuments, fences, guardrail, pipe and
underground structures, and public highways (except natural wear and tear of highway resulting
from legitimate use thereof by the Contractor), etc., Whenever the Contractors activities damage
or injure such property, immediately restore it to a condition similar or equal to that existing
before such damage occurred, at no expense to the Department.
Protect existing bridges during the entire construction period from damage caused
by the construction operations or equipment. The Department will not require the Contractor to
provide routine repairs or maintenance for such structures. However, immediately repair, at no
expense to the Department, all damage occasioned by the construction operations. In the event
that the Contractors construction operations result in damage to a bridge requiring repairs, the
Contractor shall make such repairs with any equipment, materials, or labor at the Contractors
disposal prior to continuing Contract work.
Direct special attention to the protection of all geodetic monuments, horizontal or
vertical, located within the limits of construction.
7-11.2 Failure to Restore Damaged Property: In case of failure on the part of the
Contractor to restore such property, bridge, road or street, or to make good such damage or
injury, the Engineer may, upon 48 hours notice, proceed to repair, rebuild, or otherwise restore
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such property, road, or street as may be deemed necessary, and the Department will deduct the
cost thereof from any monies due or which may become due the Contractor under the Contract.
Nothing in this clause prevents the Contractor from receiving proper compensation for the
removal, damage, or replacement of any public or private property, not shown on the plans, that
is made necessary by alteration of grade or alignment. The Engineer will authorize such work,
provided that the Contractor, or his employees or agents, have not, through their own fault,
damaged such property.
7-11.3 Contractors Use of Streets and Roads:
7-11.3.1 On Systems Other than the State Highway System: When hauling
materials or equipment to the project over roads and bridges on the State park road system,
county road system, or city street system, and such use causes damage, immediately, at no
expense to the Department, repair such road or bridge to as good a condition as before the
hauling began.
The Department may modify the above requirement in accordance with
any agreement the Contractor might make with the governmental unit having jurisdiction over a
particular road or bridge, provided that the Contractor submits written evidence of such
agreement to the Engineer.
7-11.3.2 On the State Highway System: The Department is responsible for the
repair of any damage that hauling materials to the site causes to roads outside the limits of the
project, that are either on the State highway system (roads under the jurisdiction of the
Department) or specifically designated in the plans as haul roads from Department-furnished
material pits, except in the event damage is due to failure to comply with 7-7.2. The Contractor
is responsible for all damages to any road or bridge caused by the Contractor's failure to comply
with 7-7.2.
7-11.3.3 Within the Limits of a Construction Project: The Department will not
allow the operation of equipment or hauling units of such weight as to cause damage to
previously constructed elements of the project, including but not necessarily limited to bridges,
drainage structures, base course, and pavement. Do not operate hauling units or equipment
loaded in excess of the maximum weights specified in 7-7.2 on existing pavements that are to
remain in place (including pavement being resurfaced), cement-treated subgrades and bases,
concrete pavement, any course of asphalt pavement, and bridges. The Engineer may allow
exceptions to these weight restrictions for movement of necessary equipment to and from its
worksite, for hauling of offsite fabricated components to be incorporated into the project, and for
crossings as specified in 7-7.3.
7-11.4 Traffic Signs, Signal Equipment, Highway Lighting and Guardrail: Protect all
existing roadside signs, signal equipment, highway lighting and guardrail, for which permanent
removal is not indicated, against damage or displacement. Whenever such signs, signal
equipment, highway lighting or guardrail lie within the limits of construction, or wherever so
directed by the Engineer due to urgency of construction operations, take up and properly store
the existing roadside signs, signal equipment, highway lighting and guardrail and subsequently
reset them at their original locations or, in the case of widened pavement or roadbed, at locations
designated by the Engineer.
If the Department determines that damage to such existing traffic signs, signal
equipment, highway lighting or guardrail is caused by a third party(ies), and is not otherwise due
to any fault or activities of the Contractor, the Department will, with the exception of any
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damage resulting from vandalism, compensate the Contractor for the costs associated with the
repairs. Repair damage caused by vandalism at no expense to the Department.
Payment for repairs will be in accordance with 4-3.4.
7-11.5 Operations Within Railroad Right-of-Way:
7-11.5.1 Notification to the Railroad Company: Notify the superintendent of
the railroad company, as shown on the plans, and the Engineer at least 72 hours before beginning
any operation within the limits of the railroad right-of-way; any operation requiring movement
of employees, trucks, or other equipment across the tracks of the railroad company at other than
an established public crossing; and any other work that may affect railroad operations or
property.
7-11.5.2 Contractors Responsibilities: Comply with whatever requirements an
authorized representative of the railroad company deems necessary in order to safeguard the
railroads property and operations. The Contractor is responsible for all damages, delays, or
injuries and all suits, actions, or claims brought on account of damages or injuries resulting from
the Contractors operations within or adjacent to railroad company right-of-way.
7-11.5.3 Watchman or Flagging Services: The railroad company will furnish
protective services (i.e., watchman or flagging services) to ensure the safety of railroad
operations during certain periods of the project. The Department will reimburse the railroad
company for the cost thereof. Schedule work that affects railroad operations so as to minimize
the need for protective services by the railroad company.
7-11.6 Utilities:
7-11.6.1 Arrangements for Protection or Adjustment: Do not commence work
at points where the construction operations are adjacent to utility facilities until all necessary
arrangements have been made for removal, temporary removal, relocation, de-energizing,
deactivation or adjustment with the utility facilities owner to protect against damage that might
result in expense, loss, disruption of service, or other undue inconvenience to the public or to the
owners. The Contractor is solely and directly responsible to the owners and operators of such
properties for all damages, injuries, expenses, losses, inconveniences, or delays caused by the
Contractors operations.
Do not request utility removal, temporary removal, relocation, deenergizing, deactivation, or adjustment when work can be accomplished within the utility work
schedules. In the event that removal, temporary removal, relocation, de-energizing, deactivation,
or adjustment of a utility or a particular sequence of timing in the relocation of a utility is
necessary and has not been addressed in a utility work schedule, the Engineer will determine the
necessity for any such utility work. Coordinate such work as to cause the least impediment to the
overall construction operations and utility service. The Department is not responsible for utility
removal, temporary removal, relocation, de-energizing, deactivation, or adjustment work where
such work is determined not necessary by the Engineer or done solely for the benefit or
convenience of the utility owner or its contractor, or the Contractor.
7-11.6.2 Cooperation with Utility Owners: Cooperate with the owners of all
underground or overhead utility lines in their removal and rearrangement operations in order that
these operations may progress in a reasonable manner, that duplication or rearrangement work
may be reduced to a minimum, and that services rendered by the utility owners will not be
unnecessarily interrupted.
In the event of interruption of water or other utility services as a result of
accidental breakage, exposure, or lack of support, promptly notify the proper authority and
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cooperate with the authority in the prompt restoration of service. If water service is interrupted
and the Contractor is performing the repair work, the Contractor shall work continuously until
the service is restored. Do not begin work around fire hydrants until the local fire authority has
approved provisions for continued service.
7-11.6.3 Utility Adjustments: Certain utility adjustments and reconstruction
work may be underway during the progress of the Contract. Cooperate with the various utility
construction crews who are maintaining utility service. Exercise due caution when working
adjacent to relocated utilities. The Contractor shall repair all damage to the relocated utilities
resulting from his operations at no expense to the Department. The requirements of 7-11.1 and
7-11.6.2 outline the Contractors responsibility for of protecting utility facilities. The
Department will include in the Contract the utility authorities who are scheduled to perform
utility work on the project.
7-11.6.4 Weekly Meetings: Conduct weekly meetings on the job site with all the
affected utility companies and the Engineer in attendance to coordinate project construction and
utility relocation. Submit a list of all attendees one week in advance to the Engineer for approval.
Provide the approved Work Progress Schedule and Work Plan for the
project, as specified in 8-3.2, to document the schedule and plan for road construction and utility
adjustments.
When utility relocations no longer affect construction activities, the
Contractor may discontinue the meetings with the Engineers approval.
7-12 Responsibility for Damages, Claims, etc.
7-12.1 Contractor to Provide Indemnification: The Contractor shall indemnify and
hold harmless the Department, its officers and employees from liabilities, damages, losses and
costs, including, but not limited to, reasonable attorneys fees, to the extent caused by the
negligence, recklessness, or intentional wrongful misconduct of the Contractor and persons
employed or utilized by the Contractor in the performance of the construction Contract.
It is specifically agreed between the parties executing this Contract that it is not
intended by any of the provisions of any part of the Contract to create in the public or any
member thereof, a third party beneficiary hereunder, or to authorize anyone not a party to this
Contract to maintain a suit for personal injuries or property damage pursuant to the terms or
provisions of this Contract.
7-12.2 Guaranty of Payment for Claims: The Contractor guaranties the payment of all
just claims for materials, supplies, tools, or labor and other just claims against him or any
subcontractor, in connection with the Contract. The Departments final acceptance and payment
does not release the Contractors bond until all such claims are paid or released.
7-13 Insurance.
7-13.1 Workers Compensation Insurance: Provide Workers Compensation Insurance
in accordance with the laws of the State of Florida and in amounts sufficient to secure the
benefits of the Florida Workers Compensation Law for all employees. If subletting any of the
work, ensure that the employees of the subcontractors are covered by similar insurance. Ensure
that any equipment rental agreements that include operators who are employees of independent
Contractors, sole proprietorships or partners are covered by similar insurance. The Engineer will
accept equivalent approved protection in lieu of insurance.
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7-13.2 Contractors Public Liability and Property Damages Liability Insurance:
Furnish evidence to the Department that, with respect to the operations performed, regular
Contractors Public Liability Insurance providing for a limit of not less than $1,000,000 for all
damages arising out of bodily injuries to, or death of, one person and, subject to that limit for
each person, a total limit of $5,000,000 for all damages arising out of bodily injuries to, or death
of, two or more persons in any one occurrence; and regular Contractors Property Damage
Liability Insurance providing for a limit of not less than $50,000 for all damages arising out of
injury to, or destruction of, property in any one occurrence and, subject to that limit per
occurrence, a total (or aggregate) limit of $100,000 for all damages arising out of injury to, or
destruction of, property during the policy period is carried.
Cause the Department to be an additional insured party on the Contractors Public
Liability and Property Damages Liability Insurance policies that insure the Contractor for the
described work that it performs under the Contract.
7-13.3 Contractors Protective Public Liability and Property Damage Liability
Insurance: Furnish evidence to the Department that, with respect to the operations performed by
subcontractors, regular Contractors Protective Public Liability Insurance providing for a limit of
not less than $1,000,000 for all damages arising out of bodily injuries to, or death of, one person
and, subject to that limit for each person, a total limit of $5,000,000 for all damages arising out
of bodily injuries to, or death of, two or more persons in any one occurrence; and regular
Contractors Protective Property Damage Liability Insurance providing for a limit of not less
than $50,000 for all damages arising out of injury to, or destruction of, property in any one
occurrence and, subject to that limit per occurrence, a total (or aggregate) limit of $100,000 for
all damages arising out of injury to, or destruction of, property during the policy period is
carried.
Cause the Department to be an additional insured party on the Contractors
Protective Public Liability and Property Damage Liability Insurance policies that insure the
Contractor for the described work that it performs under the Contract.
7-13.4 Insurance Required for Construction at Railroads:
7-13.4.1 General: In addition to any other forms of insurance or bonds required
under the terms of the Contract, when the Contract includes the construction of a railroad grade
crossing, overpass, or underpass structure, or a railroad crossing signal installation, or any other
work or operations by the Contractor within the limits of the railroad right-of-way, including any
encroachments thereon from work or operations in the vicinity of the railroad right-of-way,
provide insurance of the types set forth below and in amounts not less than specified herein.
7-13.4.2 Railroads Protective Public Liability and Property Damage
Liability Insurance: Furnish the Department with an original insurance policy that, with respect
to the operations performed, will provide for and in behalf of the railroad company regular
liability insurance providing coverage for bodily injury, death, and property damage limited to a
combined single limit of $2,000,000 per occurrence with an aggregate limit of $6,000,000 for the
term of the policy.
7-13.5 Insurance for Protection of Utility Owners: When the work under the Contract
involves work on or in the vicinity of utility-owned property or facilities, furnish the Department
with evidence that, with respect to the operations performed, General Comprehensive Liability
Insurance or its equivalent providing for a limit of not less than $1,000,000 for bodily injury or
death to person(s) per occurrence and $300,000 property damage each occurrence is carried. The
Department and Utility Company are to be Additional Named Insureds, and the policy will be
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primary to any coverage maintained by the Department or Company. Do not make any material
change or cancellation to the policy without providing the Department with ten days prior
written notice.
7-13.6 Submission and Approval of Policies; Termination: Furnish two copies of each
required policy to the Engineer at the Preconstruction Conference.
Provide all insurance policies in such form and with insurers that are acceptable
to the Department, and to the railroad company or the utility owner. Keep insurance in behalf of
a railroad company in force until the Department accepts that the Contractor has satisfactorily
completed all work required under the Contract. Keep insurance in behalf of a utility owner in
force, in the full amount specified herein, until 30 days after the Department accepts the work.
7-14 Contractors Responsibility for Work.
Until the Departments acceptance of the work, take charge and custody of the work, and
take every necessary precaution against injury or damage to the work by the action of the
elements or from any other cause whatsoever, arising either from the execution or from the
nonexecution of the work. Rebuild, repair, restore, and make good, without additional expense to
the Department, all injury or damage to any portion of the work occasioned by any of the above
causes before its completion and acceptance, except that in case of extensive or catastrophic
damage, the Department may, at its discretion, reimburse the Contractor for the repair of such
damage due to unforeseeable causes beyond the control of and without the fault or negligence of
the Contractor, including but not restricted to Acts of God, of the public enemy, or of
governmental authorities.
7-15 Opening Sections of Highway to Traffic.
Whenever any bridge or section of roadway is in acceptable condition for travel, the
Engineer may direct the Contractor to open it to traffic. The Departments direction to open a
bridge or roadway does not constitute an acceptance of the bridge or roadway, or any part
thereof, or waive any Contract provisions. Perform all necessary repairs or renewals, on any
section of the roadway or bridge thus opened to traffic under instructions from the Engineer, due
to defective material or work or to any cause other than ordinary wear and tear, pending
completion and the Engineers acceptance of the roadway or bridge, or other work, at no expense
to the Department.
7-16 Wage Rates for Federal-Aid Projects.
For all projects that include Federal-aid participation, the Special Provisions contain
requirements with regard to payment of predetermined minimum wages. Predetermined Wage
Rate Decisions (U.S. Department of Labor provided Wage Rate Tables) exist for Heavy,
Highway, and Building Construction Projects.
7-17 Supplemental Agreements.
Section 337.11 of the Florida Statutes as amended, which prescribe certain limitations on
the use of supplemental agreements, are a part of the Contract.
7-18 Scales for Weighing Materials.
7-18.1 Applicable Regulations: When determining the weight of material for payment,
use scales meeting the requirements of Chapter 531 of Florida Statutes, pertaining to
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specifications, tolerances, and regulations, as administered by the Bureau of Weights and
Measures of the Florida Department of Agriculture.
7-18.2 Base for Scales: Place such scales on a substantial horizontal base to provide
adequate support and rigidity and to maintain the level of the scales.
7-18.3 Protection and Maintenance: Maintain all scale parts in proper condition as to
level and vertical alignment, and fully protect them against contamination by dust, dirt, and other
matter that might affect their operation.
7-19 Source of Forest Products.
As required by Section 255.20 of the Florida Statutes, where price and quality are equal,
and when available, use only timber, timber piling, or other forest products that are produced and
manufactured in the State of Florida. This provision does not apply to Federal-aid projects.
7-20 Regulations of Air Pollution from Asphalt Plants.
7-20.1 General: Perform all work in accordance with all Federal, State, and local laws
and regulations regarding air pollution and burning. In particular, pay attention to Chapters 17-2
and 17-5 of the Rules and Regulations of the Department of Environmental Protection, and to
any part of the State Implementation Plan applicable to the project. See also 110-9.2 regarding
burning of debris.
7-20.2 Dust Control: Ensure that excessive dust is not transported beyond the limits of
construction in populated areas. The Contractor may control dust for embankments or other
cleared or unsurfaced areas by applying water or calcium chloride, as directed by the Engineer.
Use calcium chloride in accordance with 102-5. When included in the plans, install mulch, seed,
sod, or temporary paving as early as practical. Control dust during the storage and handling of
dusty materials by wetting, covering, or other means as approved by the Engineer.
7-20.3 Asphalt Material: Use only emulsified asphalt, unless otherwise stated in the
plans and allowed by Chapter 17-2 of the Rules and Regulations of the Department of
Environmental Protection. Store and handle asphalt materials and components so as to minimize
unnecessary release of hydrocarbon vapors.
7-20.4 Asphalt Plants: Operate and maintain asphalt plants in accordance with
Chapter 17-2 of the Rules and Regulations of the Department of Environmental Protection.
Provide the plant site with a valid permit as required under Chapter 17-2 prior to start of work.
7-21 Dredging and Filling.
Section 370.033 of the Florida Statutes, requires that all persons, who engage in certain
dredge or fill activities in the State of Florida, obtain a certificate of registration from the Florida
Department of Environmental Protection, Tallahassee, Florida 32301, and that they keep
accurate logs and records of all such activities for the protection and conservation of the natural
resources. Obtain details as to the application of this law from the Department of Environmental
Protection.
7-22 Available Funds.
For Contracts in excess of $25,000 or a term for more than one year, comply with the
following provisions of Chapter 339 of the Florida Statutes:
The Department will not, during any fiscal year, expend money, incur any liability, or
enter into any Contract that, by its terms, involves the expenditures of money in excess of the
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amounts budgeted as available for expenditure during such fiscal year. If the Department enters
into such a Contract, verbal or written, in violation of this subsection, such Contract is null and
void, and the Department will not make any payments thereon. The Department will require a
statement from the Departments comptroller that funds are available prior to entering into any
such Contract or other binding commitment of funds. Nothing herein contained prevents the
Department from executing Contracts for a period exceeding one year, but the Department will
make such Contracts executory only for the value of the services to be rendered or agreed to be
paid for in succeeding fiscal years. The Department will incorporate this paragraph verbatim in
all Contracts in excess of $25,000 or having a term for more than one year.
7-23 Contractors Motor Vehicle Registration.
The Contractor shall provide the Department with proof that all motor vehicles operated
or caused to be operated by such Contractor are registered in compliance with Chapter 320 of the
Florida Statutes. Submit such proof of registration in the form of a notarized affidavit to the
Department.
The Department will not make payment to the Contractor until the required proof of
registration is on file with the Department.
If the Contractor fails to register any motor vehicle that he operates in Florida, pursuant
to Chapter 320 of the Florida Statutes, the Department may disqualify the Contractor from
bidding, or the Department may suspend and revoke the Contractors certificates of qualification.
7-24 Disadvantaged Business Enterprise Program.
7-24.1 Disadvantaged Business Enterprise Affirmative Action Plan: Prior to award of
the Contract, have an approved Disadvantaged Business Enterprise (DBE) Affirmative Action
Program Plan filed with the Equal Opportunity Office. Update and resubmit the plan every three
years. No Contract will be awarded until the Department approves the Plan. The DBE
Affirmative Action Program Plan is incorporated into and made a part of the Contract.
7-24.2 Required Contract and Subcontract DBE Assurance Language: In accordance
with 49 CFR 26.13 (b), the Contract FDOT signs with the Contractor (and each subcontract the
prime contractor signs with a subcontractor) must include the following assurance: The
Contractor, sub-recipient or subcontractor shall not discriminate on the basis of race, color,
national origin, or sex in the performance of this contract. The Contractor shall carry out
applicable requirements of 49 CFR Part 26 in the award and administration of DOT-assisted
Contracts. Failure by the Contractor to carry out these requirements is a material breach of this
Contract, which may result in the termination of this Contract or such other remedy as the
recipient deems appropriate.
7-24.3 Plan Requirements: Include the following in the DBE Affirmative Action
Program Plan:
(a) A policy statement, signed by an authorized representative (president, chief
executive officer, or chairman of the contractor), expressing a commitment to use DBEs in all
aspects of contracting to the maximum extent feasible, outlining the various levels of
responsibility, and stating the objectives of the program. Circulate the policy statement
throughout the Contractors organization.
(b) The designation of a Liaison Officer within the Contractors organization, as
well as support staff, necessary and proper to administer the program, and a description of the
authority, responsibility, and duties of the Liaison Officer and support staff. The Liaison Officer
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and staff are responsible for developing, managing, and implementing the program on a day-today basis for carrying out technical assistance activities for DBEs and for disseminating
information on available business opportunities so that DBEs are provided an equitable
opportunity to participate in Contracts let by the Department.
(c) Utilization of techniques to facilitate DBE participation in contracting
activities which include, but are not limited to:
1. Soliciting price quotations and arranging a time for the review of plans,
quantities, specifications, and delivery schedules, and for the preparation and presentation of
quotations.
2. Providing assistance to DBEs in overcoming barriers such as the
inability to obtain bonding, financing, or technical assistance.
3. Carrying out information and communication programs or workshops
on contracting procedures and specific contracting opportunities in a timely manner, with such
programs being bilingual where appropriate.
4. Encouraging eligible DBEs to apply for certification with the
Department.
5. Contacting Minority Contractor Associations and city and county
agencies with programs for disadvantaged individuals for assistance in recruiting and
encouraging eligible DBE contractors to apply for certification with the Department.
7-24.4 DBE Records and Reports: Submit the Anticipated DBE Participation Statement
at or before the Pre-Construction Conference. Report monthly, through the Equal Opportunity
Reporting System on the Departments Website, actual payments (including retainage) made to
DBEs for work performed with their own workforce and equipment in the area in which they are
certified. Report payments made to all DBE and Minority Business Enterprise (MBE)
subcontractors and DBE and MBE construction material and major suppliers. The Equal
Opportunity Office will provide instructions on accessing this system. Develop a record keeping
system to monitor DBE affirmative action efforts which include the following:
(a) the procedures adopted to comply with these Specifications;
(b) the number of subordinated Contracts on Department projects awarded to
DBEs;
(c) the dollar value of the Contracts awarded to DBEs;
(d) the percentage of the dollar value of all subordinated Contracts awarded to
DBEs as a percentage of the total Contract amount;
(e) a description of the general categories of Contracts awarded to DBEs; and
(f) the specific efforts employed to identify and award Contracts to DBEs.
Upon request, provide the records to the Department for review.
Maintain all such records for a period of five years following acceptance of final
payment and have them available for inspection by the Department and the Federal Highway
Administration.
7-24.5 Counting DBE Participation and Commercially Useful Functions:
49 CFR Part 26.55 specifies when DBE credit shall be awarded for work performed by a DBE.
DBE credit can only be awarded for work actually performed by DBEs themselves for the types
of work for which they are certified. On the Anticipated DBE Participation Statement only
include the dollars that a DBE is expected to earn for work they perform with their own
workforce and equipment. Submit a revised Anticipated DBE Participation Statement to reflect
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changes to the initial Anticipated DBE Participation Statement within 14 business days from the
date of the change.
When a DBE participates in a contract, the value of the work is determined in
accordance with 49 CFR Part 26.55, for example:
(a) The Department will count only the value of the work performed by
the DBE toward DBE goals. The entire amount of the contract that is performed by the DBEs
own forces (including the cost of supplies, equipment and materials obtained by the DBE for the
contract work) will be counted as DBE credit.
(b)The Department will count the entire amount of fees or commissions
charged by the DBE firm for providing a bona fide service, such as professional, technical,
consultant, or managerial services or for providing bonds or insurance specifically required for
the performance of a Department-assisted contract, toward DBE goals, provided that the
Department determines the fees to be reasonable and not excessive as compared with fees
customarily followed for similar services.
(c) When the DBE subcontracts part of the work of its contract to another
firm, the Department will count the value of the subcontracted work only if the DBEs
subcontractor is itself a DBE. Work that a DBE subcontracts to a non-DBE firm does not count
toward DBE goals.
(d) When a DBE performs as a participant in a joint venture, the
Department will count the portion of the dollar value of the contract equal to the distinct, clearly
defined portion of the work the DBE performs with its own forces toward DBE goals.
(e) The Contractors shall ensure that only expenditures to DBEs that
perform a commercially useful function in the work of a contract may be counted toward the
voluntary DBE goal.
(f) A DBE performs a commercially useful function when it is responsible
for execution of the work of the contract and is carrying out its responsibilities by actually
performing, managing, and supervising the work involved. To perform a commercially useful
function, the DBE must also be responsible, with respect to materials and supplies used on the
contract, for negotiating price, determining quality and quantity, ordering the material, and
installing (where applicable) and paying for the material itself.
(g) To determine whether a DBE is performing a commercially useful
function, the Department will evaluate the amount of work subcontracted, industry practices,
whether the amount the firm is to be paid under the contract is commensurate with the work it is
actually performing and the DBE credit claimed for its performance of the work, and other
relevant factors.
(h) A DBE does not perform a commercially useful function if its role is
limited to that of an extra participant in a transaction, contract, or project through which funds
are passed in order to obtain the appearance of DBE participation.
(i) If a DBE does not perform or exercise responsibility for at least 30% of
the total cost of its contract with its own workforce, or if the DBE subcontracts a greater portion
of the work of a contract than would be expected on the basis of normal industry practice for the
type of work involved, the DBE has not performed a commercially useful function.
7-24.6 Prompt Payments: Meet the requirements of 9-5 for payments to all DBE
subcontractors.
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7-25 On-The-Job Training Requirements.
As part of the Contractors equal employment opportunity affirmative action program,
training shall be provided as follows:
The Contractor shall provide on-the-job training aimed at developing full
journeymen in the type(s) of trade or job classification(s) involved in the work. In the event the
Contractor subcontracts a portion of the contract work, he/she shall determine how many, if any,
of the trainees are to be trained by the subcontractor provided, that the Contractor shall retain the
primary responsibility for meeting the training requirements imposed by this Section. The
Contractor shall apply the requirements of this Section to such subcontract
The number of trainees will be estimated on the number of calendar days of the
contract, the dollar value, and the scope of work to be performed. The trainee goal will be
finalized at a Post-Preconstruction Trainee Evaluation Meeting and the goal will be distributed
among the work classifications based on the following criteria:
1) Determine the number of trainees on Federal Aid Contract:
(a) No trainees will be required for contracts with a contract time
allowance of less than 225 calendar days.
(b) If the contract time allowance is 225 calendar days or more, the
number of trainees shall be established in accordance with the following chart:
Estimated Contract Amount
Under $1,000,000
Over $1,000,000 to $4,000,000
Over $4,000,000 to $6,000,000
Over $6,000,000 to $12,000,000
Over $12,000,000 to $18,000,000
Over $18,000,000 to $24,000,000
Over $24,000,000 to $31,000,000
Over $31,000,000 to $37,000,000
Over $37,000,000 to $43,000,000
Over $43,000,000 to $49,000,000
Over $49,000,000 to $55,000,000
Over $55,000,000 to $62,000,000
Over $62,000,000 to $68,000,000
Over $68,000,000 to $74,000,000
Over $74,000,000 to $81,000,000
Over $81,000,000 to $87,000,000
Over $87,000,000 to $93,000,000
Over $93,000,000 to $99,000,000
Over $99,000,000 to $105,000,000
Over $105,000,000 to $112,000,000
Over $112,000,000 to $118,000,000
Over $118,000,000 to $124,000,000
Over $124,000,000 to $130,000,000
Over $130,000,000 to *
*One additional trainee per $6,000,000 of estimated Construction Contract amount over
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Trainees Required
0
2
3
5
7
9
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Estimated Contract Amount
Trainees Required
$130,000,000
Further, if the Contractor or subcontractor requests to utilize banked trainees as discussed
later in this Section, a Banking Certificate will be validated at this meeting allowing credit to the
Contractor for previously banked trainees. Banked credits of prime Contractors working as
Subcontractors may be accepted for credit. The Contractors Project Manager, the Construction
Project Engineer and the Departments District Contract Compliance Manager will attend this
meeting. Within ten days after the Post-Preconstruction Training Evaluation Meeting, the
Contractor shall submit to the Department for approval an On-The-Job Training Schedule
indicating the number of trainees to be trained in each selected classification and the portion of
the contract time during which training of each trainee is to take place. This schedule may be
subject to change if the following occur:
1. When a start date on the approved On-The-Job Training Schedule has been
missed by 14 or more days;
2. When there is a change(s) in previously approved classifications;
3. When replacement trainees are added due to voluntary or involuntary
termination
The revised schedule will be resubmitted to and approved by the Departments District
Contract Compliance Manager.
The following criteria will be used in determining whether or not the Contractor has
complied with this Section as it relates to the number of trainees to be trained:
1. Full credit will be allowed for each trainee that is both enrolled and
satisfactorily completes training on this Contract. Credit for trainees, over the established
number for this Contract, will be carried in a bank for the Contractor and credit will be
allowed for those surplus trainees in subsequent, applicable projects. A banked trainee is
described as an employee who has been trained on a project, over and above the established goal,
and for which the Contractor desires to preserve credit for utilization on a subsequent project.
2. Full credit will be allowed for each trainee that has been previously enrolled in
the Departments approved training program on another contract and continues training in the
same job classification for a significant period and completes his/her training on this Contract.
3. Full credit will be allowed for each trainee who, due to the amount of work
available in his/her classification, is given the greatest practical amount of training on the
contract regardless of whether or not the trainee completes training.
4. Full credit will be allowed for any training position indicated in the approved
On-The-Job Training Schedule, if the Contractor can demonstrate that he/she has made his/her a
good faith effort to provide training in that classification.
5. No credit will be allowed for a trainee whose employment by the Contractor is
involuntarily terminated unless the Contractor can clearly demonstrate good cause for this
action.
The Contractor shall, as far as is practical, comply with the time frames established in the
approved On-The-Job Training Schedule. When this proves to be impractical, a revised schedule
shall be submitted and approved as provided above.
Training and upgrading of minorities, women and economically disadvantaged persons
toward journeyman status is a primary objective of this Section. Accordingly, the Contractor
shall make every effort to enroll minority trainees and women (e.g., by conducting systematic
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and direct recruitment through public and private sources likely to yield minority and women
trainees) to the extent such persons are available within a reasonable area of recruitment. If a
non-minority male is enrolled into On-The-Job Training, the On-The-Job Training Notification
of Personnel Action Form notifying the District Contract Compliance Manager of such action
shall be accompanied by a disadvantaged certification or a justification for such action
acceptable to the Departments District Contract Compliance Manager. The Contractor will be
given an opportunity and will be responsible for demonstrating the steps that he has taken in
pursuance thereof, prior to a determination as to whether the Contractor is in compliance with
this Section. This training is not intended, and shall not be used, to discriminate against any
applicant for training, whether a minority, woman or disadvantaged person.
No employee shall be employed as a trainee in any classification in which he/she has
successfully completed a training course leading to journeyman status, has been employed as a
journeyman, or has had extensive experience in the classification being considered for training.
The Contractor shall satisfy this requirement by including appropriate questions in the employee
application or by other suitable means. Regardless of the method used, the Contractors records
should document the findings in each case.
The minimum length and type of training for each classification will be as established at
the Post-Preconstruction Trainee Evaluation Meeting and approved by the Department.
Graduation to journeyman status will be based upon satisfactory completion of a Proficiency
Demonstration set up at the completion of training and established for the specific training
classification, completion of the minimum hours in a training classification range, and the
employers satisfaction that the trainee does meet journeyman status in the classification of
training. Upon reaching journeyman status, the following documentation must be forwarded to
the District Contract Compliance Office:
Trainee Enrollment and Personnel Action Form
Proficiency Demonstration Verification Form indicating completion of each
standard established for the classification signed by representatives of both the Contractor and
the Department; and,
A letter stating that the trainee has sufficiently progressed in the craft and is being
promoted to journeyman status.
The Department and the Contractor shall establish a program that is tied to the scope of
the work in the project and the length of operations providing it is reasonably calculated to meet
the equal employment opportunity obligations of the Contractor and to qualify the average
trainee for journeyman status in the classifications concerned, by at least, the minimum hours
prescribed for a training classification. Furthermore, apprenticeship programs registered with the
U.S. Department of Labor, Bureau of Apprenticeship and Training, or with a State
apprenticeship agency recognized by the Bureau and training programs approved but not
necessarily sponsored by the U.S. Department of Labor, Manpower Administration, Bureau of
Apprenticeship and Training shall also be considered acceptable provided it is being
administered in a manner consistent with the equal employment obligations of Federal Aid
highway construction contract. Approval or acceptance of a training schedule shall be obtained
from the Department prior to commencing work on the classifications covered by the program.
A voluntary On-The-Job Training Program is available to a Contractor which has been
awarded a state funded project. Through this program, the Contractor will have the option to
train employees on state funded projects for banked credit as discussed previously in this
provision, to be utilized on subsequent Federal Aid Projects where training is required. Those
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Contractors availing themselves of this opportunity to train personnel on state funded projects
and bank trainee hours for credit shall comply with all training criteria set forth in this Section
for Federal Aid Projects; voluntary banking may be denied by the Department if staff is not
available to monitor compliance with the training criteria.
It is the intention of these provisions that training is to be provided in the construction
crafts rather than clerk-typists or secretarial type positions. Training is permissible in positions
such as office engineers, estimators, etc., where the training is oriented toward construction
applications. Training in the laborer classification may be permitted provided that significant and
meaningful training is provided and approved by the District Contract Compliance Office. Some
offsite training is permissible as long as the training is an integral part of an approved training
program and does not compromise a significant part of the overall training.
When approved in advance by the District Contract Compliance Manager, credit will be
given for training of persons in excess of the number specified herein under the current contract
or a Contractor will be allowed to bank trainees who have successfully completed a training
program and may apply those trainees to a training requirement in subsequent project(s) upon
approval of the Departments District Contract Compliance Manager. This credit will be given
even though the Contractor may receive training program funds from other sources, provided
such other source do not specifically prohibit the Contractor from receiving other form of
compensation. Credit for offsite training indicated above may only be made to the Contractor
where he does one or more of the following and the trainees are concurrently employed on a
Federal Aid Project; contributes to the cost of the training, provides the instruction to the trainee
and pays the trainees wages during the offsite training period.
No credit shall be given to the Contractor if either the failure to provide the required
training, or the failure to hire the trainee as a journeyman for a period ample enough to allow the
employee time to gain experience in the training classification or failure to continue training the
employee time to gain experience in the training classifications is caused by the Contractor and
evidences a lack of good faith on the part of the Contractor in meeting the requirements of this
Section.
The Contractor shall compensate the trainee at no less than the laborer rate established in
the Contract at the onset of training. This compensation rate will be increased to the
journeymans wage for that classification upon graduation from the training program.
The Contractor shall furnish the trainee a copy of the program he will follow in providing
the training. The Contractor shall provide each trainee with a certification showing the type and
length of training satisfactorily completed. The Contractor shall enroll a trainee in one training
classification at a time to completion before the trainee can be enrolled in another classification
on the same project.
The Contractor shall maintain records to document the actual hours each trainee is
engaged in training on work being performed as a part of this Contract.
The Contractor shall submit to the District Contract Compliance Manager a copy of an
On-The-Job Training Notification of Personnel Action form no later than seven days after the
effective date of the action when the following occurs: a trainee is transferred on the project,
transferred from the project to continue training on another contract, completes training, is
upgraded to journeyman status or voluntary terminates or is involuntary terminated from the
project.
The Contractor shall furnish to the District Contract Compliance Manager a copy of a
Monthly Time Report for each trainee. The Monthly Time Report for each month shall be
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submitted no later than the tenth day of the subsequent month. The Monthly Time Report shall
indicate the phases and sub-phases of the number of hours devoted to each.
Highway or Bridge Carpenter Helper, Mechanic Helper, Rodman/Chainman,
Timekeeper, trainees will not be approved for the On-The-Job Training Program.
Painters, Electricians, and Mechanics are identified as crafts under-utilized by minorities.
All training classifications except Laborers are identified as under-utilized by women.
Priority selection should also include those crafts under-utilized and/or void of minorities
and/or women by that particular companys workforce.
If the Contractor does not select a training classification that has been targeted as an
under-utilized craft, and those classifications can be used for the selection of training for this
project, the On-The-Job Training Schedule will not be approved unless written justification for
exceptions is attached.
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SECTION 8
PROSECUTION AND PROGRESS
8-1 Subletting or Assigning of Contracts.
Do not, sell, transfer, assign or otherwise dispose of the Contract or Contracts or any
portion thereof, or of the right, title, or interest therein, without written consent of the
Department. If the Contractor chooses to sublet any portion of the Contract, the Contractor must
provide a written request to sublet work on the Certification of Sublet Work form developed by
the Department for this purpose. With the Engineers acceptance of the request, the Contractor
may sublet a portion of the work, but shall perform with his own organization work amounting to
not less than 40% of the total Contract amount. The Certification of Sublet Work request will be
deemed acceptable by the Department, for purposes of the Departments consent, unless the
Engineer notifies the Contractor within 5 business days of receipt of the Certification of Sublet
Work that the Department is not consenting to the requested subletting.
Include in the total Contract amount the cost of materials and manufactured component
products, and their transportation to the project site. For the purpose of meeting this requirement
the Department will not consider off-site commercial production of materials and manufactured
component products that the Contractor purchases, or their transportation to the project, as
subcontracted work.
If the Contractor sublets a part of a Contract item, the Department will use only the sublet
proportional cost in determining the percentage of subcontracted normal work.
Execute all agreements to sublet work in writing and include all pertinent provisions and
requirements of the Contract. Upon request, furnish the Department with a copy of the
subcontract. The subletting of work does not relieve the Contractor or the surety of their
respective liabilities under the Contract.
The Department recognizes a subcontractor only in the capacity of an employee or agent
of the Contractor, and the Engineer may require the Contractor to remove the subcontractor as in
the case of an employee.
8-2 Work Performed by Equipment-Rental Agreement.
The limitations set forth in 8-1, concerning the amount of work that may be sublet, do not
apply to work performed by equipment-rental agreement. However, for any work proposed to be
performed by equipment-rental agreement, notify the Engineer in writing of such intention
before using the rented equipment, and indicate whether the equipment will be rented on an
operated or non-operated basis. Include with the written notice a listing and description of the
equipment and a description of the particular work to be performed with such equipment. As an
exception to the above requirements, the Department will not require written notice for
equipment to be rented (without operators) from an equipment dealer or from a firm whose
principal business is the renting or leasing of equipment.
The operators of all rented equipment, whether rented on an operated or a non-operated
basis, are subject to all wage rate requirements applicable to the project. When renting
equipment without operators, the Contractor shall carry the operators on his own payroll. For
equipment that is rented on an operated basis, and when required by the Contract or requested by
the Engineer, furnish payrolls from the lessor with the names of the operators shown thereon.
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When a lessor provides rentals of equipment on an operated basis that exceed $10,000,
such lessor is subject to any Equal Employment Opportunity requirements that are applicable to
the project.
8-3 Prosecution of Work.
8-3.1 Compliance with Time Requirements: Commence work in accordance with the
accepted working schedule and provide sufficient labor, materials and equipment to complete the
work within the time limit(s) set forth in the proposal. Should the Contractor fail to furnish
sufficient and suitable equipment, forces, and materials, as necessary to prosecute the work in
accordance with the required schedule, the Engineer may withhold all estimates that are, or may
become due, or suspend the work until the Contractor corrects such deficiencies.
8-3.2 Submission of Working Schedule: Within 21 calendar days after Contract award
or at the preconstruction conference, whichever is earlier, submit to the Engineer a work
progress schedule for the project. The Engineer will review and respond to the Contractor within
15 calendar days of receipt.
Provide a schedule that shows the various activities of work in sufficient detail to
demonstrate a reasonable and workable plan to complete the project within the Contract Time.
Show the order and interdependence of activities and the sequence for accomplishing the work.
Describe all activities in sufficient detail so that the Engineer can readily identify the work and
measure the progress on of each activity. Show each activity with a beginning work date, a
duration, and a monetary value. Include activities for procurement fabrication, and deliver of
materials, plant, and equipment, and review time for shop drawings and submittals. Include
milestone activities when milestones are required by the Contract Documents. In a project with
more than one phase, adequately identify each phase and its completion date, and do not allow
activities to span more than one phase.
Conduct sufficient liaison and provide sufficient information to indicate
coordination activities with utility owners that have facilities within the limits of construction
have been resolved. Incorporate in the schedule any utility adjustment schedules included in the
Contract Documents unless the utility company and the Department mutually agree to changes to
the utility schedules shown in the Contract.
Submit a working plan with the schedule, consisting of a concise written
description of the construction plan.
The Engineer will return inadequate schedules to the Contractor for corrections.
Resubmit a corrected schedule within 15 calendar days from the date of the Engineers return
transmittal.
Submit an updated Work Progress Schedule, for Engineers acceptance, if there is
a significant change in the planned order or duration of an activity. The Engineer will review the
corrected schedule and respond within 7 calendar days of receipt.
By acceptance of the schedule, the Engineer does not endorse or otherwise certify
the validity or accuracy of the activity durations or sequencing of activities. The Engineer will
use the accepted schedule as the baseline against which to measure the progress.
If the Contractor fails to finalize either the initial or a revised schedule in the time
specified, the Engineer will withhold all Contract payments until the Engineer accepts the
schedule.
8-3.3 Beginning Work: Notify the Engineer not less than five days in advance of the
planned start day of work. Upon the receipt of such notice, the Engineer may give the Contractor
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Notice to Proceed and may designate the point or points to start the work. In the Notice to
Proceed, the Engineer may waive the five day advance notice and authorize the Contractor to
begin immediately. Notify the Engineer in writing at least two days in advance of the starting
date of important features of the work. Do not commence work under the Contract until after the
Department has issued the Notice to Proceed. The Department will issue the Notice to Proceed
within 20 calendar days, excluding Saturdays, Sundays and Holidays, after execution of the
Contract.
8-3.4 Provisions for Convenience of Public: Schedule construction operations so as to
minimize any inconvenience to adjacent businesses or residences. Where necessary, the
Engineer may require the Contractor to first construct the work in any areas along the project
where inconveniences caused by construction operations would present a more serious handicap.
In such critical locations, where there is no assurance of continuous effective prosecution of the
work once the construction operations are begun, the Engineer may require the Contractor to
delay removal of the existing (usable) facilities.
8-3.5 Preconstruction Conference: Immediately after awarding the Contract but before
the Contractor begins work, the Engineer will call a preconstruction conference at a place the
Engineer designates to go over the construction aspects of the project. Attend this meeting, along
with the Department and the various utility companies that will be involved with the road
construction.
8-4 Limitations of Operations.
8-4.1 Night Work: During active nighttime operations, furnish, place and maintain
lighting sufficient to permit proper workmanship and inspection. Use lighting with 5 ft-cd
minimum intensity. Arrange the lighting to prevent interference with traffic or produce undue
glare to property owners. Operate such lighting only during active nighttime construction
activities. Provide a light meter to demonstrate that the minimum light intensity is being
maintained.
Lighting may be accomplished by the use of portable floodlights, standard
equipment lights, existing street lights, temporary street lights, or other lighting methods
approved by the Engineer.
Submit a lighting plan at the Preconstruction Conference for review and
acceptance by the Engineer. Submit the plan on standard size plan sheets (not larger than
24 by 36 inch), and on a scale of either 100 or 50 feet to 1 inch. Do not start night work prior to
the Engineers acceptance of the lighting plan.
During active nighttime operations, furnish, place and maintain variable message
signs to alert approaching motorists of lighted construction zones ahead. Operate the variable
message signs only during active construction activities.
Include compensation for lighting for night work in the Contract prices for the
various items of the Contract. Take ownership of all lighting equipment for night work.
8-4.2 Sequence of Operations: Do not open up work to the prejudice of work already
started. The Engineer may require the Contractor to finish a section on which work is in progress
before starting work on any additional section.
8-4.3 Interference with Traffic: At all times conduct the work in such manner and in
such sequence as to ensure the least practicable interference with traffic. Operate all vehicles and
other equipment safely and without hindrance to the traveling public. Park all private vehicles
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outside the clear zone. Place materials stored along the roadway so as to cause no obstruction to
the traveling public as possible.
Where existing pavement is to be widened and stabilizing is not required, prevent
any open trench from remaining after working hours by scheduling operations to place the full
thickness of widened base by the end of each day. Do not construct widening strips
simultaneously on both sides of the road, except where separated by a distance of at least
1/4 mile along the road and where either the work of excavation has not been started or the base
has been completed.
8-4.4 Coordination with other Contractors: Sequence the work and dispose of
materials so as not to interfere with the operations of other Contractors engaged upon adjacent
work; join the work to that of others in a proper manner, in accordance with the spirit of the
Contract Documents; and perform the work in the proper sequence in relation to that of other
contractors; all as may be directed by the Engineer.
Each contractor is responsible for any damage done by him or his agents to the
work performed by another contractor.
8-4.5 Drainage: Conduct the operations and maintain the work in such condition to
provide adequate drainage at all times. Do not obstruct existing functioning storm sewers,
gutters, ditches, and other run-off facilities.
8-4.6 Fire Hydrants: Keep fire hydrants on or adjacent to the highway accessible to fire
apparatus at all times, and do not place any material or obstruction within 15 feet of any fire
hydrant.
8-4.7 Protection of Structures: Do not operate heavy equipment close enough to pipe
headwalls or other structures to cause their displacement.
8-4.8 Fencing: Erect permanent fence as a first order of business on all projects that
include fencing where the Engineer determines that the fencing is necessary to maintain the
security of livestock on adjacent property, or for protection of pedestrians who are likely to gain
access to the project from adjacent property.
8-4.9 Contaminated Materials: When the construction operations encounter or expose
any abnormal condition that may indicate the presence of a contaminated material, discontinue
such operations in the vicinity of the abnormal condition and notify the Engineer immediately.
Be alert for the presence of tanks or barrels; discolored or stained earth, metal, wood, ground
water; visible fumes; abnormal odors; excessively hot earth; smoke; or other conditions that
appear abnormal as possible indicators of the presence of contaminated materials. Treat these
conditions with extraordinary caution.
Make every effort to minimize the spread of any contaminated materials into
uncontaminated areas.
Do not resume the construction operations in the vicinity of the abnormal
conditions until so directed by the Engineer.
Dispose of the contaminated material in accordance with the requirements and
regulations of any Local, State, or Federal agency having jurisdiction. Where the Contractor
performs work necessary to dispose of contaminated material, and the Contract does not include
pay items for disposal, the Department will pay for this work as provided in 4-4.
The Department may agree to hold harmless and indemnify the Contractor for
damages when the Contractor discovers or encounters contaminated materials or pollutants
during the performance of services for the Department when the presence of such materials or
pollutants were unknown or not reasonably discoverable. Such indemnification agreements are
82
only effective if the Contractor immediately stops work and notifies the Department of the
contaminated material or pollutant problem.
Such indemnification agreements are not valid for damages resulting from the
Contractors willful, wanton, or intentional conduct or the operations of Contaminated and
Hazardous Material Contractors.
8-5 Qualifications of Contractors Personnel.
Provide competent, careful, and reliable superintendents, foremen, and workmen. Provide
workmen with sufficient skill and experience to properly perform the work assigned to them.
Provide workmen engaged on special work, or skilled work, such as bituminous courses or
mixtures, concrete bases, pavements, or structures, or in any trade, with sufficient experience in
such work to perform it properly and satisfactorily and to operate the equipment involved.
Provide workmen that shall make due and proper effort to execute the work in the manner
prescribed in the Contract Documents, or the Engineer may take action as prescribed below.
It is prohibited as a conflict of interest for a Contractor to subcontract with a Consultant
to perform Contractor Quality Control when the Consultant is under contract with the
Department to perform work on any project described in the Contractors Contract with the
Department. Prior to approving a Consultant for Contractor Quality Control, the Contractor shall
submit to the Department a Certificate from the proposed Consultant certifying that no conflict
of interest exists.
Whenever the Engineer determines that any person employed by the Contractor is
incompetent, unfaithful, intemperate, disorderly, or insubordinate, the Engineer will provide
written notice and the Contractor shall discharge the person from the work. Do not employ any
discharged person on the project without the written consent of the Engineer. If the Contractor
fails to remove such person or persons, the Engineer may withhold all estimates that are or may
become due, or suspend the work until the Contractor complies with such orders. Protect,
defend, indemnify, and hold the Department, its agents, officials, and employees harmless from
all claims, actions, or suite arising from such removal, discharge, or suspension of employees.
8-6 Temporary Suspension of Contractors Operations.
8-6.1 Authority to Suspend Contractors Operations: The Engineer has the authority
to suspend the Contractors operations, wholly or in part. The Engineer will order such
suspension in writing, giving in detail the reasons for the suspension. Contract Time will be
charged during all suspensions of Contractors operations. The Department may grant an
extension of Contract time in accordance with 8-7.3.2 when determined appropriate in the
Departments sole judgment.
No additional compensation or time extension will be paid or granted to the
Contractor when the operations are suspended for the following reasons:
a. The Contractor fails to comply with the Contract Documents.
b. The Contractor fails to carry out orders given by the Engineer.
c. The Contractor causes conditions considered unfavorable for continuing
the Work.
Immediately comply with any suspension order. Do not resume operations until
authorized to do so by the Engineer in writing. Any operations performed by the Contractor, and
otherwise constructed in conformance with the provisions of the Contract, after the issuance of
the suspension order and prior to the Engineers authorization to resume operations will be at no
cost to the Department. Further, failure to immediately comply with any suspension order will
83
also constitute an act of default by the Contractor and is deemed sufficient basis in and of itself
for the Department to declare the Contractor in default, in accordance with 8-9, with the
exception that the Contractor will not have ten calendar days to correct the conditions for which
the suspension was ordered.
8-6.1.1 State of Emergency: The Engineer has the authority to suspend the
Contractors operations, wholly or in part, pursuant to a Governors Declaration of a State of
Emergency. The Engineer will order such suspension in writing, giving in detail the reasons for
the suspension. Contract Time will be charged during all suspensions of Contractors operations.
The Department, at its sole discretion, may grant an extension of Contract Time and reimburse
the Contractor for specific costs associated with such suspension. Further, in such instances, the
Departments determination as to entitlement to either time or compensability will be final,
unless the Contractor can prove by clear and convincing evidence to a Disputes Review Board
that the Departments determination was without any reasonable factual basis
8-6.2 Prolonged Suspensions: If the Engineer suspends the Contractors operations for
an indefinite period, store all materials in such manner that they will not obstruct or impede the
traveling public unnecessarily or become damaged in any way. Take every reasonable precaution
to prevent damage to or deterioration of the work performed. Provide suitable drainage of the
roadway by opening ditches, shoulder drains, etc., and provide any temporary structures
necessary for public travel through the project.
8-6.3 Permission to Suspend Contractors Operations: Do not suspend operations or
remove equipment or materials necessary for completing the work without obtaining the
Engineers written permission. Submit all requests for suspension of operations in writing to the
Engineer, and identify specific dates to begin and end the suspension. The Contractor is not
entitled to any additional compensation for suspension of operations during such periods.
8-6.4 Suspension of Contractors Operations - Holidays and Special Events: Unless
the Contractor submits a written request to work during one or more days of a Holiday or Special
Event at least ten calendar days in advance of the beginning date of the Holiday or Special Event
and receives written approval from the Engineer, the Contractor shall not work on the following
days: Martin Luther King, Jr. Day; Memorial Day; the Saturday and Sunday immediately
preceding Memorial Day; Independence Day; Independence Day (Observed); Labor Day; the
Friday, Saturday, and Sunday immediately preceding Labor Day; Veterans Day; Veterans Day
(Observed); the Wednesday immediately preceding Thanksgiving Day; Thanksgiving Day; the
Friday, Saturday and Sunday immediately following Thanksgiving Day; December 24 through
January 2, inclusive; and Special Events noted in the Plans. Contract Time will be charged
during these Holiday and Special Event periods. Contract time will be adjusted in accordance
with 8-7.3.2. The Contractor is not entitled to any additional compensation beyond any allowed
Contract Time adjustment for suspension of operations during such Holiday and Special Event
periods.
During such suspensions, remove all equipment and materials from the clear
zone, except those required for the safety of the traveling public and retain sufficient personnel at
the job site to properly meet the requirements of Sections 102 and 104. The Contractor is not
entitled to any additional compensation for removal of equipment from clear zones or for
compliance with Section 102 and Section 104 during such Holiday and Special Event periods.
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8-7 Computation of Contract Time.
8-7.1 General: Perform the contracted work fully, entirely, and in accordance with the
Contract Documents within the Contract Time specified in the proposal, or as may be extended
in accordance with the provisions herein below.
The Department considers in the computation of the allowable Contract Time the
effect that utility relocation and adjustments have on job progress and the scheduling of
construction operations required in order to adequately maintain traffic, as detailed in the plans
or as scheduled in the Special Provisions.
8-7.2 Date of Beginning of Contract Time: The date on which Contract Time begins is
either (1) the date on which the Contractor actually begins work, or (2) the date for beginning the
charging of Contract Time as set forth in the proposal; whichever is earlier.
8-7.3 Adjusting Contract Time:
8-7.3.1 Increased Work: The Department may grant an extension of Contract
Time when it increases the Contract amount due to overruns in original Contract items, adds new
work items, or provides for unforeseen work. The Department will base the consideration for
granting an extension of Contract Time on the extent that the time normally required to complete
the additional designated work delays the Contract completion schedule.
8-7.3.2 Contract Time Extensions: The Department may grant an extension of
Contract Time when a controlling item of work is delayed by factors not reasonably anticipated
or foreseeable at the time of bid. The Department may allow such extension of time only for
delays occurring during the Contract Time period or authorized extensions of the Contract Time
period. When failure by the Department to fulfill an obligation under the Contract results in
delays to the controlling items of work, the Department will consider such delays as a basis for
granting a time extension to the Contract.
Whenever the Engineer suspends the Contractors operations, as provided
in 8-6, for reasons other than the fault of the Contractor, the Engineer will grant a time extension
for any delay to a controlling item of work due to such suspension. The Department will not
grant time extensions to the Contract for delays due to the fault or negligence of the Contractor.
The Department does not include an allowance for delays caused by the
effects of inclement weather or suspension of Contractors operations as defined in 8-6.4, in
establishing Contract Time. The Engineer will continually monitor the effects of weather and,
when found justified, grant time extensions on either a bimonthly or monthly basis. The
Engineer will not require the Contractor to submit a request for additional time due to the effects
of weather.
The Department will grant time extensions, on a day for day basis, for
delays caused by the effects of rains or other inclement weather conditions, related adverse soil
conditions or suspension of operations as defined in 8-6.4 that prevent the Contractor from
productively performing controlling items of work resulting in:
(1) The Contractor being unable to work at least 50% of the
normal work day on pre-determined controlling work items; or
(2) The Contractor must make major repairs to work damaged by
weather, provided that the damage is not attributable to the Contractors failure to perform or
neglect; and provided that the Contractor was unable to work at least 50% of the normal
workday on pre-determined controlling work items.
No additional compensation will be made for delays caused by the effects
of inclement weather.
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The Department will consider the delays in delivery of materials or
component equipment that affect progress on a controlling item of work as a basis for granting a
time extension if such delays are beyond the control of the Contractor or supplier. Such delays
may include an area-wide shortage, an industry-wide strike, or a natural disaster that affects all
feasible sources of supply. In such cases, the Contractor shall furnish substantiating letters from
a representative number of manufacturers of such materials or equipment clearly confirming that
the delays in delivery were the result of an area-wide shortage, an industry-wide strike, etc. No
additional compensation will be made for delays caused by delivery of materials or component
equipment.
The Department will not consider requests for time extension due to delay
in the delivery of custom manufactured equipment such as traffic signal equipment, highway
lighting equipment, etc., unless the Contractor furnishes documentation that he placed the order
for such equipment in a timely manner, the delay was caused by factors beyond the
manufacturers control, and the lack of such equipment caused a delay in progress on a
controlling item of work. No additional compensation will be paid for delays caused by delivery
of custom manufactured equipment.
The Department will consider the affect of utility relocation and
adjustment work on job progress as the basis for granting a time extension only if all the
following criteria are met:
(1) Delays are the result of either utility work that was not detailed
in the plans, or utility work that was detailed in the plans but was not accomplished in reasonably
close accordance with the schedule included in the Contract Documents.
(2) Utility work actually affected progress toward completion of
controlling work items.
(3) The Contractor took all reasonable measures to minimize the
effect of utility work on job progress, including cooperative scheduling of the Contractors
operations with the scheduled utility work at the preconstruction conference and providing
adequate advance notification to utility companies as to the dates to coordinate their operations
with the Contractors operations to avoid delays.
As a condition precedent to an extension of Contract Time the Contractor
must submit to the Engineer:
A preliminary request for an extension of Contract Time must be
made in writing to the Engineer within ten calendar days after the commencement of a delay to a
controlling item of work. If the Contractor fails to submit this required preliminary request for an
extension of Contract Time, the Contractor fully, completely, absolutely and irrevocably waives
any entitlement to an extension of Contract Time for that delay. In the case of a continuing delay
only a single preliminary request for an extension of Contract Time will be required. Each such
preliminary request for an extension of Contract Time shall include as a minimum the
commencement date of the delay, the cause of the delay, and the controlling item of work
affected by the delay.
Furthermore, the Contractor must submit to the Engineer a request
for a Contract Time extension in writing within 30 days after the elimination of the delay to the
controlling item of work identified in the preliminary request for an extension of Contract Time.
Each request for a Contract Time extension shall include as a minimum all documentation that
the Contractor wishes the Department to consider related to the delay, and the exact number of
days requested to be added to Contract Time. If the Contractor contends that the delay is
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compensable, then the Contractor shall also be required to submit with the request for a Contract
Time extension a detailed cost analysis of the requested additional compensation. If the
Contractor fails to submit this required request for a Contract Time extension, with or without a
detailed cost analysis, depriving the Engineer of the timely opportunity to verify the delay and
the costs of the delay, the Contractor waives any entitlement to an extension of Contract Time or
additional compensation for the delay.
Upon timely receipt of the preliminary request of Contract Time
from the Contractor, the Engineer will investigate the conditions, and if it is determined that a
controlling item of work is being delayed for reasons beyond the control of the Contractor the
Engineer will take appropriate action to mitigate the delay and the costs of the delay. Upon
timely receipt of the request for a Contract Time extension the Engineer will further investigate
the conditions, and if it is determined that there was an increase in the time or the cost of
performance of the controlling item of work beyond the control of the Contractor, then an
adjustment of Contract Time will be made, and a monetary adjustment will be made, excluding
loss of anticipated profits, and the Contract will be modified in writing accordingly.
The existence of an accepted schedule, including any required
update(s), as stated in 8-3.2, is a condition precedent to the Contractor having any right to the
granting of an extension of contract time or any monetary compensation arising out of any delay.
Contractor failure to have an accepted schedule, including any required update(s), for the period
of potential impact, or in the event the currently accepted schedule and applicable updates do not
accurately reflect the actual status of the project or fail to accurately show the true controlling or
non-controlling work activities for the period of potential impact, will result in any entitlement
determination as to time or money for such period of potential impact being limited solely to the
Departments analysis and identification of the actual controlling or non-controlling work
activities. Further, in such instances, the Departments determination as to entitlement as to
either time or compensability will be final, unless the Contractor can prove by clear and
convincing evidence to a Disputes Review Board that the Departments determination was
without any reasonable factual basis.
8-8 Failure of Contractor to Maintain Satisfactory Progress.
8-8.1 General: Pursue the work to completion: Section 337.16 of the Florida Statutes
establishes certain requirements pertaining to the suspension or revocation of a Contractors
Certificate of Qualification because of delinquency on a previously awarded Contract.
8-8.2 Regulations Governing Suspension for Delinquency:
(a) A Contractor is delinquent when the allowed Contract Time for performing
the work has expired, and the Contractor has not completed the Contract work.
(b) Once the Department determines that the Contractor is delinquent, the
Department will give the Contractor written notice of intent to suspend the Contractors
Certificate of Qualification. If the Contractor disagrees with the delinquency, the Contractor
shall file a request for an administrative hearing with the Clerk of Agency Proceedings within
ten days of receipt of the notice of intent to suspend. If the Contractor does not file a request, the
Department will make the suspension conclusive and final. The request for hearing is filed when
the Contractor delivers it to, and it is received by, the Clerk of Agency Proceedings, Mail
Station 58, Room 562, Haydon Burns Building, 605 Suwannee Street, Tallahassee, Florida
32399-0450.
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(c) If the Contractor files a request for a hearing, the Department will schedule the
hearing within 30 days of the hearing officers receipt of the request.
(d) The Department will continue the period of suspension of the Contractors
Certificate of Qualification until the Contractor is no longer delinquent. If the Contractor
requests an administrative hearing, the Department's final order, depending on the outcome of
the hearing, will set forth the time period of suspension for the number of days the Department
determines that the Contractor was delinquent, even if the Contractor cures the delinquency
during the pendency of the administrative proceedings.
(e) During the period of suspension of the Contractors Certificate of
Qualification, the Department will not allow the Contractor and its affiliates to bid on any
Department Contract, regardless of dollar amount, and will not approve the Contractor as a
subcontractor on any Department contract.
(f) The Department may grant extensions of time during the prosecution of the
work as allowed under these Specifications regardless of the Contractors delinquency status.
8-9 Default and Termination of Contract.
8-9.1 Determination of Default: The following acts or omissions constitute acts of
default and, except as to subparagraphs (i and k), the Department will give notice, in writing, to
the Contractor and his surety for any delay, neglect or default, if the Contractor:
(a) fails to begin the work under the Contract within the time specified in the
Notice to Proceed;
(b) fails to perform the work with sufficient workmen and equipment or with
sufficient materials to ensure prompt completion of the Contract;
(c) performs the work unsuitably, or neglects or refuses to remove materials or to
perform anew such work that the Engineer rejects as unacceptable and unsuitable;
(d) discontinues the prosecution of the work, or fails to resume discontinued work
within a reasonable time after the Engineer notifies the Contractor to do so;
(e) becomes insolvent or is declared bankrupt, or files for reorganization under
the bankruptcy code, or commits any act of bankruptcy or insolvency, either voluntarily or
involuntarily;
(f) allows any final judgment to stand against him unsatisfied for a period of ten
calendar days;
(g) makes an assignment for the benefit of creditors;
(h) fails to comply with Contract requirements regarding minimum wage
payments or EEO requirements;
(i) fails to comply with the Engineers written suspension of work order within
the time allowed for compliance and which time is stated in that suspension of work order; or
(j) for any other cause whatsoever, fails to carry on the work in an acceptable
manner, or if the surety executing the bond, for any reasonable cause, becomes unsatisfactory in
the opinion of the Department.
(k) fails to comply with 3-9.
For a notice based upon reasons stated in subparagraphs (a) through (h) and (j): if
the Contractor, within a period of ten calendar days after receiving the notice described above,
fails to correct the conditions of which complaint is made, the Department will, upon written
certificate from the Engineer of the fact of such delay, neglect, or default and the Contractors
failure to correct such conditions, have full power and authority, without violating the Contract,
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to take the prosecution of the work out of the hands of the Contractor and to declare the
Contractor in default.
If the Contractor, after having received a prior notice described above for any
reason stated in subparagraph (b), (c), (d), (e), (f) or (h), commits a second or subsequent act of
default for any reason covered by the same subparagraph (b), (c), (d), (e), (f) or (h) as stated in
the prior notice, and regardless whether the specific reason is the same, then, regardless of
whether the Contractor has cured the deficiency stated in that prior notice, the Department will,
upon written certificate from the Engineer of the fact of such delay, neglect or default and the
Contractors failure to correct such conditions, have full power and authority, without any prior
written notice to the Contractor and without violating the Contract, to take the prosecution of the
work out of the hands of the Contractor and to declare the Contractor in default.
Regarding subparagraph (i), if the Contractor fails to comply with the Engineers
written suspension of work order within the time allowed for compliance and which time is
stated in that suspension of work order, the Department will, upon written certificate from the
Engineer of the fact of such delay and the Contractors failure to correct that condition, have full
power and authority, without violating the Contract, to immediately take the prosecution of the
work out of the hands of the Contractor and to declare the Contractor in default.
Regarding subparagraph (k), if the Contractor fails to comply with 3-9, the
Department will have full power and authority, without violating the Contract, to immediately
take the prosecution of the work out of the hands of the Contractor and to declare the Contractor
in default.
The Department has no liability for anticipated profits for unfinished work on a
Contract that the Department has determined to be in default.
Notwithstanding the above, the Department shall have the right to declare the
Contractor (or its affiliate) in default and immediately terminate this Contract, without any
prior notice to the Contractor, in the event the Contractor (or its affiliate) is at any time
convicted of a contract crime, as these terms are defined in Section 337.165(1), Florida
Statutes. The Departments right to default the Contractor (or its affiliate) for conviction of a
contract crime shall extend to and is expressly applicable to any and all Department Contracts
that were either advertised for bid; for which requests for proposals or letters of interest were
requested; for which an intent to award was posted or otherwise issued; or for which a Contract
was entered into, after the date that the underlying or related criminal indictment, criminal
information or other criminal charge was filed against the Contractor (or its affiliate) that
resulted in the conviction. In the event the Department terminates this Contract for this reason,
the Contractor shall hereby forfeit any claims for additional compensation, extra time, or
anticipated profits. The Contractor shall only be paid for any completed work up to the date of
termination. Further, the Contractor shall be liable for any and all additional costs and expenses
the Department incurs in completing the Contract work after such termination.
8-9.2 Termination of Contract for Convenience: The Department may terminate the
entire Contract or any portion thereof, if the Secretary determines that a termination is in the
Departments interest. The Secretary will deliver to the Contractor a Written Notice of
Termination specifying the extent of termination and the effective date.
When the Department terminates the entire Contract, or any portion thereof,
before the Contractor completes all items of work in the Contract, the Department will make
payment for the actual number of units or items of work that the Contractor has completed, at the
Contract unit price, and according to the formulas and provisions set forth in 4-3.2 for items of
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work partially completed, and such payments will constitute full and complete compensation for
such work or items. No payment of any kind or amount will be made for items of work not
started. The Department will not consider any claim for loss of anticipated profits, or overhead
of any kind (including home office and jobsite overhead or other indirect impacts) except as
provided in 4-3.2 for partially completed work.
The Department will consider reimbursing the Contractor for actual cost of
mobilization (when not otherwise included in the Contract) including moving equipment to the
job where the volume of the work that the Contractor has completed is too small to compensate
the Contractor for these expenses under the Contract unit prices.
The Department may purchase at actual cost acceptable materials and supplies
procured for the work, that the Department has inspected, tested, and approved and that the
Contractor has not incorporated in the work. Submit the proof of actual cost, as shown by
receipted bills and actual cost records, at such points of delivery as the Engineer may designate.
Termination of a contract or a portion thereof, under the provisions of this
Subarticle, does not relieve the Contractor or the surety of its responsibilities for the completed
portion of the Contract or its obligations for and concerning any just claims arising out of the
work performed.
All Contractor claims for additional payment, due to the Departments
termination of the entire Contract or any portion thereof, must meet the requirements of 5-12.
8-9.3 Completion of Work by Department: Upon declaration of default, the
Department will have full power to appropriate or use any or all suitable and acceptable
materials and equipment on the site and may enter into an agreement with others to complete the
work under the Contract, or may use other methods to complete the work in an acceptable
manner. The Department will charge all costs that the Department incurs because of the
Contractors default, including the costs of completing the work under the Contract, against the
Contractor. If the Department incurs such costs in an amount that is less than the sum that would
have been payable under the Contract had the defaulting Contractor completed the work then the
Department will pay the difference to the defaulting Contractor. If the Department incurs such
costs in an amount that exceeds the sum that would have been payable under the Contract, then
the Contractor and the surety shall be liable and shall pay the State the amount of the excess.
If, after the ten day notice period and prior to any action by the Department to
otherwise complete the work under the Contract, the Contractor establishes his intent to
prosecute the work in accordance with the Departments requirements, then the Department may
allow the Contractor to resume the work, in which case the Department will deduct from any
monies due or that may become due under the Contract, any costs to the Department incurred by
the delay, or from any reason attributable to the delay.
8-10 Liquidated Damages for Failure to Complete the Work.
8-10.1 Highway Code Requirements Pertaining to Liquidated Damages:
Section 337.18, paragraph (2) of the Florida Statutes, requires that the Department adopt
regulations for the determination of default and provides that the Contractor pay liquidated
damages to the Department for any failure of the Contractor to complete the Contract work
within the Contract Time. These Code requirements govern, and are herewith made a part of the
Contract.
8-10.2 Amount of Liquidated Damages: Applicable liquidated damages are the
amounts established in the following schedule:
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$50,000 and under..........................................................$642
Over $50,000 but less than $250,000 ............................$758
$250,000 but less than $500,000 ...................................$966
$500,000 but less than $2,500,000 .............................$1,532
$2,500,000 but less than $5,000,000 ..........................$2,374
$5,000,000 but less than $10,000,000 ........................$3,226
$10,000,000 but less than $15,000,000 ......................$4,624
$15,000,000 but less than $20,000,000 ......................$4,276
$20,000,000 and over.......................................... $7,864 plus
............................... 0.00005 of any amount over $20 million
8-10.3 Determination of Number of Days of Default: For all contracts, regardless of
whether the Contract Time is stipulated in calendar days or working days, the Engineer will
count default days in calendar days.
8-10.4 Conditions under which Liquidated Damages are Imposed: If the Contractor
or, in case of his default, the surety fails to complete the work within the time stipulated in the
Contract, or within such extra time that the Department may have granted then the Contractor or,
in case of his default, the surety shall pay to the Department, not as a penalty, but as liquidated
damages, the amount so due as determined by the Code requirements, as provided in 8-10.2.
8-10.5 Right of Collection: The Department has the right to apply, as payment on such
liquidated damages, any money the Department owes the Contractor.
8-10.6 Allowing Contractor to Finish Work: The Department does not waive its right
to liquidated damages due under the Contract by allowing the Contractor to continue and to
finish the work, or any part of it, after the expiration of the Contract Time including granted time
extensions.
8-10.7 Completion of Work by Department: In the case of a default of the Contract
and the completion of the work by the Department, the Contractor and his surety are liable for
the liquidated damages under the Contract, but the Department will not charge liquidated
damages for any delay in the final completion of the Departments performance of the work due
to any unreasonable action or delay on the part of the Department.
8-11 Release of Contractors Responsibility.
The Department considers the Contract complete when the Contractor has completed all
work and the Department has accepted the work. The Department will then release the
Contractor from further obligation except as set forth in his bond, and except as provided in 513.
8-12 Recovery of Damages Suffered by Third Parties.
In addition to the damages provided for in 8-10.2 and pursuant to Section 337.18 of the
Florida Statutes, when the Contractor fails to complete the work within the Contract Time or
within such additional time that the Department may grant the Department may recover from the
Contractor amounts that the Department pays for damages suffered by third parties unless the
failure to timely complete the work was caused by the Departments act or omission.
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SECTION 9
MEASUREMENT AND PAYMENT
9-1 Measurement of Quantities.
9-1.1 Measurement Standards: The Engineer will measure all work completed
under the Contract in accordance with the United States Standard Measures.
9-1.2 Method of Measurements: The Engineer will take all measurements
horizontally or vertically.
9-1.3 Determination of Pay Areas:
9-1.3.1 Final Calculation: When measuring items paid for on the basis of
area of finished work, where the pay quantity is designated to be determined by
calculation, the Engineer will use lengths and widths in the calculations based on the
station to station dimensions shown on the plans; the station to station dimensions
actually constructed within the limits designated by the Engineer; or the final dimensions
measured along the surface of the completed work within the neat lines shown on the
plans or designated by the Engineer. The Engineer will use the method or combination of
methods of measurement that reflect, with reasonable accuracy, the actual surface area of
the finished work as the Engineer determines.
9-1.3.2 Plan Quantity: When measuring items paid for on the basis of
area of finished work, where the pay quantity is designated to be the plan quantity, the
Engineer will determine the final pay quantity based on the plan quantity subject to the
provisions of 9-3.2. Generally, the Engineer will calculate the plan quantity using lengths
based on station to station dimensions and widths based on neat lines shown in the plans.
9-1.4 Construction Outside Authorized Limits: The Engineer will not pay for
surfaces constructed over a greater area than authorized, or for material that the
Contractor has moved from outside of slope stakes and lines shown on the plans, except
where the Engineer provides written instruction for the Contractor to perform such work.
9-1.5 Truck Requirements: Provide all trucks with numbers and certify that all
trucks used have a manufacturers certification or permanent decal showing the truck
capacity rounded to the nearest tenth of a cubic yard placed on both sides of the truck.
This capacity will include the truck body only and any side boards added will not be
included in the certified truck body capacity. Ensure the lettering and numbers are legible
for identification purposes at all times.
9-1.6 Ladders and Instrument Stands for Bridge Projects: On bridge projects,
in order to facilitate necessary measurements, provide substantial ladders to the tops of
piers and bents, and place and move such ladders as the Engineer directs.
For bridge projects crossing water or marshy areas, supply fixed stands for
instrument mounting and measurements, in accordance with the details stipulated in the
Specifications for the project.
9-2 Scope of Payments.
9-2.1 Items Included in Payment: Accept the compensation as provided in the
Contract as full payment for furnishing all materials and for performing all work
contemplated and embraced under the Contract; also for all loss or damage arising out of
the nature of the work or from the action of the elements, or from any unforeseen
difficulties or obstructions which may arise or be encountered in the prosecution of the
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work until its final acceptance; also for all other costs incurred under the provisions of
Division I.
For any item of work contained in the proposal, except as might be
specifically provided otherwise in the basis of payment clause for the item, include in the
Contract unit price (or lump sum price) for the pay item or items the cost of all labor,
equipment, materials, tools and incidentals required for the complete item of work,
including all requirements of the Section specifying such item of work, except as
specifically excluded from such payments.
9-2.1.1 Fuels: The Department will, in the Contract Documents, provide
an estimated quantity for fuel requirements for gasoline and diesel to cover the work
specified in the Contract. Price adjustments will be made only for the amount of gasoline
and diesel fuel estimated by the Department as required to complete the Contract. The
requirement of each type of fuel for each pay item is estimated by multiplying the
Departments standard fuel factor for that pay item by the quantity of that pay item. On
Contracts with an original Contract Time in excess of 120 calendar days, the Department
will make price adjustments on each applicable progress estimate to reflect increases or
decreases in the price of gasoline and diesel from those in effect during the month in
which bids were received. The Contractor will not be given the option of accepting or
rejecting these adjustments. Price adjustments for these fuels will be made only when the
current fuel price (CFP) varies by more than 5% from the price prevailing in the month
when bids were received (BFP), and then only on the portion that exceeds 5%.
Price adjustments will be based on the monthly bulk average price
for gas and diesel as derived by the Department. These average indexes shall be
determined by averaging bulk fuel prices on the first day of each month as quoted by
major oil companies that are reasonably expected to furnish fuel for projects in the State
of Florida. Average price indices for gasoline and diesel will be available on the
Construction Office website before the 15th of each month, at the following URL:
http://www.dot.state.fl.us/construction/fuel&Bit/Fuel&Bit.shtm .
Payment will be based on the quantities shown on the progress
estimate on all items for which established standard fuel factors are on a file maintained
by the Department.
Payment on progress estimates will be adjusted to reflect
adjustments in the prices for gasoline and diesel in accordance with the following:
When fuel prices have decreased between month of bid and month
of this progress estimate:
Ai = Fi (Pi - 0.95 Pb) during a period of decreasing prices.
Ai = Total dollar amount - positive or negative - of the cost
adjustment for each kind of fuel used by the Contractor during the month i.
Fi = Total gallons calculated as being used during the
month.
Pi = Average price for fuel prevailing during month i.
Pb = Average price for fuel prevailing during the month
b when bids were received on this Contract.
When fuel prices have increased between month of bid and month
of this progress estimate:
Ai = Fi (Pi - 1.05 Pb) during a period of increasing prices.
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Ai = Total dollar amount - positive or negative - of the cost
adjustment for each kind of fuel used by the Contractor during the month i.
Fi = Total gallons calculated as being used during the
month.
Pi = Average price for fuel prevailing during month i.
Pb = Average price for fuel prevailing during the month
b when bids were received on this Contract.
Payment will be made on the current progress estimate to reflect
the index difference at the time work was performed.
Adjustments will be paid or charged to the Prime Contractor only.
Any Contractor receiving an adjustment under this provision shall distribute the proper
proportional part of such adjustment to subcontractors who perform applicable work.
9-2.1.2 Bituminous Material: Prepare a Contractors Certification of
Quantities, using the Departments current approved form for Superpave Asphalt Base,
Turnout Construction (Asphalt), Asphalt Treated Permeable Base, Superpave Asphaltic
Concrete, Miscellaneous Asphalt Pavement and Asphalt Rubber Membrane Interlayer
pay items. Submit this certification to the Engineer no later than Twelve Oclock noon
Monday after the estimate cut-off or as directed by the Engineer, based on the quantity of
asphalt produced and accepted on the roadway per Contract. Ensure the certification
includes the Contract Number, Financial Project Identification (FPID) Number,
Certification Date and Number, the period the certification represents and the tons
produced for each asphalt pay item.
On Contracts having an original Contract Time of more than
365 calendar days, or more than 5,000 tons of asphalt concrete, the Department will
adjust the bid unit price for bituminous material, excluding cutback and emulsified
asphalt to reflect increases or decreases in the Asphalt Price Index (API) of bituminous
material from that in effect during the month in which bids were received. The Contractor
will not be given the option of accepting or rejecting this adjustment. Bituminous
adjustments will be made only when the current API (CAPI) varies by more than 5% of
the API prevailing in the month when bids were received (BAPI), and then only on the
portion that exceeds 5%.
The Department will determine the API for each month by
averaging quotations in effect on the first day of the month at all terminals that could
reasonably be expected to furnish bituminous material to projects in the State of Florida.
The API will be available on the Construction Office website
before the 15th of each month at the following URL:
http://www.dot.state.fl.us/construction/fuel&Bit/Fuel&Bit.shtm .
Payment on progress estimates will be adjusted to reflect
adjustments in the prices for bituminous materials in accordance with the following:
$ Adjustment = (ID)(Gallons)
Where ID = Index Difference = [CAPI - 0.95(BAPI)] when
the API has decreased between the month of bid and month of this progress estimate.
Where ID = Index Difference = [CAPI - 1.05(BAPI)] when
the API has increased between the month of bid and month of this progress estimate.
Payment will be made on the current progress estimate to reflect
the index difference at the time work was performed.
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For asphalt concrete items payable by the ton or square yard, the
number of gallons will be determined assuming a mix design with 6.25% liquid asphalt
weighing 8.58 lb/gal.
For Asphalt concrete items payable by the cubic yard, the number
of gallons will be determined assuming a mix design with 3% liquid asphalt weighing
8.58 lb/gal.
9-2.2 Non-Duplication of Payment: In cases where the basis of payment clause
in these Specifications relating to any unit price in the bid schedule requires that the unit
price cover and be considered compensation for certain work or material essential to the
item, the Department will not measure or pay for this same work or material under any
other pay item that may appear elsewhere in these Specifications.
9-3 Compensation for Altered Quantities.
9-3.1 General: When alteration in plans or quantities of work not requiring a
supplemental agreement as hereinbefore provided for are offered and performed, the
Contractor shall accept payment in full at Contract unit bid prices for the actual quantities
of work done, and no allowance will be made for increased expense, loss of expected
reimbursement, or loss of anticipated profits suffered or claimed by the Contractor,
resulting either directly from such alterations, or indirectly from unbalanced allocation
among the Contract items of overhead expense on the part of the bidder and subsequent
loss of expected reimbursement therefore, or from any other cause.
Compensation for alterations in plans or quantities of work requiring
supplemental agreements shall be stipulated in such agreement, except when the
Contractor proceeds with the work without change of price being agreed upon, the
Contractor shall be paid for such increased or decreased quantities at the Contract unit
prices bid in the Proposal for the items of work. If no Contract unit price is provided in
the Contract, and the parties cannot agree as to a price for the work, the Contractor agrees
to do the work in accordance with 4-3.2.
9-3.2 Payment Based on Plan Quantity:
9-3.2.1 Error in Plan Quantity: As used in this Article, the term
substantial error is defined as the smaller of (a) or (b) below:
(a) a difference between the original plan quantity and final
quantity of more than 5%,
(b) a change in quantity which causes a change in the amount
payable of more than $5,000.
On multiple job Contracts, changes made to an individual pay item
due to substantial errors will be based on the entire Contract quantity for that pay item.
Where the pay quantity for any item is designated to be the original
plan quantity, the Department will revise such quantity only in the event that the
Department determines it is in substantial error. In general, the Department will
determine such revisions by final measurement, plan calculations, or both, as additions to
or deductions from plan quantities.
In the event that either the Department or the Contractor contends
that the plan quantity for any item is in error and additional or less compensation is
thereby due, the claimant shall submit, at their own expense, evidence of such in the form
of acceptable and verifiable measurements or calculations. The Department will not
revise the plan quantity solely on the basis of a particular method of construction that the
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Contractor selects. For earthwork items, the claimant must note any differences in the
original ground surfaces from that shown in the original plan cross-sections that would
result in a substantial error to the plan quantity, and must be properly documented by
appropriate verifiable level notes, acceptable to both the Contractor and the Department,
prior to disturbance of the original ground surface by construction operations. The
claimant shall support any claim based upon a substantial error for differences in the
original ground surface by documentation as provided above.
9-3.2.2 Authorized Changes in Limits of Work: Where the Department
designates the pay quantity for any item to be the original plan quantity and authorizes a
plan change which results in an increase or decrease in the quantity of that item, the
Department will revise the plan quantity accordingly. In general, the Department will
determine such revisions by final measurement, plan calculations or both.
9-3.2.3 Specified Adjustments to Pay Quantities: Do not apply the
limitations specified in 9-3.2.1 and 9-3.2.2 to the following:
(1) Where these Specifications or Special Provisions provide that
the Department determines the pay quantity for an item on the basis of area of finished
work adjusted in accordance with the ratio of measured thickness to nominal thickness.
(2) Where these Specifications provide for a deduction due to test
results falling outside of the allowable specified tolerances.
(3) To payment for extra length fence posts, as specified in
550-6.3.
9-3.3 Lump Sum Quantities:
9-3.3.1 Error in Lump Sum Quantity: Where the Department designates
the pay quantity for an item to be a lump sum and the plans show an estimated quantity,
the Department will adjust the lump sum compensation only in the event that either the
Contractor submits satisfactory evidence or the Department determines and furnishes
satisfactory evidence that the lump sum quantity shown is in substantial error as defined
in 9-3.2.1.
9-3.3.2 Authorized Changes in Work: Where the Department designates
the pay quantity for an item to be a lump sum and the plans show an estimated quantity,
the Department will adjust compensation for that item proportionately when an
authorized plan change is made which results in an increase or decrease in the quantity of
that item. When the plans do not show an estimated plan quantity or the applicable
specifications do not provide adjustments for contingencies, the Department will
compensate for any authorized plan change resulting in an increase or decrease in the cost
of acceptably completing the item by establishing a new unit price through a
supplemental agreement as provided in 4-3.2.
9-3.4 Deviation from Plan Dimensions: If the Contractor fails to construct any
item to plan or to authorized dimensions within the specified tolerances, the Engineer, at
his discretion will: require the Contractor to reconstruct the work to acceptable tolerances
at no additional cost to the Department; accept the work and provide the Contractor no
pay; or accept the work and provide the Contractor a reduced final pay quantity or
reduced unit price. The Department will not make reductions to final pay quantities for
those items designated to be paid on the basis of original plan quantity or a lump sum
quantity under the provisions of this Article unless such reduction results in an aggregate
monetary change per item of more than $100, except that for earthwork items, the
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aggregate change must exceed $5,000 or 5% of the original plan quantity, whichever is
smaller. If, in the opinion of the Engineer, the Contractor has made a deliberate attempt to
take advantage of the construction tolerances as defined in 120-12.1 to increase borrow
excavation in fill sections or to decrease the required volume of roadway or lateral ditch
excavation or embankment, the Department will take appropriate measurements and will
apply reductions in pay quantities. The Department will not use the construction
tolerance, as defined in 120-12.1, as a pay tolerance. The construction tolerance is not to
be construed as defining a revised authorized template.
9-4 Deleted Work.
The Department will have the right to cancel the portions of the Contract relating
to the construction of any acceptable item therein, by making an adjustment in payment
to the Contractor of a fair and equitable amount covering the value of all cancelled work
less all items of cost incurred prior to the date that the Engineer cancels the work.
9-5 Partial Payments.
9-5.1 General: The Engineer will make partial payments on monthly estimates
based on the amount of work that the Contractor completes during the month (including
delivery of certain materials, as specified herein below). The Engineer will make
approximate monthly payments, and the Department will correct all partial estimates and
payments in the subsequent estimates and in the final estimate and payment.
The Department will base the amount of such payments on the total value
of the work that the Contractor has performed to the date of the estimate, based on the
quantities completed and the Contract prices, less payments previously made and less any
retainage withheld.
Retainage will not be withheld until the percent of allowable Contract time
used exceeds 75%. From that time forward, the Department will withhold retainage of
10% of the amount due on the current estimate as retainage when the percent of
allowable Contract time used exceeds the percent of Contract amount earned by more
than 15%.
Contract amount is defined as the original Contract amount adjusted by
approved supplemental agreements.
Contract time is defined as the original Contract time adjusted by
approved Contract time extensions.
Retainage will be determined for each job on multiple job Contracts. The
Department will not accept Securities, Certificates of Deposit or letters of credit as a
replacement for retainage. Amounts withheld will not be released until payment of the
final estimate.
9-5.2 Unsatisfactory Payment Record: In accordance with Sections 255.05 and
337.16 of the Florida Statutes, and the rules of the Department, the Department may
disqualify the Contractor from bidding on future Department contracts if the Contractors
payment record in connection with contract work becomes unsatisfactory.
9-5.3 Withholding Payment:
9-5.3.1 Withholding Payment for Defective Work: If the Department
discovers any defective work or material prior to the final acceptance, or if the
Department has a reasonable doubt as to the integrity of any part of the completed work
prior to final acceptance, then the Department will not allow payment for such defective
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or questioned work until the Contractor has remedied the defect and removed any causes
of doubt.
9-5.3.2 Withholding Payment for Failure to Comply: The Department
will withhold progress payments from the Contractor if he fails to comply with any or all
of the following within 60 days after beginning work:
(a) comply with and submit required paperwork relating to
prevailing wage rate provisions, Equal Employment Opportunity, On-The-Job Training,
and Affirmative Action;
(b) comply with the requirement to all necessary information,
including actual payments to DBEs, all other subcontractors and major suppliers, through
the Internet based Equal Opportunity Reporting System;
(c) comply with or make a good faith effort to ensure employment
opportunity for minorities and females in accordance with the required contract
provisions for Federal Aid Construction Contracts, and
(d) comply with or make a good faith effort to meet On-The-Job
Training goals.
The Department will withhold progress payments until the
Contractor has satisfied the above conditions.
9-5.4 Release of Retainage After Acceptance: When the Contractor has
furnished the Department with all submittals required by the Contract, such as invoices,
EEO reports, materials certifications, certification of materials procured, etc., (excluding
Contractors letter of acceptance of final amount due and Form 21-A release) and the
Engineer has determined that the measurement and computation of pay quantities is
correct, the Department may reduce the retainage to $1,000 plus any amount that the
Department elects to deduct for defective work as provided in 9-5.3.
The Department will not allow a semifinal estimate under the provisions
of the above paragraphs unless the time elapsing between (1) acceptance of the project
and receipt of all test reports, invoices, etc., and (2) submission of the final estimate to the
Contractor for acceptance, exceeds or is expected to exceed ten days.
The Department may deduct from payment estimates any sums that the
Contractor owes to the Department on any account. Where more than one project or job
(separate job number) is included in the Contract, the Department will distribute the
reduced retainage as provided in the first paragraph of this Subarticle to each separate
project or job in the ratio that the Contract value of the work for the particular job bears
to the total Contract amount.
9-5.5 Partial Payments for Delivery of Certain Materials:
9-5.5.1 General: The Department will allow partial payments for new
materials that will be permanently incorporated into the project and are stockpiled in
approved locations in the project vicinity. Stockpile materials so that they will not be
damaged by the elements and in a manner that identifies the project on which they are to
be used.
The following conditions apply to all payments for stockpiled
materials:
(1) There must be reasonable assurance that the stockpiled
material will be incorporated into the specific project on which partial payment is made.
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applicable specifications.
(2) The stockpiled material must be approved as meeting
(3) The total quantity for which partial payment is made
shall not exceed the estimated total quantity required to complete the project.
(4) The Contractor shall furnish the Engineer with copies of
certified invoices to document the value of the materials received. The amount of the
partial payment will be determined from invoices for the material up to the unit price in
the Contract.
(5) Delivery charges for materials delivered to the jobsite
will be included in partial payments if properly documented.
(6) Partial payments will not be made for materials which
were stockpiled prior to award of the Contract for a project.
9-5.5.2 Partial Payment Amounts: The following partial payment
restrictions apply:
(1) Partial payments less than $5,000 for any one month will not be
processed.
(2) Partial payments for structural steel and precast prestressed
items will not exceed 85% of the bid price for the item. Partial payments for all other
items will not exceed 75% of the bid price of the item in which the material is to be used.
(3) Partial payment will not be made for aggregate and base course
material received after paving or base construction operations begin except when a
construction sequence designated by the Department requires suspension of paving and
base construction after the initial paving operations, partial payments will be reinstated
until the paving and base construction resumes.
9-5.5.3 Off Site Storage: If the conditions of 9-5.5.1 are satisfied, partial
payments will be allowed for materials stockpiled in approved in-state locations.
Additionally, partial payments for materials stockpiled in approved out-of-state locations
will be allowed if the conditions of 9-5.5.1 and the following conditions are met:
(1) Furnish the Department a Materials Bond stating the supplier
guarantees to furnish the material described in the Contract to the Contractor and
Department. Under this bond, the Obligor shall be the material supplier and the Obligees
shall be the Contractor and the Florida Department of Transportation. The bond shall be
in the full dollar amount of the bid price for the materials described in the contract.
(2) The following clauses must be added to the construction
Contract between the Contractor and the supplier of the stockpiled materials:
Notwithstanding anything to the contrary, <supplier> will
be liable to the Contractor and the Florida Department of Transportation should
<supplier> default in the performance of this agreement.
Notwithstanding anything to the contrary, this agreement,
and the performance bond issued pursuant to this agreement, does not alter, modify, or
otherwise change the Contractors obligation to furnish the materials described in this
agreement to the Florida Department of Transportation.
(3) The agreement between the Contractor and the supplier of the
stockpiled materials must include provisions that the supplier will store the materials and
that such materials are the property of the Contractor.
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9-5.6 Certification of Payment to Subcontractors: The term subcontractor, as
used herein, includes persons or firms furnishing materials or equipment incorporated
into the work or stockpiled for which the Department has made partial payment and firms
working under equipment-rental agreements. The Contractor is required to pay all
subcontractors for satisfactory performance of their Contracts before the Department will
make a further progress (partial) payment. The Contractor shall also return all retainage
withheld to the subcontractors within 30 days after the subcontractors work is
satisfactorily complete, as determined by the Department. Prior to receipt of any progress
(partial) payment, the prime contractor shall certify that all subcontractors having an
interest in the Contract were paid for satisfactory performance of their Contracts and that
the retainage is returned to subcontractors within 30 days after satisfactory completion of
the subcontractors work. Provide this certification in the form designated by the
Department.
Within 30 days of the Contractors receipt of the final progress payment or
any other payments thereafter, except the final payment, the Contractor shall pay all
subcontractors and suppliers having an interest in the Contract for all work completed
and materials furnished. The Department will honor an exception to the above when the
Contractor demonstrates good cause for not making any required payment and furnishes
written notification of any such good cause to both the Department and the affected
subcontractors or suppliers within said 30 day period.
The Contractor shall indemnify and provide defense for the Department
when called upon to do so for all claims or suits against the Department, by third parties,
pertaining to Contractor payment or performance issues arising out of the Contract. It is
expressly understood that the monetary limitation on the extent of the indemnification
shall be the approved Contract amount, which shall be the original Contract amount as
may be increased by subsequent Supplemental Agreements.
9-6 Record of Construction Materials.
9-6.1 General: For all construction materials used in the construction of the
project, (except materials exempted by 9-6.2), preserve for the Departments inspection
the invoices and records of the materials for a period of three years from the date of
completion of the project. Apply this requirement when subcontractors purchase
materials, and obtain the invoices and other materials records from the subcontractors. By
providing the materials, the Contractor certifies that all invoices will be maintained for
the required period.
9-6.2 Non-Commercial Materials: The provisions of 9-6.1 do not apply to
materials generally classed as non-commercial, such as fill materials, local sand, sandclay, or local materials used as stabilizer.
9-7 Disputed Amounts Due the Contractor.
The Department reserves the right to withhold from the final estimate any
disputed amounts between the Contractor and the Department. The Department will
release all other amounts due, as provided in 9-8.
9-8 Acceptance and Final Payment.
9-8.1 Acceptance and Final Payment Documents: Whenever the Contractor has
completely performed the work provided for under the Contract and the Engineer has
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performed a final inspection and made final acceptance (as provided in 5-10 and 5-11),
and subject to the terms of 8-11, the Engineer will prepare a final estimate showing the
value of the work as soon as the Engineer makes the necessary measurements and
computations. The Engineer will correct all prior estimates and payments in the final
estimate and payment. The Department will pay the estimate, less any sums that the
Department may have deducted or retained under the provisions of the Contract, as soon
as practicable after final acceptance of the work, along with all executed supplemental
agreements received after final acceptance.
If the Contractor fails to furnish all required Contract Documents as listed
in (a) through (h) below within 90 days of the Departments offer of final payment or
request for refund of overpayment, the Department may suspend the Contractors
Certificate of Qualification under the provisions of Florida Administrative Code 14-22.
(a) The Contractor has agreed in writing to accept the balance due
or refund the overpayment, as determined by the Department, as full settlement of his
account under the Contract and of all claims in connection therewith, or the Contractor,
has through the use of the Qualified Acceptance Letter, accepted the balance due or
refunded the overpayment, as determined by the Department, with the stipulation that his
acceptance of such payment or the making of such refund does not constitute any bar,
admission, or estoppel, or have any effect as to those payments in dispute or the subject
of a pending claim between the Contractor and the Department. To receive payment
based on a Qualified Acceptance Letter, define in writing the dispute or pending claim
with full particular of all items of all issues in dispute, including itemized amounts
claimed for all particulars of all items, and submit it as part of the Qualified Acceptance
Letter. The Contractor further agrees, by submitting a Qualified Acceptance Letter that
any pending or future arbitration claim or suit is limited to those particulars, including the
itemized amounts, defined in the original Qualified Acceptance Letter, and that he will
commence with any such arbitration claim or suit within 820 calendar days from and
after the time of final acceptance of the work and that his failure to file a formal claim
within this period constitutes his full acceptance of the Engineers final estimate and
payment. The overpayment refund check from the Contractor, if required, will be
considered a part of any Acceptance Letter executed.
(b) The Contractor has properly maintained the project, as
specified hereinbefore.
(c) The Contractor has furnished a sworn affidavit to the effect that
the Contractor has paid all bills and no suits are pending (other than those exceptions
listed, if any) in connection with work performed under the Contract and that the
Contractor has not offered or made any gift or gratuity to, or made any financial
transaction of any nature with, any employee of the Department in the performance of the
Contract. Include with the listed tort liability exceptions, if any, evidence of adequate
insurance coverage as required in 7-13.
(d) The surety on the Contract bond consents, by completion of
their portion of the affidavit and surety release subsequent to the Contractors completion
of his portion, to final payment to the Contractor and agrees that the making of such
payment does not relieve the surety of any of its obligations under the bond.
(e) The Contractor has complied with and settled all requirements
pertaining to any wage-rate provisions.
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(f) The Contractor has furnished all required mill tests and analysis
reports to the Engineer.
(g) The Contractor has furnished the Construction Compliance
with Specifications and Plans Certification. Provide the Engineer with a notarized final
certification of compliance with the requirements of Section 105 to accompany the final
estimate. Certification must be on a form provided by the Engineer.
(h) The Contractor has furnished and the Department has accepted
the as-built drawings and certified survey in accordance with the requirements of
Section 555, 556, 557 and 611.
9-8.2 Review of Engineers Final Estimate: The Department may review the
Engineers final estimate and make changes as necessary. If changes are made, the
Contractor will be so notified in writing in the Notification of Findings Due to
Additional Review. This notification letter will detail the changes made as a result of the
review, and will stipulate the actions to be taken by the Department and those required by
the Contractor. The issuance of a Notification of Findings Due to Additional Review
will not impact the requirements of 9-8.1, above.
Complete the required actions and return the signed Notification of
Findings Due to Additional Review to the Department within the timeframe specified in
9-8.1. If the Notification of Findings Due to Additional Review is received after the
time has expired in 9-8.1, return to the Department within 30 days signifying agreement
or disagreement with the findings. For disagreement items, provide a full explanation
including the item(s) and amount. For any claim or part of a claim that pertains solely to
the Notification of Findings Due to Additional Review disputes, submit full and
complete claim documentation as described in 5-12.3 as to such claim dispute issues
within 90 days of receipt of the notification. Failure to return the signed notification or to
furnish such claim documentation within the time frames specified may result in
suspension of the Contractors Certificate of Qualification under the provisions of Florida
Administrative Code 14-22.
9-9 Interest Due on Delayed Payments.
The Department will determine and pay any interest due the Contractor for delays
in final payment in accordance with Section 337.141 of the Florida Statutes.
9-10 Offsetting Payments.
Section 337.145 of the Florida Statutes, providing for offsetting payments to the
Contractor, is hereby made a part of this Contract:
(1) After settlement, arbitration, or final adjudication of any claim of the
Department for work done pursuant to a construction contract with any party, the
Department may offset such amount from payments due for work done on any
construction contract, excluding amounts owed to subcontractors, suppliers, and laborers,
which it has with the party owing such amount if, upon demand, payment of the amount
is not made within 60 days to the Department.
(2) Offsetting any amount pursuant to (1) above shall not be considered a
breach of Contract by the Department.
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DIVISION II
Construction Details
GENERAL CONSTRUCTION OPERATIONS
SECTION 100
CONSTRUCTION EQUIPMENT-GENERAL REQUIREMENTS
100-1 General.
Unless restricted to a specific type by the Contract Documents or the Engineer, the
Contractor may perform the work using equipment, tools, machinery, etc., of his own choosing.
Provide a unique alphanumeric identification number on all equipment (other than small tools)
used on the project. This number shall be a minimum of 2 inches high and appear on both sides
of the equipment. Place the number in such a manner so as to contrast sharply in color with the
background on which it is placed. Ensure that the number, which may be painted or otherwise
permanently affixed to the equipment, is clearly legible at all times. Provide, upon submittal of
Notice of Intent to Claim or Preliminary Time Extension Request in accordance with 5-12.2, a
list showing all equipment (other than small tools) for which the Contractor may request
compensation, its identification number with serial number, manufacturer, year manufactured,
model and description. Update this list to account for equipment moving to or from the project
and provide certification weekly, by close of business on Friday, the equipment, its unique
number and the dates and hours that the equipment was assigned to this project for the
proceeding week. No compensation will be made for any equipment used during any time period
when the said equipment is not listed in the weekly certification. Failure to provide this
information in the time specified may result in the Engineer withholding all Contract Payments
until receipt of such information. Note that facilities to be constructed under the Contract are
adequate to support only their design loads in their completed construction stage. If the
Contractors equipment or procedures during construction damage any part of the facility, the
Contractor will replace or repair it as directed by the Engineer at no expense to the Department.
100-2 Equipment Condition and Approval.
100-2.1 Approval: Provide on site and in due time prior to its need, in working
condition, all equipment to be used in construction of the project, subject to approval or
disapproval by the Engineer. Use only factory recommended exhaust mufflers on internal
combustion engines. Remove from the job, alter, or repair equipment which is disapproved by
the Engineer. Ensure that the number of units, the sizes, etc., of the equipment on hand are
adequate to complete the work within the Contract Time.
100-2.2 Maintenance: Consistent with public interest, safety, and good practice,
maintain all equipment, tools, and machinery used in a satisfactory working condition
throughout the period they are on the job site. Also, provide adequate equipment maintenance
procedures to promote continuous satisfactory working condition and minimize noise pollution
caused by construction equipment.
100-2.3 Stationary Equipment: Screen all stationary equipment such as pumps,
compressors, generators, etc., from noise sensitive receivers if that equipment is to operate
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beyond normal working hours. If it is feasible, screen this equipment during normal working
hours to reduce noise impacts.
100-3 Experimental Equipment.
100-3.1 General: To encourage the development and use of new or improved equipment,
the Engineer may grant the Contractor permission to use equipment other than that normally
used and currently accepted, upon approval of the Contractors written request for permission to
use such equipment in place of the normally used equipment. The Engineer, before considering
or granting such request, may require that the Contractor establish, at his own expense,
satisfactory evidence that the proposed equipment will produce work equal in quality to that
produced by the specified equipment, and meets any applicable local, state or federal noise
abatement laws, by-laws, ordinances and regulation in effect.
100-3.2 Conditions of Approval: When the Engineer grants permission for the use of
new or improved equipment, understand that the Engineer gives such permission for the purpose
of testing the quality of work this equipment actually produces. The Engineer will maintain the
right to retract permission for use of the equipment at any time that, in his opinion, the
Contractor does not obtain results that are at least equal to the results obtainable with currently
accepted equipment. Upon the Engineers withdrawal of such permission for the use of the
equipment, use the equipment currently accepted and normal for the work, and remove and
dispose of, or otherwise remedy, at no expense to the Department, any work which the Engineer
considers defective or unsatisfactory as a result of the use of such experimental equipment. If the
Engineer approved the use of particular equipment on a particular project, the Engineers
approval does not extend to the use of the particular equipment on any other project.
Furthermore, the Contractor is fully responsible for producing finished work of the quality
required by the Contract Documents.
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SECTION 101
MOBILIZATION
101-1 Description.
Perform preparatory work and operations in mobilizing for beginning work on the
project, including, but not limited to, those operations necessary for the movement of personnel,
equipment, supplies, and incidentals to the project site and for the establishment of temporary
offices, buildings, safety equipment and first aid supplies, and sanitary and other facilities.
Include the costs of bonds and any required insurance and any other preconstruction
expense necessary for the start of the work, excluding the cost of construction materials.
101-2 Basis of Payment.
101-2.1 When a Separate Item is Included in the Proposal: When the proposal
includes a separate item of payment for this work, the work and incidental costs specified as
being covered under this Section will be paid for at the Contract lump sum price for the item of
Mobilization.
Payment will be made under:
Item No. 101- 1Mobilization -lump sum.
101-2.2 Partial Payments: When the proposal includes a separate pay item for
Mobilization and the Notice to Proceed has been issued, partial payments will be made in
accordance with the following:
For contracts of 120 contract days duration or less, partial payment will be made
at 50% of the bid price per month for the first two months. For contracts in excess of 120
contract days duration, partial payment will be made at 25% of the bid price per month for the
first four months. In no event shall more than 50% of the bid price be paid prior to commencing
construction on the project site.
Total partial payments for Mobilization on any project, including when more than
one project or job is included in the Contract, will be limited to 10% of the original Contract
amount for that project. Any remaining amount will be paid upon completion of all work on the
Contract.
Retainage, as specified in 9-5, will be applied to all partial payments.
Partial payments made on this item will in no way act to preclude or limit any of
the provisions for partial payments otherwise provided for by the Contract.
101-2.3 When No Separate Item is Included in the Proposal: When the proposal does
not include a separate item for Mobilization, all work and incidental costs specified as being
covered under this Section will be included for payment under the several scheduled items of the
overall Contract, and no separate payment will be made therefore.
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SECTION 102
MAINTENANCE OF TRAFFIC
102-1 Description.
Maintain traffic within the limits of the project for the duration of the construction period,
including any temporary suspensions of the work. Construct and maintain detours. Provide
facilities for access to residences, businesses, etc., along the project. Furnish, install and maintain
traffic control and safety devices during construction. Furnish and install work zone pavement
markings for maintenance of traffic (MOT) in construction areas. Provide any other special
requirements for safe and expeditious movement of traffic specified in the Plans. MOT includes
all facilities, devices and operations as required for safety and convenience of the public within
the work zone.
Do not maintain traffic over those portions of the project where no work is to be
accomplished or where construction operations will not affect existing roads. Do not obstruct or
create a hazard to any traffic during the performance of the work, and repair any damage to
existing pavement open to traffic.
Include the cost of any work that is necessary to meet the requirements of the Contract
Documents under the MOT pay item, when there is not a pay item provided.
102-2 Materials.
Meet the following requirements:
Bituminous Adhesive ..........................................Section 970
Temporary Retroreflective Pavement MarkersSection 990
Paint ................................................................Section 971
Removable Tape .................................................Section 990
Glass Spheres ......................................................Section 971
Temporary Traffic Control Device Materials .....Section 990
Retroreflective and Nonreflective Sheeting
for Temporary Traffic Control Devices ..............Section 994
102-2.1 Temporary Traffic Control Devices: Use only the materials meeting the
requirements of Section 990, Section 994, Design Standards and the Manual on Uniform Traffic
Control Devices (MUTCD).
102-2.2 Detour: Provide all materials for the construction and maintenance of all
detours.
102-2.3 Commercial Materials for Driveway Maintenance: Provide materials of the
type typically used for base, including recycled asphalt pavement material, and having stability
and drainage properties that will provide a firm surface under wet conditions.
102-3 Specific Requirements.
102-3.1 Beginning Date of Contractors Responsibility: Maintain traffic starting the
day work begins on the project or on the first day Contract time is charged, whichever is earlier.
102-3.2 Worksite Traffic Supervisor: Provide a worksite traffic supervisor in
accordance with Section 105. Provide the worksite traffic supervisor with all equipment and
materials needed to set up, take down, maintain traffic control, and handle traffic-related
situations.
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Ensure that the worksite traffic supervisor performs the following duties:
1. Performs on site direction of all traffic control on the project.
2. Is on site during all set up and take down, and performs a drive through
inspection immediately after set up.
3. Is on site during all nighttime operations to ensure proper MOT.
4. Immediately corrects all safety deficiencies and does not permit minor
deficiencies that are not immediate safety hazards to remain uncorrected for more than 24 hours.
5. Is available on a 24 hour per day basis and present within 45 minutes
after notification of an emergency situation and is prepared to positively respond to repair the
work zone traffic control or to provide alternate traffic arrangements.
6. Conducts daily daytime and weekly nighttime inspections of projects
with predominately daytime work activities, and daily nighttime and weekly daytime inspections
of projects with predominantly nighttime work activities of all traffic control devices, traffic
flow, pedestrian, bicyclist, and business accommodations.
Advise the project personnel of the schedule of these inspections
and give them the opportunity to join in the inspection as is deemed necessary. Submit a
comprehensive weekly report, using the Departments currently approved form, to the Engineer
detailing the condition of all traffic control devices (including pavement markings) being used.
Include assurances in the inspection report that pedestrians are accommodated with a safe,
accessible travel path around work sites separated from mainline traffic in compliance with the
Americans with Disabilities Act (ADA) Standards for Transportation Facilities, that existing or
detoured bicyclist paths are being maintained satisfactorily throughout the project limits, and that
existing businesses in work areas are being provided with adequate entrances for vehicular and
pedestrian traffic during business hours. Have the worksite traffic supervisor sign the report and
certify that all of the above issues are being handled in accordance with the Contract Documents.
When deficiencies are found, the worksite traffic supervisor is to note such deficiencies and
include the proposed corrective actions, including the date corrected.
The Department may disqualify and remove from the project a worksite traffic
supervisor who fails to comply with the provisions of this Section. The Department may
temporarily suspend all activities, except traffic, erosion control and such other activities that are
necessary for project maintenance and safety, for failure to comply with these provisions.
102-4 Alternative Traffic Control Plan.
The Contractor may propose an alternative traffic control plan (TCP) to the plan
presented in the Contract Documents. Have the Contractors Engineer of Record sign and seal
the alternative plan. Prepare the TCP in conformance with and in the form outlined in the current
version of the Departments Plans Preparation Manual. Indicate in the plan a TCP for each phase
of activities. Take responsibility for identifying and assessing any potential impacts to a utility
that may be caused by the alternate TCP proposed by the Contractor, and notify the Department
in writing of any such potential impacts to utilities.
Engineers approval of the alternate TCP does not relieve the Contractor of sole
responsibility for all utility impacts, costs, delays or damages, whether direct or indirect,
resulting from Contractor initiated changes in the design or construction activities from those in
the original Contract Specifications, Design Plans (including TCPs) or other Contract Documents
and which effect a change in utility work different from that shown in the Utility Plans, joint
project agreements or utility relocation schedules.
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The Department reserves the right to reject any alternative TCP. Obtain the Engineers
written approval before beginning work using an alternate TCP. The Engineers written approval
is required for all modifications to the TCP. The Engineer will only allow changes to the TCP in
an emergency without the proper documentation.
102-5 Traffic Control.
102-5.1 Standards: FDOT Design Standards are the minimum standards for the use in
the development of all TCPs. The MUTCD, Part VI is the minimum national standard for traffic
control for highway construction, maintenance, and utility operations. Follow the basic principles
and minimum standards contained in these documents for the design, application, installation,
maintenance, and removal of all traffic control devices, warning devices and barriers which are
necessary to protect the public and workers from hazards within the project limits.
102-5.2 Maintenance of Roadway Surfaces: Maintain all lanes that are being used for
the MOT, including those on detours and temporary facilities, under all weather conditions. Keep
the lanes reasonably free of dust, potholes and rutting. Provide the lanes with the drainage
facilities necessary to maintain a smooth riding surface under all weather conditions.
102-5.3 Number of Traffic Lanes: Maintain one lane of traffic in each direction.
Maintain two lanes of traffic in each direction at existing four (or more) lane cross roads, where
necessary to avoid undue traffic congestion. Construct each lane used for MOT at least as wide
as the traffic lanes existing in the area before commencement of construction. Do not allow
traffic control and warning devices to encroach on lanes used for MOT.
The Engineer may allow the Contractor to restrict traffic to one-way operation for
short periods of time provided that the Contractor employs adequate means of traffic control and
does not unreasonably delay traffic. When a construction activity requires restricting traffic to
one-way operations, locate the flaggers within view of each other when possible. When visual
contact between flaggers is not possible, equip them with 2-way radios, official, or pilot vehicles,
or use traffic signals.
102-5.4 Crossings and Intersections: Provide and maintain adequate accommodations
for intersecting and crossing traffic. Do not block or unduly restrict any road or street crossing
the project unless approved by the Engineer. Before beginning any construction, provide the
Engineer the names and phone numbers of persons that can be contacted when signal operation
malfunctions.
102-5.5 Access for Residences and Businesses: Provide continuous access to all
residences and all places of business.
102-5.6 Protection of the Work from Injury by Traffic: Where traffic would be
injurious to a base, surface course, or structure constructed as a part of the work, maintain all
traffic outside the limits of such areas until the potential for injury no longer exists.
102-5.7 Flagger: Provide trained flaggers in accordance with Section 105.
102-5.8 Conflicting Pavement Markings: Where the lane use or where normal vehicle
or pedestrian paths are altered during construction, remove all pavement markings (paint, tape,
thermoplastic, raised pavement markers, etc.) that will conflict with the adjusted vehicle or
pedestrian paths. Use of paint to cover conflicting pavement markings is prohibited. Remove
conflicting pavement markings using a method that will not damage the surface texture of the
pavement and which will eliminate the previous marking pattern regardless of weather and light
conditions.
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Remove all pavement markings that will be in conflict with next phase of
operation vehicle pedestrian paths as described above, before opening to vehicle traffic or use
by pedestrians.
Cost for removing conflicting pavement markings (paint, tape, thermoplastic,
raised pavement markers, etc.) to be included in Maintenance of Traffic, Lump Sum.
102-5.9 Vehicle and Equipment Visibility: Equip all pickups and automobiles used on
the project with a minimum of one Class 2 amber or white warning light that meets the Society
of Automotive Engineers Recommended Practice SAE J595, dated November 1, 2008, or SAE
J845, dated December 1, 2007, and incorporated herein by reference. Existing lights that meet
SAE J845, dated March, 1992, or SAE J1318, dated April, 1986, may be used to its end of
service life. Lights should be unobstructed by ancillary vehicle equipment such as ladders, racks
or booms. If the light is obstructed, additional lights will be required. The lights shall be
operating when a vehicle is in a work area where a potential hazard exists, when operating the
vehicle at less than the average speed for the facility while performing work activities, making
frequent stops or called for in the Plans or Design Standards.
Equip all other vehicles and equipment with a minimum of 4 square feet of
retroreflective sheeting or flashing lights.
To avoid distraction to motorists, do not operate the lights on the vehicles or
equipment when the vehicles are outside the clear zone or behind a barrier.
102-5.10 No Waiver of Liability: Conduct operations in such a manner that no undue
hazard results due to the requirements of this Article. The procedures and policies described
herein in no way acts as a waiver of any terms of the liability of the Contractor or his surety.
102-6 Detours.
102-6.1 General: Construct and maintain detour facilities wherever it becomes necessary
to divert traffic from any existing roadway or bridge, or wherever construction operations block
the flow of traffic.
102-6.2 Construction: Plan, construct, and maintain detours for the safe passage of
traffic in all conditions of weather. Provide the detour with all facilities necessary to meet this
requirement. Where pedestrian facilities are detoured, blocked or closed during the work, provide
safe alternate accessible routes through or around the work zone meeting the requirements of the
ADA Standards for Transportation Facilities.
When the Plans call for the Department to furnish detour bridge components,
construct the pile bents in accordance with the Plans, unless otherwise authorized by the
Engineer.
Submit a letter with the following: company name, phone number, office address,
project contact person, project number, detour bridge type, bridge length, span length, location
and usage time frames, to the Engineer at least 30 calendar days before the intended pick-up
date, to obtain the storage facility location and list of components for the project. Upon receipt of
letter, the Engineer will, within ten calendar days provide an approved material list to the
Contractor and the appropriate Department storage yard.
Provide a letter with an original company seal, identifying the representative with
authority to pick up components, to the Engineer at least 10 calendar days before the proposed
pick-up date. The Department is not obligated to load the bridge components without this notice.
Take responsibility and sign for each item loaded at the time of issuance.
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Provide timber dunnage, and transport the bridge components from the designated
storage facility to the job site. Unload, erect, and maintain the bridge, then dismantle the bridge
and load and return the components to the designated storage facility.
Notify the Engineer in writing at least 10 calendar days before returning the
components. Include in this notice the name of the Contractors representative authorized to sign
for return of the bridge components. The yard supervisor is not obligated to unload the bridge
components without this notice.
The Department will provide equipment and an operator at the Departments
storage facility to assist in loading and unloading the bridge components. Furnish all other labor
and equipment required for loading and unloading the components.
The Departments representative will record all bridge components issued or
returned on the Detour Bridge Issue and Credit Ticket. The tickets must be signed by a
Department and a Contractor representative, after loading or unloading each truck to document
the quantity and type of bridging issued or returned.
Bind together all bridge components to be returned in accordance with the
instructions given by the storage facility. The yard supervisor will repack components that are
not packed in compliance with these instructions. Upon request, written packing instructions will
be made available to the Contractor, before dismantling of the bridge for return to the
Departments storage facility.
Assume responsibility for any shortage or damage to the bridge components.
Monies due the Contractor will be reduced at the rate of $35.00 per hour plus materials for
repacking, repairs or replacement of bridge components.
The skid resistance of open steel grid decking on the detour bridge may decrease
gradually after opening the bridge to traffic. The Department will furnish a pneumatic floor
scabbler machine for roughening the roadway surface of the detour bridge decking. Provide an
air compressor at the job site with 200 cubic foot per minute capacity, 90 psi air pressure for the
power supply of the machine, and an operator. Transport the scabbler machine to and from the
Departments structures shop. Repair any damage to the scabbler machine caused by operations
at no expense to the Department. Perform scabbling when determined necessary by the Engineer.
The Department will pay for the cost of scabbling as Unforeseeable Work in accordance with
4-4.
Return the bridge components to the designated storage facility beginning no later
than 10 calendar days after the date the detour bridge is no longer needed, the date the new
bridge is placed in service, or the date Contract Time expires, whichever is earliest. Return the
detour bridging at an average of not less than 200 feet per week. Upon failure to return the bridge
components to the Department within the time specified, compensate the Department for the
bridge components not returned at the rate of $5.00 per 10 feet, per day, per bridge, for single
lane; and $10.00 per 10 feet, per day, per bridge, for dual lane until the bridge components are
returned to the Department.
102-6.3 Construction Methods: Select and use construction methods and materials that
provide a stable and safe detour facility. Construct the detour facility to have sufficient durability
to remain in good condition, supplemented by maintenance, for the entire period that the detour
is required.
102-6.4 Removal of Detours: Remove detours when they are no longer needed and
before the Contract is completed. Take ownership of all materials from the detour and dispose of
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them, except for the materials on loan from the Department with the stipulation that they are
returned.
102-6.5 Detours Over Existing Roads and Streets: When the Department specifies that
traffic be detoured over roads or streets outside the project area, do not maintain such roads or
streets. However, maintain all signs and other devices placed for the purpose of the detour.
102-6.6 Operation of Existing Movable Bridges: The Department will maintain and
operate existing moveable bridges that are to be removed by the Contractor until such time as
they are closed to traffic. During this period, make immediate repairs of any damage to such
structures caused by use or operations related to the work at no expense to the Department, but
do not provide routine repairs or maintenance. In the event that use or operations result in
damage to a bridge requiring repairs, give such repairs top priority to any equipment, material, or
labor available.
102-7 Traffic Control Officer.
Provide uniformed law enforcement officers, including marked law enforcement
vehicles, to assist in controlling and directing traffic in the work zone when the following types
of work is necessary on projects:
1. Directing traffic/overriding the signal in a signalized intersection.
2. When Design Standards, Index No. 619 is used on freeway facilities
(interstates, toll roads, and expressways) at nighttime for work within the travel lane.
3. When Design Standards, Index No. 655 Traffic Pacing for overhead work is
called for in the Plans or approved by the Engineer.
4. When pulling conductor/cable above an open traffic lane on limited access
facilities, when called for in the Plans or approved by the Engineer.
5. When Design Standards, Index No. 625 Temporary Road Closure 5 Minutes or
Less is used.
102-8 Driveway Maintenance.
102-8.1 General: Ensure that each residence and business has safe, stable, and
reasonable access.
102-8.2 Construction Methods: Place, level, manipulate, compact, and maintain the
material, to the extent appropriate for the intended use.
As permanent driveway construction is accomplished at a particular location, the
Contractor may salvage and reuse previously placed materials that are suitable for reuse on other
driveways.
102-9 Temporary Traffic Control Devices.
102-9.1 Installation and Maintenance: Install and maintain temporary traffic control
devices as detailed in the Plans, Index 600 of the Design Standards and when applicable, in
accordance with the approved vendor drawings, as provided on the Departments Qualified
Products List (QPL) or the Departments Approved Products List (APL). Erect the required
temporary traffic control devices to prevent any hazardous conditions and in conjunction with
any necessary traffic re-routing to protect the traveling public, workers, and to safeguard the
work area. Use only those devices that are on the QPL or the APL. Immediately remove or cover
any devices that do not apply to existing conditions.
All temporary traffic control devices must meet the requirements of National
Cooperative Highway Research Program Report 350 (NCHRP 350) or the Manual for Assessing
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Safety Hardware 2009 (MASH) and current FHWA directives. Manufacturers seeking evaluation
must furnish certified test reports showing that their product meets all test requirements set forth
by NCHRP 350 or the MASH. Manufacturers seeking evaluation of Category I devices for
inclusion on the QPL shall include the manufacturers self-certification letter. Manufacturers
seeking evaluation of Category II and Category III devices for inclusion on the QPL shall
include the FHWA WZ numbered acceptance letter with attachments and vendor drawings of the
device in sufficient detail to enable the Engineer to distinguish between this and similar devices.
For devices requiring field assembly or special site preparation, vendor drawings shall include all
field assembly details and technical information necessary for proper application and installation
and must be signed and sealed by a Professional Engineer registered in the State of Florida.
Manufacturers seeking evaluation of Category IV devices for inclusion on the QPL or APL must
comply with the requirements of Section 990 and include detailed vendor drawings of the device
along with technical information necessary for proper application, field assembly and
installation.
Ensure that the QPL or APL number is permanently marked on the device at a
readily visible location. Sheeting used on devices is exempt from this marking requirement.
Notify the Engineer of any scheduled operation which will affect traffic patterns
or safety sufficiently in advance of commencing such operation to permit his review of the plan
for the proposed installation of temporary traffic control devices.
Ensure an employee is assigned the responsibility of maintaining the position and
condition of all temporary traffic control devices throughout the duration of the Contract. Keep
the Engineer advised at all times of the identification and means of contacting this employee on a
24 hour basis.
Keep temporary traffic control devices in the correct position, properly directed,
clearly visible and clean, at all times. Ensure that all traffic control devices meet acceptable
standards as outlined in American Traffic Safety Services Association (ATSSA) Quality
Guidelines for Temporary Traffic Control Devices and Features. Immediately repair, replace or
clean damaged, defaced or dirty devices.
102-9.2 Work Zone Signs: Provide signs in accordance with the Plans and Design
Standards. Meet the requirements of 700-2.5 and 990-8 Use only approved systems, which
includes sign support posts or stands and attachment hardware (nuts, bolts, clamps, brackets,
braces, etc.), meeting the vendor requirements specified on the QPL drawings.
Attach the sign to the sign support using hardware meeting the manufacturers
recommendations and as specified in the Design Standards.
Provide Federal Highway Administrations (FHWA) accepted sign substrate for use with
accepted sign stands on the National Highway System (NHS) under the provisions of the
NCHRP Report 350 Recommended Procedures for the Safety Performance Evaluation of
Highway Features.
102-9.3 Business Signs: Provide and place signs in accordance with the Plans and
Design Standards, Index No. 600 series. Furnish signs having retroreflective sheeting meeting
the requirements of Section 990.
102-9.4 High Intensity Flashing Lights: Furnish Type B lights in accordance with the
Plans and Design Standards.
102-9.5 Warning/Channelizing Devices: Furnish warning/channelizing devices in
accordance with the Plans and Design Standards.
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102-9.5.1 Retroreflective Collars for Traffic Cones: Use collars for traffic
cones listed on the QPL that meet the requirements of Section 990. Use cone collars at night
designed to properly fit the taper of the cone when installed. Place the upper 6 inch collar a
uniform 3-1/2 inches distance from the top of the cone and the lower 4 inch collar a uniform
2 inches distance below the bottom of the upper 6 inch collar. Ensure that the collars are capable
of being removed for temporary use or attached permanently to the cone in accordance with the
manufacturers recommendations. Provide a white sheeting having a smooth outer surface and
that has the property of a retroreflector over its entire surface.
102-9.5.2 Barrier Wall (Temporary): Furnish, install, maintain, remove and
relocate a temporary barrier wall in accordance with the Plans. Ensure that temporary concrete
barrier wall for use on roadway sections, complies with Design Standards, Index Nos. 412, 415
or 414 as specified in the Plans. Ensure that temporary concrete barrier wall for use on bridge
and wall sections, complies with Design Standards, Index No 414 as specified in the Plans.
Ensure that temporary water filled barrier wall used on roadway sections meets the NCHRP
Report 350 criteria or the MASH and is listed on the QPL. Barriers meeting the requirements of
Design Standards, Index Nos. 412, 415 or temporary water filled barriers on the QPL will not be
accepted as an alternate to barriers meeting the requirements of Design Standards, Index
No. 414.
102-9.5.3 Glare Screen (Temporary): Use temporary glare screens listed on the
QPL that meet the requirements of Section 990. Furnish, install, maintain, remove and relocate
glare screen systems in conjunction with temporary barrier wall at locations identified in the
Plans.
Ensure the anchorage of the glare screen to the barrier is capable of safely
resisting an equivalent tensile load of 600 pounds per foot of glare screen, with a requirement to
use a minimum of three fasteners per barrier section.
When glare screen is utilized on temporary barrier wall, warning lights
will not be required.
102-9.6 Temporary Crash Cushion (Redirective/Gating): Furnish, install, maintain
and subsequently remove temporary crash cushions in accordance with the details and notes
shown in the Plans, the Design Standards, and requirements of the pre-approved alternatives
listed on the QPL. Maintain the crash cushions until their authorized removal. Repair all
attachment scars to permanent structures and pavements after crash cushion removal. Make
necessary repairs due to defective material, work, or Contractor operations at no cost to the
Department. Restore crash cushions damaged by the traveling public within 24 hours after
notification as authorized by the Engineer.
102-9.7 Guardrail (Temporary): Furnish guardrail (temporary) in accordance with the
Plans and Design Standards. Meet the requirements of Section 536.
102-9.8 Arrow Board: Furnish arrow boards that meet the requirements of Section 990
as required by the Plans and Design Standards to advise approaching traffic of lane closures or
shoulder work. Type B arrow boards may be used on low to intermediate speed (0 mph to
50 mph) facilities or for maintenance or moving operations on any speed facility. Type C arrow
boards shall be used for all other operations on high-speed (50 mph and greater) facilities and
may be substituted for Type B arrow boards on any speed facility.
102-9.9 Portable Changeable Message Sign (PCMS): Furnish PCMSs that meet the
requirements of Section 990 as required by the Plans and Design Standards to supplement other
temporary traffic control devices used in work zones.
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A truck mounted PCMS may be used as a stand alone MOT device only when
used for accident or incident management situations as defined in the MUTCD and is listed on
the APL.
102-9.10 Portable Regulatory Signs (PRS): Furnish PRSs that meet the requirements of
990 as required by the Plans and Design Standards.
Activate portable regulatory signs only during active work activities and
deactivate when no work is being performed.
102-9.11 Radar Speed Display Unit (RSDU): Furnish RSDUs that meet the
requirements of Section 990 as required by the Plans and Design Standards to inform motorists
of the posted speed and their actual speed.
Activate the radar speed display unit only during active work activities and
deactivate when no work is being performed.
102-9.12 Temporary Signalization and Maintenance: Provide temporary signalization
and maintenance at existing, temporary, and new intersections including but not limited to the
following:
(1) Installation of temporary poles and span wire assemblies as shown in
the Plans,
(2) Temporary portable traffic signals as shown in the Plans,
(3) Adding or shifting signal heads,
(4) Trouble calls,
(5) Maintaining intersection and coordination timing and preemption
devices.
Restore any loss of operation within 12 hours after notification.
Provide traffic signal equipment that meets the requirements of the Design
Standards and 603-2. The Engineer may approve used signal equipment if it is in acceptable
condition. Replacement components for traffic signal cabinet assemblies will be provided by the
maintaining agency.
102-9.13 Temporary Traffic Detection and Maintenance: Provide temporary traffic
detection and maintenance at existing, temporary, and new signalized intersections. Provide
temporary traffic detection equipment listed on the APL. Restore any loss of detection within
12 hours. Ensure 90% accuracy per signal phase, measured at the initial installation and after any
lane shifts, by comparing sample data collected from the detection system with ground truth data
collected by human observation. Collect the sample and ground truth data for a minimum of five
minutes during a peak and five minutes during an off-peak period with a minimum three
detections for each signal phase. Perform the test in the presence of the Engineer.
102-9.14 Truck Mounted Attenuators and Trailer Mounted Attenuators: Furnish,
install and maintain only those attenuators that meet the requirements of NCHRP 350 or the
MASH.
Use truck mounted attenuators or trailer mounted attenuators, when called for in
the Design Standards. Use attenuators listed on the QPL.
When attenuators are called for, use either a truck mounted attenuator or a trailer
mounted attenuator system designed and installed in accordance with the manufacturers
recommendations.
Equip the attenuator cartridge with lights and reflectors in compliance with
applicable Florida motor vehicle laws, including turn signals, dual tail lights, and brake lights.
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Ensure that lights are visible in both the raised and lowered positions if the unit is capable of
being raised.
Ensure that the complete unit is painted DOT yellow (Fed. Std. 595 b,
No. 13538). Stripe the rear facing of the cartridge in the operating position with the alternating
6 inch white and 6 inch safety orange 45 degree striping to form an inverted V at the center of
the unit and slope down and toward the outside of the unit, in both directions from the center. In
the raised position, place at least the same square footage of striping on the bottom of the
cartridge as placed on the rear facing cartridge in the open position. Use Type III
retroreflectorized sheeting for striping.
Attenuators will not be paid for separately. Include the cost of the truck with
either a truck mounted attenuator or a trailer mounted attenuator in MOT Lump Sum. Payment
includes all costs, including furnishing, maintaining and removal when no longer required, and
all materials, labor, tools, equipment and incidentals required for attenuator maintenance.
102-9.15 Temporary Raised Rumble Strip Sets: When called for in the Plans, furnish,
install, maintain, remove, and reinstall temporary raised rumble strip sets.
Install the temporary raised rumble strip sets per the manufacturers
recommendations and in accordance with Design Standards, Index No. 600.
The temporary raised rumble strip may be either a removable polymer striping
tape or a molded engineered polymer material.
102-9.16 Automated Flagger Assistance Devices (AFAD): Furnish, install, maintain,
remove and relocate AFADs in accordance with the Plans and Design Standards. Position
AFADs where they are clearly visible to oncoming traffic and out of the lane of traffic. The
devices may be operated either by a single flagger at one end of the traffic control zone, from a
central location, or by a separate flagger near each devices location.
AFADs may be either a remotely controlled Stop/Slow AFAD mounted on either
a trailer or a movable cart system, or a remotely controlled Red/Yellow Lens AFAD.
AFADs will not be paid for separately. AFADs may be used as a supplement or
an alternate to flaggers in accordance with Index 603. Include the cost for AFADs in
Maintenance of Traffic Lump Sum.
102-9.17 Temporary Lane Separator: Furnish, install, maintain, remove and relocate
temporary lane separator in accordance with the Plans and Design Standards, Index No 600.
Anchor the portable temporary lane separator with a removable anchor bolt. Use epoxy on bridge
decks where anchoring is not allowed. Remove the epoxy from the bridge deck by hydroblasting
or other method approved by the Engineer.
102-10 Work Zone Pavement Marking.
102-10.1 Description: Furnish and install work zone pavement markings for MOT in
construction areas and in close conformity with the lines and details shown in the Plans and
Design Standards.
Centerlines, lane lines, edge lines, stop bars and turn arrows will be required in
work zones prior to opening the road to traffic.
The most common types of work zone pavement markings are painted pavement
markings and removable tape. Other types of work zone pavement markings may be identified in
the Plans.
102.10.2 Painted Pavement Markings:
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102-10.2.1 General: Use painted pavement markings meeting the requirements of
Section 710. Use standard waterborne paint unless otherwise identified in the Plans or approved
by the Engineer.
102-10.3 Removable Tape:
102-10.3.1 General: Use removable tape listed on the QPL and meeting the
requirements of 990-4.
102-10.3.2 Application: Apply removable tape with a mechanical applicator to
provide pavement lines that are neat, accurate and uniform. Equip the mechanical applicator with
a film cut-off device and with measuring devices that automatically and accumulatively measure
the length of each line placed within an accuracy tolerance of plus or minus 2%. Ensure
removable tape adheres to the road surface. Removable tape may be placed by hand on short
sections, 500 feet or less, if it is done in a neat accurate manner.
102-10.3.3 Retroreflectivity: Apply white and yellow traffic stripes and
markings that will attain an initial retroreflectivity of not less than 300 mcd/lxm2 for white and
contrast markings and not less than 250 mcd/lxm2 for yellow markings. Black portions of
contrast tapes and black masking tapes must be non-reflective and have a reflectance of less than
5 mcd/lx m2. At the end of the six month service life, the retroreflectance of white and yellow
removable tape shall not be less than 150 mcd/lxm2.
102-10.3.4 Removability: Provide removable tape capable of being removed
from bituminous concrete and portland cement concrete pavement intact or in substantially large
strips, either manually or by a mechanical roll-up device, at temperatures above 40F, without the
use of heat, solvents, grinding or blasting.
102-10.4 Temporary Retroreflective Pavement Markers (RPMs): Use markers listed
on the QPL and meeting the requirements of 990-5. Apply all markers in accordance with the
Design Standards, Index No. 600, prior to opening the road to traffic. Replace markers any time
after installation when more than three consecutive markers fail or are missing, at no expense to
the Department, in a timely manner, as directed by the Engineer.
102-11 Method of Measurement.
102-11.1 General: Devices installed/used on the project on any calendar day or portion
thereof, within the allowable Contract Time, including time extensions which may be granted,
will be paid for at the Contract unit price for the applicable pay item, except those paid for as
Lump Sum.
102-11.2 Traffic Control Officers: The quantity to be paid for will be at the Contract
unit price per hour (4 hour minimum) for the actual number of officers certified to be on the
project site, including any law enforcement vehicles and all other direct and indirect costs.
Payment will be made only for those traffic control officers specified in the Plans and authorized
by the Engineer.
102-11.3 Special Detours: When a detour facility is specifically detailed in the Plans, or
is otherwise described or detailed as a special item, and an item for separate payment is included
in the proposal, the work of constructing, maintaining, and subsequently removing such detour
facilities will be paid for separately. Traffic control devices, warning devices, barriers, signing,
and pavement markings for special detours will also be paid for separately.
When the Plans show more than one detour, each detour will be paid for
separately, at the Contract lump sum price for each.
Where a separate item for a specific detour facility is included in the proposal,
payment will be made under special detour.
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102-11.4 Arrow Board: The quantity to be paid at the contract unit price will be for the
number of arrow boards certified as installed/used on the project on any calendar day or portion
thereof within the contract time.
102-11.5 Work Zone Signs: The number of temporary post-mounted signs (temporary
regulatory, warning and guide) certified as installed/used on the project will be paid for at the
Contract unit price for work zone signs. When multiple signs are located on single or multiple
posts, each sign panel will be paid individually. Signs greater than 20 square feet and detailed in
the Plans will be paid for under Lump Sum MOT.
Temporary portable signs (excluding mesh signs) and vehicular mounted signs
will be included for payment under work zone signs, only if used in accordance with the Design
Standards.
102-11.6. Business Signs: The number of business signs certified as installed/used on the
project will be paid for at the Contract unit price for business signs.
102-11.7 High Intensity Flashing Lights: The number of high intensity flashing lights
(Type B) certified as installed/used on the project will be paid for at the Contract unit price for
high intensity flashing lights (temporary - Type B).
102-11.8 Channelizing Devices: The number of Type I, Type II, direction indicator
barricade, Type III, vertical panel, drum and longitudinal channelizing devices certified as
installed/used on the project meeting the requirements of Design Standards, Index No. 600 and
have been properly maintained will be paid for at the Contract unit prices for barricade
(temporary). Payment will be made for each channelizing device that is used to delineate trailer
mounted devices. Payment will be made for channelizing devices delineating portable
changeable message signs during the period beginning 14 working days before Contract Time
begins as authorized by the Engineer.
102-11.9 Barrier Wall (Temporary): The Contract unit price for barrier wall
(temporary) will be full compensation for furnishing, installing, maintaining, and removing the
barrier wall. When called for, the Contract unit price for barrier wall (temporary/relocate) will be
full compensation for relocating the barrier. The certified quantity to be paid for will be
determined by the number of sections times the nominal length of each section.
102-11.10 Lights, Temporary, Barrier Wall Mount: The number of Type C steady
burn lights, mounted on barrier wall, certified as installed/used on the project, meeting the
requirements of the Design Standards and have been properly maintained will be paid for at the
Contract unit price for lights temporary, barrier wall mount.
102-11.11 Glare Screen (Temporary): The certified quantity to be paid for will be
determined by the number of sections times the nominal length of each section.
102-11.12 Temporary Crash Cushions:
102-11.12.1 Redirective: The quantity to be paid for will be the number of
temporary crash cushions (redirective) certified as installed/used and maintained on the project,
including object marker.
102-11.12.2 Gating: The quantity to be paid for will be the number of temporary
crash cushions (gating) certified as installed/used and maintained on the project, including object
marker.
102-11.13 Temporary Guardrail: The quantity to be paid for will be the length, in feet,
of temporary guardrail constructed and certified as installed/used on the project. The length of a
run of guardrail will be determined as a multiple of the nominal panel lengths.
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102-11.14 Advance Warning Arrow Panel: The quantity to be paid at the Contract unit
price will be for the number of advance warning arrow panels certified as installed/used on the
project on any calendar day or portion thereof within the contract time.
102-11.15 Portable Changeable Message Sign: The quantity to be paid at the Contract
unit price will be for the number of portable changeable message signs certified as installed/used
on the project on any calendar day or portion thereof within the contract time. Payment will be
made for each portable changeable message sign that is used during the period beginning
fourteen working days before Contract Time begins as authorized by the Engineer.
102-11.16 Portable Regulatory Signs: The quantity to be paid for will be the number of
portable regulatory signs certified as installed/used on the project on any calendar day or portion
thereof within the Contract time, will be paid for the Contract unit price for portable regulatory
sign.
102-11.17 Radar Speed Display Unit: The quantity to be paid for will be the number of
radar speed display units certified as installed/used on the project on any calendar day or portion
thereof within the Contract Time, will be paid for the Contract unit price for radar speed display
unit.
102-11.18 Temporary Signalization and Maintenance: For existing intersections, the
quantity to be paid for will be the number of signalized intersections per day for the full duration
of the Contract. For temporary intersections, the quantity to be paid for will be the number of
signalized intersections per day for the duration of the temporary intersection. No separate
payment will be made for temporary signalization and maintenance at new intersections.
102-11.19 Temporary Traffic Detection and Maintenance: For existing intersections,
the quantity to be paid for will be the number of signalized intersections per day beginning the
day Contract Time begins and ending the day the permanent detection is operational and the final
lane configuration is in place. For temporary and new intersections, the quantity to be paid for
will be the number of signalized intersections per day beginning the day the temporary detection
is functional and ending the day: the permanent detection is operational and the final lane
configuration is in place for a new intersection; or, when the detection is removed for a
temporary intersection.
102-11.20 Work Zone Pavement Markings: The quantities, furnished and installed, to
be paid for will be the length of skip and solid pavement markings, and the area of pavement
markings placed as follows:
(a) The total transverse distance, in feet, of skip pavement marking authorized and
acceptably applied. The length of actual applied line will depend on the skip ratio of the material
used. Measurement will be the distance from the beginning of the first stripe to the end of the last
stripe with proper deductions made for unpainted intervals as determined by plan dimensions or
stations, subject to 9-1.3.
(b) The net length, in feet, of solid pavement marking authorized and acceptably
applied.
(c) The number of directional arrows or pavement messages authorized and
acceptably applied.
(d) The number of temporary RPMs authorized and acceptably applied.
102-11.21 Temporary Raised Rumble Strips: The quantity to be paid for will be the
number of temporary raised rumble strip sets certified as installed/used on the project on any
calendar day or portion thereof within the Contract Time.
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102-11.22 Temporary Lane Separator: The quantity of temporary lane separator to be
paid for will be plan quantity, in feet, including drainage gaps, completed and accepted.
102-12 Submittals.
102-12.1 Submittal Instructions: Prepare a certification of quantities, using the
Departments current approved form, for certified MOT payment items for each project in the
Contract. Submit the certification of quantities to the Engineer. The Department will not pay for
any disputed items until the Engineer approves the certification of quantities.
102-12.2 Contractors Certification of Quantities: Request payment by submitting a
certification of quantities no later than Twelve Oclock noon Monday after the estimate cut-off
date or as directed by the Engineer, based on the amount of work done or completed. Ensure the
certification consists of the following:
(a) Contract Number, FPID Number, Certification Number, Certification Date and
the period that the certification represents.
(b) The basis for arriving at the amount of the progress certification, less
payments previously made and less an amount previously retained or withheld. The basis will
include a detail breakdown provided on the certification of items of payment in accordance with
102-13. After the initial setup of the MOT items and counts, the interval for recording the counts
will be made weekly on the certification sheet unless there is a change. This change will be
documented on the day of occurrence. Some items may necessitate a daily interval of recording
the counts.
102-13 Basis of Payment.
102-13.1 Maintenance of Traffic (General Work): When an item of work is included
in the proposal, price and payment will be full compensation for all work and costs specified
under this Section except as may be specifically covered for payment under other items.
102-13.2 Traffic Control Officers: Price and payment will be full compensation for the
services of the traffic control officers.
102-13.3 Special Detours: Price and payment will be full compensation for providing all
detour facilities shown in the Plans and all costs incurred in carrying out all requirements of this
Section for general MOT within the limits of the detour, as shown in the Plans.
102-13.4 Commercial Materials for Driveway Maintenance: Price and payment will
be full compensation for all work and materials specified for this item, including specifically all
required shaping and maintaining of driveways.
102-13.5 Work Zone Signs: Price and payment will be full compensation for all work
and materials for furnishing signs, supports and necessary hardware, installation, relocating,
maintaining and removing signs.
102-13.6. Business Signs: Price and payment will be full compensation for all materials
and labor required for furnishing, installing, relocating, maintaining, and removing the signs as
well as the cost of installing any logos provided by business owners.
102-13.7 High Intensity Warning Lights: Price and payment will be full compensation
for furnishing, installing, operating, relocating, maintaining and removing high intensity flashing
lights (Type B).
102-13.8 Channelizing Devices: Prices and payment will be full compensation for
furnishing, installing, relocating, maintaining and removing the channelizing devices, including
the costs associated with attached warning lights as required.
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102-13.9 Barrier Wall (Temporary): Price and payment will be full compensation for
furnishing, installing, maintaining, and removing the barrier. When called for, barrier wall
(temporary) (relocate) will be full compensation for relocating the barrier.
102-13.10 Lights, Temporary, Barrier Wall Mount: Price and payment will be full
compensation for all work and materials for furnishing, installing and maintaining the warning
lights mounted on barrier wall. Payment will not be made for lights that are improperly placed or
are not working.
102-13.11 Glare Screen (Temporary): Price and payment will be full compensation for
furnishing, installing, maintaining, and removing the glare screen certified as installed/used on
the project. When called for, glare screen (relocate) will be full compensation for relocating the
glare screen.
102-13.12 Temporary Crash Cushion (Redirective/Gating): Price and payment will be
full compensation for furnishing, installing, maintaining and subsequently removing such crash
cushions. Payment for restoring damaged crash cushions will be the manufacturers/distributors
invoice price for the new materials/parts plus 20% markup. The 20% markup is compensation
for all necessary work including; but not limited to, labor, equipment, supplies and profit, as
authorized by the Engineer. Additional MOT required for the repair of the crash cushion will be
paid for under the appropriate MOT pay item.
102-13.13 Temporary Guardrail: Price and payment will be full compensation for
furnishing all materials required for a complete installation, including end anchorage assemblies
and any end connections to other structures and for installing, maintaining and removing
guardrail.
102-13.14 Arrow Board: Price and payment will be full compensation for furnishing,
installing, operating, relocating, maintaining and removing arrow boards.
102-13.15 Portable Changeable Message Sign: Price and payment will be full
compensation for furnishing, installing, operating, relocating, maintaining and removing portable
changeable message signs.
102-13.16 Portable Regulatory Signs: Price and payment will be full compensation for
furnishing, installing, relocating, maintaining and removing a completely functioning system as
described in these Specifications portable regulatory signs. Price and payment will be full
compensation for furnishing, installing, operating, relocating, maintaining and removing portable
regulatory signs.
Payment will include all labor, materials, incidentals, repairs and any actions
necessary to operate and maintain the unit at all times that work is being performed or traffic is
being affected by construction and/or MOT operations.
102-13.17 Radar Speed Display Unit: Price and payment will be made only for a
completely functioning system as described in these specifications. Payment will include all
labor, hardware, accessories, signs, and incidental items necessary for a complete system.
Payment will include any measurements needed to insure that the unit conforms to all
specification requirements.
Payment will include all labor, materials, incidentals, repairs and any actions
necessary to operate and maintain the unit at all times that work is being performed or traffic is
being affected by construction and/or MOT operations. Price and payment will be full
compensation for furnishing, installing, operating, relocating, maintaining and removing radar
speed display unit.
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102-13.18 Temporary Signalization and Maintenance: Price and payment will
constitute full compensation for furnishing, installing, operating, maintaining and removing
temporary traffic control signals including all equipment and components necessary to provide
an operable traffic signal. Payment will be withheld for each day at each intersection where the
temporary signalization is not operational within 12 hours after notification.
102-13.19 Temporary Traffic Detection and Maintenance: Price and payment will
constitute full compensation for furnishing, installing, operating, maintaining and removing
temporary traffic detection including all equipment and components necessary to provide an
acceptable signalized intersection. Take ownership of all equipment and components. Payment
will be withheld for each day at each intersection where the temporary detection is not
operational within 12 hours after notification.
102-13.20 Temporary Raised Rumble Strips: Price and payment will be full
compensation for all work and materials described in this Section, including all cleaning and
preparing of surfaces, disposal of all debris, furnishing of all materials, application, curing,
removal, reinstalling and protection of all items, protection of traffic, furnishing of all tools,
machines and equipment, and all incidentals necessary to complete the work.
102-13.21 Work Zone Pavement Markings: Price and payment will be full
compensation for all work specified including, all cleaning and preparing of surfaces, furnishing
of all materials, application, curing and protection of all items, protection of traffic, furnishing of
all tools, machines and equipment, and all incidentals necessary to complete the work. Final
payment will be withheld until all deficiencies are corrected.
Removable tape may be substituted for work zone paint at no additional cost to
the Department.
Payment for temporary RPMs used to supplement line markings will be paid for
under temporary retroreflective pavement markers. Install these markers as detailed in the
Design Standards.
102-13.22 Temporary Lane Separator: Price and payment will be full compensation
for all work specified in this Section.
102-13.23 Payment Items: Payment will be made under:
Item No. 102- 1Item No. 102- 2Item No. 102- 3Item No. 102- 14Item No. 102- 60Item No. 102- 61Item No. 102- 71Item No. 102- 75Item No. 102- 94Item No. 102- 73Item No. 102- 74Item No. 102- 76Item No. 102- 77Item No. 102- 78Item No. 102- 79-
Maintenance of Traffic - lump sum.
Special Detour - lump sum.
Commercial Material for Driveway Maintenance - per
cubic yard.
Traffic Control Officer - per hour.
Work Zone Sign - per each per day.
Business Sign - each.
Barrier Wall - per foot.
Temporary Lane Separator - per foot
Glare Screen - per foot.
Guardrail (Temporary) - per foot.
Barricade (Temporary) - per each per day.
Arrow Board - per each per day.
High Intensity Flashing Lights (Temporary - Type B) - per
each per day.
Temporary Retroreflective Pavement Markers - each.
Lights, Temporary, Barrier Wall Mount - per each per day.
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Item No. 102- 81Item No. 102- 89Item No. 102- 99Item No. 102-104Item No. 102-107Item No. 102-150Item No. 102-150Item No. 102-910Item No. 102-911Item No. 102-912Item No. 710Item No. 711-
Crash Cushion (Gating) (Temporary) - per location.
Crash Cushion (Redirective) (Temporary) - per location.
Portable Changeable Message Sign (Temporary) - per each
per day.
Temporary Signalization and Maintenance - per
intersection per day.
Temporary Traffic Detection and Maintenance - per
intersection per day.
Portable Regulatory Sign - per each per day.
Radar Speed Display Unit - per each per day.
Temporary Raised Rumble Strip Set - per set per day
Removable Tape (White/Black) - per foot.
Removable Tape (Yellow) - per foot.
Painted Pavement Markings.
Thermoplastic Traffic Stripes and Markings.
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SECTION 103
TEMPORARY WORK STRUCTURES
103-1 Description.
103-1.1 Scope of Work: Construct temporary work structures used solely to support
construction equipment. Temporary structures include but are not limited to work bridges,
elevated platforms and rail systems. Items such as barges, mats, or items such as falsework or
scaffolding are not included in this Section. If a temporary structure type other than the structure
type shown in the plans is chosen, assume responsibility for obtaining all necessary permit
revisions and the Engineers approval. Conform to any limitations contained in the plans and
permits. Do not place embankment outside the limits shown in the plans. The cost of the
embankment, placing, compaction, and removal will be included in the lump sum price for
Temporary Work Structure.
103-1.2 Materials: Construct the temporary work structure using materials sufficient to
handle the anticipated loads. Assume responsibility for the design of the temporary structure.
103-1.3 Navigation Requirements: Submit drawings showing the location of the
temporary work structures relative to the navigable waterway to the Coast Guard at least 60 days
prior to beginning construction of the structure, or as required by conditions of the permit.
Provide adequate lighting of the structure during the duration of construction as required by the
Coast Guard or local authorities.
103-2 Basis of Payment.
103-2.1 General: The unit price for the temporary work structure will include all costs
associated with the design, materials, labor, installation, removal and disposal of the structure.
103-2.2 Partial Payments: When the plans include a separate pay item for temporary
work structure, 75% of the lump sum price will be paid upon completion of the temporary work
structure, and 25% will be paid upon complete removal of the temporary work structure from the
project site. When the project requires numerous structures or multiple setups (leap frog type) of
the same system, the 75% will be split evenly between the various structures or setups. Partial
payments for any project will be limited to 5% of the original Contract amount for that project.
Any remaining amount will be paid upon completion of all work on the project.
When more than one project is included in the Contract, the above percentages
will apply separately to each project which has a separate pay item for temporary work
structures.
Payment will be made under:
Item No. 103- 1Temporary Work Structures - lump sum.
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SECTION 104
PREVENTION, CONTROL, AND ABATEMENT OF
EROSION AND WATER POLLUTION
104-1 Description.
Provide erosion control measures on the project and in areas outside the right-of-way
where work is accomplished in conjunction with the project, so as to prevent pollution of water,
detrimental effects to public or private property adjacent to the project right-of-way and damage
to work on the project. Construct and maintain temporary erosion control features or, where
practical, construct and maintain permanent erosion control features as shown in the Plans or as
may be directed by the Engineer.
104-2 General.
Coordinate the installation of temporary erosion control features with the construction of
the permanent erosion control features to the extent necessary to ensure economical, effective,
and continuous control of erosion and water pollution throughout the life of the Contract.
Due to unanticipated conditions, the Engineer may direct the use of control features or
methods other than those included in the original Contract. In such event, the Department will
pay for this additional work as unforeseeable work.
104-3 Control of Contractors Operations Which May Result in Water Pollution.
Prevent pollution of streams, canals, lakes, reservoirs, and other water impoundments
with fuels, oils, bitumens, calcium chloride, or other harmful materials. Also, conduct and
schedule operations to avoid or otherwise minimize pollution or siltation of such water
impoundments, and to avoid interference with movement of migratory fish. Do not dump any
residue from dust collectors or washers into any live stream.
Restrict construction operations in rivers, streams, lakes, tidal waters, reservoirs, canals,
and other water impoundments to those areas where it is necessary to perform filling or
excavation to accomplish the work shown in the Plans and to those areas which must be entered
to construct temporary or permanent structures. As soon as conditions permit, promptly clear
rivers, streams, and impoundments of all obstructions placed therein or caused by construction
operations.
Do not frequently ford live streams with construction equipment. Wherever an
appreciable number of stream crossings are necessary at any one location, use a temporary
bridge or other structure.
Except as necessary for construction, do not deposit excavated material in rivers, streams,
canals, or impoundments, or in a position close enough thereto, to be washed away by high water
or runoff.
Where pumps are used to remove highly turbid waters from enclosed construction areas
such as cofferdams or forms, treat the water by one or more of the following methods prior to
discharge into State waters: pumping into grassed swales or appropriate vegetated areas or
sediment basins, or confined by an appropriate enclosure such as turbidity barriers when other
methods are not considered appropriate.
Do not disturb lands or waters outside the limits of construction as staked, except as
authorized by the Engineer.
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Obtain the Engineers approval for the location of, and method of operation in, borrow
pits, material pits, and disposal areas furnished for waste material from the project (other than
commercially operated sources) such that erosion during and after completion of the work will
not result in probability of detrimental siltation or water pollution.
104-4 Materials for Temporary Erosion Control.
The Engineer will not require testing of materials used in construction of temporary
erosion control features other than as provided for geotextile fabric in 985-3 unless such material
is to be incorporated into the completed project. When no testing is required, the Engineer will
base acceptance on visual inspection.
The Contractor may use new or used materials for the construction of temporary silt
fence, staked turbidity barriers, and floating turbidity barrier not to be incorporated into the
completed project, subject to the approval of the Engineer.
104-5 Preconstruction Requirements.
At the Preconstruction Conference, provide to the Department an Erosion Control Plan
meeting the requirements or special conditions of all permits authorizing project construction. If
no permits are required or the approved permits do not contain special conditions or specifically
address erosion and water pollution, the project Erosion Control Plan will be governed by 7-1.1,
7-2.2, 7-8.1, 7-8.2, and Section 104.
When a DEP generic permit is issued, the Contractors Erosion Control Plan shall be
prepared to accompany the Departments Stormwater Pollution Prevention Plan (SWPPP).
Ensure the Erosion Control Plan includes procedures to control off-site tracking of soil by
vehicles and construction equipment and a procedure for cleanup and reporting of non-storm
water discharges, such as contaminated groundwater or accidental spills. Do not begin any soil
disturbing activities until Department approval of the Contractors Erosion Control Plan,
including required signed certification statements.
Failure to sign any required documents or certification statements will be considered a
default of the Contract. Any soil disturbing activities performed without the required signed
documents or certification statements may be considered a violation of the DEP Generic Permit.
When the SWPPP is required, prepare the Erosion Control Plan in accordance with the
planned sequence of operations and present in a format acceptable to the Department. The
Erosion Control Plan shall describe, but not be limited to, the following items or activities:
(1) For each phase of construction operations or activities, supply the following
information:
(a) Locations of all erosion control devices
(b) Types of all erosion control devices
(c) Estimated time erosion control devices will be in operation
(d) Monitoring schedules for maintenance of erosion control devices
(e) Methods of maintaining erosion control devices
(f) Containment or removal methods for pollutants or hazardous wastes
(2) The name and telephone number of the person responsible for monitoring and
maintaining the erosion control devices.
(3) Submit for approval the Erosion Control Plans meeting paragraphs 3a, 3b, or
3c below:
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(a) Projects permitted by the Southwest Florida Water Management
District (SWFWMD), require the following:
Submit a copy of the Erosion Control Plan to the Engineer for
review and to the appropriate SWFWMD Office for review and approval. Include the
SWFWMD permit number on all submitted data or correspondence.
The Contractor may schedule a meeting with the appropriate
SWFWMD Office to discuss his Erosion Control Plan in detail, to expedite the review and
approval process. Advise the Engineer of the time and place of any meetings scheduled with
SWFWMD.
Do not begin construction activities until the Erosion Control Plan
receives written approval from both SWFWMD and the Engineer.
(b) Projects permitted by the South Florida Water Management District or
the St. Johns River Water Management District, require the following:
Obtain the Engineers approval of the Erosion Control Plan.
Do not begin construction activities until the Erosion Control Plan
receives written approval from the Engineer.
(c) Projects authorized by permitting agencies other than the Water
Management Districts or projects for which no permits are required require the following:
The Engineer will review and approve the Contractors Erosion
Control Plan.
Do not begin construction activities until the Erosion Control Plan
receives written approval from the Engineer.
Comply with the approved Erosion Control Plan.
104-6 Construction Requirements.
104-6.1 Limitation of Exposure of Erodible Earth: The Engineer may limit the surface
areas of unprotected erodible earth exposed by the construction operation and may direct the
Contractor to provide erosion or pollution control measures to prevent contamination of any
river, stream, lake, tidal waters, reservoir, canal, or other water impoundments or to prevent
detrimental effects on property outside the project right-of-way or damage to the project. Limit
the area in which excavation and filling operations are being performed so that it does not exceed
the capacity to keep the finish grading, turf, sod, and other such permanent erosion control
measures current in accordance with the accepted schedule.
Do not allow the surface area of erodible earth that clearing and grubbing
operations or excavation and filling operations expose to exceed 750,000 square feet without
specific prior approval by the Engineer. This limitation applies separately to clearing and
grubbing operations and excavation and filling operations.
The Engineer may increase or decrease the amount of surface area the Contractor
may expose at any one time.
104-6.2 Incorporation of Erosion and Sediment Control Features: Incorporate
permanent erosion control features into the project at the earliest practical time. Use temporary
erosion and sediment control features found in the State of Florida Erosion and Sediment Control
Designer and Reviewer Manual (E&SC Manual) to correct conditions that develop during
construction which were not foreseen at the time of design, to control erosion and sediment
prior to the time it is practical to construct permanent control features, or to provide immediate
temporary control of erosion and sediment that develops during normal construction operations,
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which are not associated with permanent erosion control features on the project. An electronic
version of the E&SC Manual can be found at the following URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/FLErosio
nSedimentManual.pdf
Install all sediment control devices in a timely manner to ensure the control of
sediment and the protection of lakes, streams, gulf or ocean waters, or any wetlands associated
therewith and to any adjacent property outside the right-of-way as required.
At sites where exposure to such sensitive areas is prevalent, complete the
installation of any sediment control device prior to the commencement of any earthwork.
After installation of sediment control devices, repair portions of any devices
damaged at no expense to the Department. The Engineer may authorize temporary erosion and
sediment control features when finished soil layer is specified in the Contract and the limited
availability of that material from the grading operations will prevent scheduled progress of the
work or damage the permanent erosion control features.
104-6.3 Scheduling of Successive Operations: Schedule operations such that the area of
unprotected erodible earth exposed at any one time is not larger than the minimum area
necessary for efficient construction operations, and the duration of exposure of uncompleted
construction to the elements is as short as practicable.
Schedule and perform clearing and grubbing so that grading operations can follow
immediately thereafter. Schedule and perform grading operations so that permanent erosion
control features can follow immediately thereafter if conditions on the project permit.
104-6.4 Details for Temporary Erosion and Sediment Control Features:
104-6.4.1 General: Use temporary erosion, sediment and water pollution control
features found in the E&SC Manual. These features consist of, but are not limited to, temporary
turf, rolled erosion control products, sediment containment systems, runoff control structures,
sediment barriers, inlet protection systems, silt fences, turbidity barriers, and chemical treatment.
For design details for some of these items, refer to the Design Standards and E&SC Manual.
104-6.4.2 Temporary Turf: The Engineer may designate certain areas of turf or
sod constructed in accordance with Section 570 as temporary erosion control features. For areas
not defined as sod, constructing temporary turf by seeding only is not an option for temporary
erosion control under this Section. The Engineer may waive the turf establishment requirements
of Section 570 for areas with temporary turf that will not be a part of the permanent construction.
104-6.4.3 Runoff Control Structures: Construct runoff control structures in
accordance with the details shown in the Plans, the E&SC Manual, or as may be approved as
suitable to adequately perform the intended function.
104-6.4.4 Sediment Containment Systems: Construct sediment containment
systems in accordance with the details shown in the Plans, the E&SC Manual, or as may be
approved as suitable to adequately perform the intended function. Clean out sediment
containment systems as necessary in accordance with the Plans or as directed.
104-6.4.5 Sediment Barriers: Provide and install sediment barriers according to
details shown in the Plans, as directed by the Engineer, or as shown in the E&SC Manual to
protect against downstream accumulation of sediment. Sediment Barriers include, but are not
limited to synthetic bales, silt fence, fiber logs and geosynthetic barriers. Reusable barriers that
have had sediment deposits removed may be reinstalled on the project as approved by the
Engineer.
104-6.4.6 Silt Fence:
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104-6.4.6.1 General: Furnish, install, maintain, and remove silt fences, in
accordance with the manufacturers directions, these Specifications, the details as shown in the
Plans, the Design Standards, and the E&SC Manual.
104-6.4.6.2 Materials and Installation: Use a geotextile fabric made
from woven or nonwoven fabric, meeting the physical requirements of Section 985 according to
those applications for erosion control.
Choose the type and size of posts, wire mesh reinforcement (if
required), and method of installation. Do not use products which have a separate layer of plastic
mesh or netting. Provide a durable and effective silt fence that controls sediment comparable to
the Design Standards and the E&SC Manual.
Erect silt fence at upland locations, across ditchlines and at
temporary locations shown in the Plans or approved by the Engineer where continuous
construction activities change the natural contour and drainage runoff. Do not attach silt fence to
existing trees unless approved by the Engineer.
104-6.4.6.3 Inspection and Maintenance: Inspect all silt fences
immediately after each rainfall and at least daily during prolonged rainfall. Immediately correct
any deficiencies. In addition, make a daily review of the location of silt fences in areas where
construction activities have changed the natural contour and drainage runoff to ensure that the
silt fences are properly located for effectiveness. Where deficiencies exist, install additional silt
fences as directed by the Engineer.
Remove sediment deposits when the deposit reaches
approximately 1/2 of the volume capacity of the silt fence or as directed by the Engineer. Dress
any sediment deposits remaining in place after the silt fence is no longer required to conform
with the finished grade, and prepare and seed them in accordance with Section 570.
104-6.4.7 Floating Turbidity Barriers and Staked Turbidity Barriers: Install,
maintain, and remove turbidity barriers to contain turbidity that may occur as the result of
dredging, filling, or other construction activities which may cause turbidity to occur in the waters
of the State. The Contractor may need to deploy turbidity barriers around isolated areas of
concern such as seagrass beds, coral communities, etc. both within as well as outside the rightof-way limits. The Engineer will identify such areas. Place the barriers prior to the
commencement of any work that could impact the area of concern. Install the barriers in
accordance with the details shown in the Plans or as approved by the Engineer. Ensure that the
type barrier used and the deployment and maintenance of the barrier will minimize dispersion of
turbid waters from the construction site. The Engineer may approve alternate methods or
materials.
Operate turbidity barriers in such a manner to avoid or minimize the
degradation of the water quality of the surrounding waters and minimize damage to areas where
floating barriers installed.
104-6.4.8 Inlet Protection System: Furnish and install inlet protection systems as
shown in the Plans, Design Standards and the E&SC Manual.
104-6.4.9 Rolled Erosion Control Products (RECPs):
104-6.4.9.1 General: Install RECPs in locations where temporary
protection from erosion is needed. Two situations occur that require artificial coverings. The two
situations have differing material requirements, which are described below.
(1) Use RECPs composed of natural or synthetic fiber mats, plastic
sheeting, or netting as protection against erosion, when directed by the Engineer, during
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temporary pauses in construction caused by inclement weather or other circumstances. Remove
the material when construction resumes.
(2) Use RECPs as erosion control blankets, at locations shown in
the Plans, to facilitate plant growth while permanent grassing is being established. For the
purpose described, use non-toxic, biodegradable, natural or synthetic woven fiber mats. Install
erosion control blankets capable of sustaining a maximum design velocity of 6.5 ft/sec as
determined from tests performed by Utah State University, Texas Transportation Institute or an
independent testing laboratory approved by the Department. Furnish to the Engineer, two
certified copies of manufacturers test reports showing that the erosion control blankets meet the
requirements of this Specification. Certification must be attested, by a person having legal
authority to bind the manufacturing company. Also, furnish two 4 by 8 inch samples for product
identification. The manufacturers test records shall be made available to the Department upon
request. Leave the material in place, as installed, to biodegrade.
104-6.4.10 Chemical Treatment: Provide chemical treatment in accordance with the
E&SC Manual. Chemical treatment may be used to clarify turbid or sediment laden water that
does not yet meet state water quality standards or as an amendment to other erosion prevention
and sediment control products to aid in their performance. The contractor must provide all of the
required toxicity testing information in accordance with the E&SC Manual to the Engineer for
review and acceptance prior to using any chemical treatment on the project site.
104-6.5 Removal of Temporary Erosion Control Features: In general, remove or
incorporate into the soil any temporary erosion control features existing at the time of
construction of the permanent erosion control features in an area of the project in such a manner
that no detrimental effect will result. The Engineer may direct that temporary features be left in
place.
104-7 Maintenance of Erosion and Sediment Control Features.
104-7.1 General: Provide routine maintenance of permanent and temporary erosion and
sediment control features, at no expense to the Department, until the project is complete and
accepted. If reconstruction of such erosion and sediment control features is necessary due to the
Contractors negligence or carelessness or, in the case of temporary erosion and sediment control
features, failure by the Contractor to install permanent erosion control features as scheduled, the
Contractor shall replace such erosion control features at no expense to the Department. If
reconstruction of permanent or temporary erosion and sediment control features is necessary due
to factors beyond the control of the Contractor, the Department will pay for replacement under
the appropriate Contract pay item or items.
Inspect all erosion and sediment control features at least once every seven
calendar days and within 24 hours of the end of a storm of 0.50 inches or greater. Maintain all
erosion control features as required in the Stormwater Pollution Prevention Plan, Contractors
Erosion Control Plan and as specified in the State of Florida Department of Environmental
Protection Generic Permit for Stormwater Discharge from Large and Small Construction
Activities.
104-8 Protection During Suspension of Contract Time.
If it is necessary to suspend the construction operations for any appreciable length of
time, shape the top of the earthwork in such a manner to permit runoff of rainwater, and
construct earth berms along the top edges of embankments to intercept runoff water. Provide
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temporary slope drains to carry runoff from cuts and embankments that are in the vicinity of
rivers, streams, canals, lakes, and impoundments. Locate slope drains at intervals of
approximately 500 feet, and stabilize them by paving or by covering with waterproof materials.
Should such preventive measures fail, immediately take such other action as necessary to
effectively prevent erosion and siltation. The Engineer may direct the Contractor to perform,
during such suspensions of operations, any other erosion and sediment control work deemed
necessary.
104-9 Method of Measurement.
When separate items for temporary erosion control features are included in the Contract,
the quantities to be paid for will be: (1) the area, in square yards, of rolled erosion control
products; (2) the length, in feet, of runoff control structures, measured along the surface of the
work constructed; (3) the number of sediment containment systems constructed and accepted; (4)
the number of sediment containment system cleanouts accomplished and accepted; (5) the
length, in feet, of sediment barriers; (6) the length, in feet, of floating turbidity barrier; (7) the
length, in feet, of staked turbidity barrier; (8) the number of inlet protection systems; (9) the area,
in square yards, of chemical treatment.(10) the number of floc logs or drums of product for
chemical treatment.
Upon acceptance by the Engineer, the quantity of floating turbidity barriers, sediment
barriers, staked turbidity barriers, and inlet protection devices will be paid for regardless of
whether materials are new, used, or relocated from a previous installation on the project.
104-10 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including construction and routine maintenance of temporary erosion control features.
Any additional costs resulting from compliance with the requirements of this Section,
other than construction, routine maintenance, and removal of temporary erosion control features,
will be included in the Contract unit prices for the item or items to which such costs are related.
The work of performance turf designated as a temporary erosion control feature in accordance
with 104-6.4.2 will be paid for under the appropriate pay items specified in Sections 570 and
580.
Separate payment will not be made for the cost of constructing temporary earth berms
along the edges of the roadways to prevent erosion during grading and subsequent operations.
The Contractor shall include these costs in the Contract prices for grading items.
Additional temporary erosion control features constructed as directed by the Engineer
will be paid for as unforeseeable work.
In case of repeated failure on the part of the Contractor to control erosion, pollution, or
siltation, the Engineer reserves the right to employ outside assistance or to use the Departments
own forces to provide the necessary corrective measures. Any such costs incurred, including
engineering costs, will be charged to the Contractor and appropriate deductions made from the
monthly progress estimate.
Payment will be made under:
Item No. 104- 1Artificial Coverings/ Rolled Erosion Control Products - per
square yard.
Item No. 104- 6Slope Drains (Temporary)/ Runoff Control Structures - per
foot.
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Item No. 104- 7Item No. 104- 9Item No. 104- 10Item No. 104- 11Item No. 104- 12Item No. 104- 18
Item No. 104- 19
Item No. 104 20
Sediment Basins/ Containment Systems - each.
Sediment Basin/ Containment system Cleanouts - each.
Sediment Barriers per foot
Floating Turbidity Barrier - per foot.
Staked Turbidity Barrier - per foot.
Inlet Protection System each.
Chemical Treatment per square yard.
Chemical Treatment (floc logs, drums of product) - each.
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SECTION 105
CONTRACTOR QUALITY CONTROL GENERAL REQUIREMENTS
105-1 General.
105-1.1 Quality Control Documentation.
105-1.1.1 Submission of Materials Certification and Reporting Test Results:
Provide certifications prior to placement of materials. Report test results at completion of the test
and meet the requirements of the applicable Specifications.
105-1.1.2 Database(s): Obtain access to the Departments databases prior to
testing and/or material placement. Database access information is available through the
Departments website. Enter all required and specified documentation and test results in the
Department databases.
105-1.1.3 Worksheets: Make available to the Department, when requested,
worksheets used for collecting test information. Ensure the worksheets at a minimum contain the
following:
a. Project Identification Number,
b. Time and Date,
c. Laboratory Identification and Name,
d. Training Identification Numbers (TIN) and initials,
e. Record details as specified within the test method.
105-1.2 Inspections to Assure Compliance with Acceptance Criteria.
105-1.2.1 General: The Department is not obligated to make an inspection of
materials at the source of supply, manufacture, or fabrication. Provide the Engineer with
unrestricted entry at all times to such parts of the facilities that concern the manufacture,
fabrication, or production of the ordered materials. Bear all costs incurred in determining
whether the material meets the requirements of these Specifications.
105-1.2.2 Quality Control Inspection: Provide all necessary inspection to assure
effective Quality Control of the operations related to materials acceptance. This includes but is
not limited to sampling and testing, production, storage, delivery, construction and placement.
Ensure that the equipment used in the production and testing of the materials provides accurate
and precise measurements in accordance with the applicable Specifications. Maintain a record of
all inspections, including but not limited to, date of inspection, results of inspection, and any
subsequent corrective actions taken. Make available to the Department the inspection records,
when requested.
105-1.2.3 Notification of Placing Order: Order materials sufficiently in advance
of their incorporation in the work to allow time for sampling, testing and inspection. Notify the
Engineer, prior to placing orders for materials.
Submit to the Engineer a fabrication schedule for all items requiring
commercial inspection, before or at the preconstruction meeting. These items include, but are not
limited to steel bridge components, overhead cantilevered sign supports with cantilevered arms
exceeding 41 feet, moveable bridge components or any other item identified as an item requiring
commercial inspection in the Contract Documents.
Notify the Engineer at least 30 days before beginning any production and
include a production schedule.
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105-2 Additional Requirements for Lump Sum Projects.
Prepare and submit to the Engineer a project-specific list of material items and quantities
to be used on the project as a Job Guide Schedule in the same format as the current Sampling,
Testing, and Reporting Guide 21 calendar days prior to commencement of construction. Provide
up-to-date quantities for the items on the Job Guide Schedule to the Engineer with each monthly
progress estimate. The Department may not authorize payment of any progress estimate not
accompanied by updated Job Guide Schedule quantities. Maintain the Job Guide Schedule
throughout the project including the quantity placed since the previous submittal, and total to
date quantity and any additional materials placed. Do not commence work activities that require
testing until the Job Guide Schedule has been reviewed and accepted by the Engineer. At final
acceptance, submit a final Job Guide Schedule that includes all materials used on the project in
the same format as the monthly reports.
105-3 Quality Control Program.
105-3.1 General: Certain operations require personnel with specific qualifications.
Certain materials require production under an approved Quality Control (QC) Plan to ensure that
these materials meet the requirements of the Contract Documents. Applicable materials include
hot mix asphalt, Portland cement concrete (Structural), earthwork, cementitious materials,
timber, steel and miscellaneous metals, galvanized metal products, prestressed and/or precast
concrete products and drainage products. For all applicable materials included in the Contract,
submit a QC Plan prepared in accordance with the requirements of this Section to the Engineer.
Do not incorporate any of these materials into the project prior to the Engineers approval of the
QC Plan.
Steel and Miscellaneous Metal products, including aluminum, are defined as the
metal components of bridges, including pedestrian and moveable bridges, overhead and
cantilevered sign supports, ladders and platforms, bearings, end wall grates, roadway gratings,
drainage items, expansion joints, roadway decking, shear connectors, handrails, galvanized
products, fencing, guardrail, light poles, high mast light poles, standard mast arm assemblies and
Monotube assemblies, stay in-place forms, casing pipe, strain poles, fasteners, connectors and
other hardware.
When accreditation or certification is required, make supporting documents from
the two previous inspections performed by the accrediting or certifying agency available to the
Department upon request.
Obtain Department approval prior to beginning production. Meet and maintain the
approved Quality Control Program requirements at all times. Production and construction of
these products without the Departments prior approval of a Quality Control Program may result
in rejection of the products. Continued approval will be subject to satisfactory results from
Department evaluations, including the Independent Assurance program. In cases of noncompliance with the approved Quality Control Program, identify all affected material and do not
incorporate or supply to the Department projects. The following conditions may result in
suspension of a Quality Control Program:
a. Failure to timely supply information required.
b. Repeated failure of material to meet Standard Specification requirements.
c. Failure to take immediate corrective action relative to deficiencies in the
performance of the Quality Control Program.
d. Certifying materials that are not produced under an approved Quality Control
Program for use on Department projects.
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e. Failure to correct any deficiencies related to any requirement of the Quality
Control Program, having received notice from the Department, within the amount of time
defined in the notice.
105-3.2 Compliance with the Materials Manual.
Producers of Flexible Pipe shall meet the requirements of Section 6.1, Volume II
of the Departments Materials Manual, which may be viewed at the following URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section61.pdf .
Producers of Precast Concrete Pipe shall meet the requirements of Section 6.2,
Volume II of the Departments Materials Manual, which may be viewed at the following URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section62.pdf .
Producers of Precast Concrete Drainage Structures shall meet the requirements of
Section 6.3, Volume II of the Departments Materials Manual, which may be viewed at the
following URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section63.pdf .
Producers of Precast/Prestressed Concrete Products shall meet the requirements of
Sections 8.1 and 8.3 of the Departments Materials Manual, which may be viewed at the
following URLs:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section81.pdf .
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section83.pdf .
Producers of Precast Prestressed Concrete Products using Self Consolidating
Concrete shall meet the requirements of Section 8.4, Volume II of the Departments Materials
Manual, which may be viewed at the following URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section84.pdf
Producers of Incidental Precast/Prestressed Concrete Products shall meet the
requirements of Section 8.2, Volume II of the Departments Materials Manual, which may be
viewed at the following URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section82.pdf .
Producers of Portland Cement Concrete shall meet the requirements of Section
9.2, Volume II of the Departments Materials Manual, which may be viewed at the following
URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section92.pdf .
Producers of Structural Steel and Miscellaneous Metal Components shall meet the
requirements of Sections 11.1 and 11.2 of the Departments Materials Manual, which may be
viewed at the following URLs:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section111.pdf .
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/Files/section112.pdf .
105-3.3 Hot Mix Asphalt , Portland Cement Concrete (Structural), Earthwork,
Cementitious Materials, Timber, Steel and Miscellaneous Metals, Galvanized Metal
Products, Prestressed and/or Precast Concrete Products and Drainage Products Quality
Control Program: Have an accepted Quality Control Program, developed in accordance with
this Section, during the production of materials to be used on Department projects.
105-3.4 Prestressed Concrete Quality Control Program: Ensure that prestressed
concrete plants participating in the Departments Acceptance Program are qualified.
Obtaining qualification requires a current certification from a Department
approved precast prestressed concrete plant certification agency and a Department approved
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Quality Control Plan, meeting the requirements of this Section. The list of Department approved
certification agencies is available on the website of the State Materials Office.
105-3.5 Steel and Miscellaneous Metals Quality Control Program: Ensure that the
fabricators of Steel and miscellaneous metal products participating in the Departments Quality
Control Acceptance Program are qualified. Obtaining qualification requires an accepted Quality
Control Plan, developed in accordance with this Section. A current American Institute for Steel
Construction (AISC) certification is a requirement for the Quality Control Acceptance Program
of the steel and miscellaneous metal fabricators, provided that AISC certification program is
available for the category of the fabrication products.
105-3.6 Producers Quality Control Plan Submittal: Depending on the type of
products, the producers shall submit their proposed Quality Control Plans to the State Materials
Office or to the District Materials Office, as described below:
105-3.6.1 State Materials Office: Producers of cementitious materials, steel and
miscellaneous metals, galvanized metal products, and aggregates must submit their proposed
Quality Control Plan to the State Materials Office for review and acceptance.
105-3.6.2 District Materials Office: Producers of hot mix asphalt, Portland
cement concrete (Structural), earthwork, timber, prestressed and/or precast concrete products and
drainage products must submit their proposed Quality Control Plan to the local District Materials
Office for acceptance. Producers located outside the State must contact the State Materials Office
for address information of the District Materials Office responsible for the review of the
proposed Quality Control Program.
105-3.7 Quality Control Plan Review and Acceptance: The Department will respond
to the producer within 21 calendar days of receipt of the proposed Quality Control Program. The
Department may perform evaluation activities to verify compliance with submitted documents
prior to acceptance.
If the Quality Control Program must be revised for any reason, including noncompliance, submit the revision to the Department. The Department will respond to the producer
within 7 calendar days of receipt of the revised Quality Control Program.
105-3.8 Contractors Quality Control Plan: Have an approved Quality Control Plan
meeting the requirements of this Section for the transportation, storage, placement, and other
related construction operations required by the Contract Documents.
105-4 Contractor Certification of Compliance.
Provide the Engineer with a notarized monthly certification of compliance with the
requirements of this Section, to accompany each progress estimate, on a form provided by the
Engineer. The Department may not authorize payment of any progress estimate not accompanied
by an executed certification document.
Final payment in accordance with 9-8 will not be made until a final notarized certification
summarizing all QC exceptions has been submitted.
105-5 Guidelines for Development of the Quality Control Plan.
105-5.1 General: Use the following guidelines for developing the QC Plan. Provide
detailed policies, methods and procedures to ensure the specified quality of all applicable
materials and related production and field operations. Include other items in addition to these
guidelines as necessary.
105-5.2 Personnel:
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105-5.2.1 Qualifications: Submit the Training Identification Numbers (TINs) or
any other information which will be traceable to the certification agencys training location and
dates for all technicians performing sampling, testing and inspection for both field and laboratory
tests. Provide the names of the CTQP certifications and other pertinent certifications held and the
expiration dates for each certification for each technician. Include employed and subcontracted
technicians.
105-5.2.2 Level of Responsibility: Identify the primary contact for the
Department. Identify roles and responsibilities of various personnel involved in the QC process.
105-5.3 Raw Materials:
105-5.3.1 Source: Identify the sources of raw materials. Provide locations and
plant or mine numbers when applicable.
105-5.3.2 Certification: Describe methods of verifying compliance of
certification with the specifications.
105-5.3.3 Disposition of Failing Materials: Describe the system for controlling
non-conforming materials, including procedures for identification, isolation and disposition.
105-5.4 Storage Facilities for Raw Materials: Describe measures and methods,
including bedding details, for preventing segregation, contamination and degradation.
Describe methods of identifying individual materials. Where applicable, submit a
site plan showing the locations of various materials.
105-5.5 Production Equipment: Describe calibration frequencies, maintenance schedule
and procedures for production equipment.
105-5.6 Plant Requirements:
105-5.6.1 Plant Identification: For those facilities producing materials listed in
Article105-3, provide the mailing address, physical address including county and X-Y (Latitude
and Longitude) coordinates of the plant, telephone and fax numbers, E-mail address, primary
contact at the plant, responsible person in charge, facility number provided by the Department,
Owner information and Vendor Number and other information as required.
105-5.6.2 Process Control System: Describe the methods and measures
established to ensure Contract compliance for the produced materials that are supplemental to the
QC sampling and testing program described in the Contract Documents. These methods and
measures will include, but are not limited to, inspection schedule, additional sampling and
testing, maintenance schedule, etc.
105-5.6.3 Loading and Shipping Control: Describe the methods and measures
for preventing segregation, contamination and degradation during loading and shipping
operations. Describe the methods established for materials to be in compliance with the
specifications at the point of use.
105-5.6.4 Types of Products Generated: Describe the products the plant is
approved to produce under Department guidelines.
105-5.7 Other Requirements:
105-5.7.1 Copy of Certification: Attach examples of certifications issued by the
plant/Contractor for the products approved by the Department.
105-5.7.2 Statement of Compliance: Include a statement of compliance with all
quality requirements set forth by the Department in the Contract Documents and Department
manuals.
105-5.7.3 Information on Producers with Accepted Quality Control
Programs: Identify the Producers of materials listed in 105-3.1 for the project. Include the
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Departments Facility Id number as part of the identification. All producers must have accepted
QC Programs and be listed on the Departments List of Producers with Accepted QC Programs.
105-5.7.4 Describing Documentation Procedure: Identify location of document
storage to enable Department review. Include QC charts, qualification/accreditation records,
inspection reports, and other pertinent/supporting documents for an approved QC Plan.
105-5.8 Final Manufactured Product - Plant Operations: Describe inspection
schedule and methods for identifying defects and non-compliance with the specifications.
Describe corrective actions and methods to resolve them.
105-5.8.1 Storage: When storage of the produced materials is required and it is
not defined in the Contract Documents, describe the methods and duration for storage. Include
measures and methods for preventing segregation, contamination and degradation during storage.
105-5.8.2 Disposition of Failing Materials: When not described in the
specifications, describe the methods and measures for identifying and controlling the failing
materials. Include preventive and corrective measures. Describe disposition of failing materials.
105-5.9 Final Manufactured Product - Field Operations:
105-5.9.1 Transportation: Describe the method of delivery from the point of
production/storage to the point of placement.
105-5.9.2 Storage: When storage of the produced materials is required and it is
not defined in the Contract Documents, describe the methods and duration for storage. Include
measures and methods for preventing segregation, contamination and degradation during storage.
105-5.9.3 Placement: Describe the methods and identify the type of equipment
used in incorporation of the materials into the project.
105-5.9.4 Disposition of Failing Materials: When not described in the
specifications, describe the methods and measures for identifying and controlling the failing
materials. Include preventive and corrective measures. Describe disposition of failing materials.
105-5.10 Testing Laboratories: Identify the laboratories performing testing. Ensure that the
testing laboratories comply with the Laboratory Qualification Program requirements of this Section.
105-6 Lab Qualification Program.
Testing Laboratories participating in the Departments Acceptance Program must have
current Department qualification when testing materials that are used on Department projects. In
addition, they must have one of the following:
a. Current AASHTO (AAP) accreditation.
b. Inspected on a regular basis per ASTM D 3740 for earthwork, ASTM D 3666
for asphalt and ASTM C 1077 for concrete for test methods used in the Acceptance Program,
with all deficiencies corrected, and under the supervision of a Specialty Engineer.
c. Current Construction Materials Engineering Council (CMEC) program
accreditation or other independent inspection program accreditation acceptable to the Engineer
and equivalent to a. or b. above.
After meeting the criteria described above, submit a Laboratory Qualification Application
to the Department. The application is available from the Departments website. Obtain the
Departments qualification prior to beginning testing. The Department may inspect the
laboratory for compliance with the accreditation requirements prior to issuing qualification.
Meet and maintain the qualification requirements at all times. Testing without
Departments qualification may result in a rejection of the test results. Continued qualifications
are subject to satisfactory results from Department evaluations, including Independent Assurance
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evaluations. In case of suspension or disqualification, prior to resumption of testing, resolve the
issues to the Departments satisfaction and obtain reinstatement of qualification. The following
conditions may result in suspension of a laboratorys qualified status:
a. Failure to timely supply required information.
b. Loss of accredited status.
c. Failure to correct deficiencies in a timely manner.
d. Unsatisfactory performance.
e. Changing the laboratorys physical location without notification to the
accrediting agency and the Engineer.
f. Delays in reporting the test data in the Departments database.
g. Incomplete or inaccurate reporting.
h. Using unqualified technicians performing testing.
Should any qualified laboratory falsify records, the laboratory qualification will be
subject to revocation by the Engineer. Falsification of project-related documentation will be
subject to further investigation and penalty under state and federal laws.
It is prohibited for any contract laboratory or staff to perform Contractor Quality Control
testing and any other Acceptance Program testing on the same contract.
105-7 Quality Control Plan Submittal.
Submit the QC Plan to the Engineer for approval within 21 calendar days after the
Contract Award. The Engineer will review the QC Plan and respond to the Contractor within
21 calendar days of receipt.
If at any time the Contractor is not in compliance with the approved QC Plan, or a part
thereof, affected portions of the plan will be disapproved. Cease work in the affected operation(s)
and submit a revision to the Engineer. If the QC Plan, or a part thereof, must be revised, submit
the revision to the Engineer. The Engineer will review the revision and respond within seven
calendar days of receipt.
Continue to work on operations that are still in compliance with the approved sections of
the QC Plan.
105-8 Personnel Qualifications.
105-8.1 General: Provide qualified personnel for sampling, testing and inspection of
materials and construction activities. Ensure that qualifications are maintained during the course
of sampling, testing and inspection.
Construction operations that require a qualified technician must not begin until
the Department verifies that the technician is on the CTQP list of qualified technicians. The
CTQP lists are subject to satisfactory results from periodic Independent Assurance evaluations.
105-8.2 QC Manager: Designate a QC Manager who has full authority to act as the
Contractors agent to institute any and all actions necessary for the successful implementation of
the QC Plan. The QC Manager must speak and understand English. The QC Manager must be
on-site at the project on a daily basis or always available upon four hours notice to administer the
QC Plan. This includes administering, implementing, monitoring, and as necessary, adjusting the
processes to ensure compliance with the Contract Documents. Ensure that the QC Manager is
qualified as such through the Construction Training/Qualification Program.
Under the direction of the QC Manager, and using Departments standard forms
provided by the Engineer, summarize the daily QC activities including testing and material
sampling. Since erasures are strictly prohibited on all reports and forms, use blue or colored ink.
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Do not use black ink. If manual corrections to original data are necessary, strike through, correct,
and date the entry, including the initials of the person making the correction. Make copies of the
completed forms available for the Department to review daily unless otherwise required in the
specifications. Ensure that the QC test data is entered into the Departments database on a daily
basis. Maintain all QC related reports and documentation for a period of three years from final
acceptance of the project. Make copies available for review by the Department upon request.
105-8.3 Worksite Traffic Supervisor: Provide a Worksite Traffic Supervisor who is
responsible for initiating, installing, and maintaining all traffic control devices as described in
Section 102 and in the Contract Documents. Ensure that the Worksite Traffic Supervisor is
certified in the advanced training category by a Department approved training Provider.
Approved Providers will be posted on the Departments website at the following URL address:
http://www.dot.state.fl.us/rddesign/MOT/MOT.shtm . Use approved alternate Worksite Traffic
Supervisors when necessary.
105-8.4 Flagger: Provide trained flaggers to direct traffic where one-way operation in a
single lane is in effect and in other situations as required. The Worksite Traffic Supervisor or
others as approved by the Department will provide training for flaggers.
105-8.5 Earthwork Quality Control Personnel:
105-8.5.1 Earthwork Level I: Ensure the technician who samples soil and
earthwork materials from the roadway project, takes earthwork moisture and density readings,
and records those data in the Density Log Book holds a Construction Training and Qualification
Program (CTQP) Earthwork Construction Inspection Level I qualification.
105-8.5.2 Earthwork Level II: Ensure the technician responsible for determining
the disposition of soil and earthwork materials on the roadway, and for interpreting and meeting
Contract Document requirements holds a CTQP Earthwork Construction Inspection Level II
qualification.
105-8.6 Asphalt Quality Control Personnel:
105-8.6.1 Plant Technicians: For asphalt plant operations, provide a QC
technician, qualified as a CTQP Asphalt Plant Level II technician, available at the asphalt plant
at all times when producing mix for the Department. Perform all asphalt plant related testing
with a CTQP Asphalt Plant Level I technician. As an exception, measurements of temperature
may be performed by someone under the supervision of a CTQP Plant Level II technician.
105-8.6.2 Paving Technicians: For paving operations (with the exception of
miscellaneous or temporary asphalt), keep a qualified CTQP Asphalt Paving Level II technician
on the roadway at all times when placing asphalt mix for the Department, and perform all testing
with a CTQP Asphalt Paving Level I technician. As an exception, measurements of cross-slope,
temperature, and yield (spread rate) can be performed by someone under the supervision of a
CTQP Paving Level II technician at the roadway.
105-8.6.3 Mix Designer: Ensure all mix designs are developed by individuals
who are CTQP qualified as an Asphalt Hot Mix Designer.
105-8.6.4 Documentation: Document all QC procedures, inspection, and all test
results and make them available for review by the Engineer throughout the life of the Contract.
Identify in the asphalt producers Quality Control Plan the Quality Control Manager(s) and/or
Asphalt Plant Level II technician(s) responsible for the decision to resume production after a
quality control failure.
105-8.7 Concrete QC Personnel:
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105-8.7.1 Concrete Field Technician - Level I: Ensure technicians performing
plastic property testing on concrete for materials acceptance are qualified CTQP Concrete Field
Technicians Level I. Plastic property testing will include but not be limited to slump,
temperature, air content, water-to-cementitious materials ratio calculation, and making and
curing concrete cylinders. Duties will include initial sampling and testing to confirm
specification compliance prior to beginning concrete placements, ensuring timely placement of
initial cure and providing for the transport of compressive strength samples to the designated
laboratories.
105-8.7.2 Concrete Field Inspector - Level II: Ensure field inspectors
responsible for the quality of concrete being placed on major bridge projects are qualified CTQP
Concrete Field Inspectors Level II. A Level II Inspector must be present on the jobsite during all
concrete placements. Prior to the placement of concrete, the inspector will inspect the element to
be cast to ensure compliance with Contract Documents. A Level II Inspector's duties may
include ensuring that concrete testing, inspection, and curing in the field are performed in
accordance with the Contract Documents. The QC Inspector will inform the Verification
Inspector of anticipated concrete placements and LOT sizes.
105-8.7.3 Concrete Laboratory Technician Level I: Ensure technicians
testing cylinders and recording concrete strength for material acceptance are qualified CTQP
Concrete Laboratory Technicians Level I. Duties include final curing, compressive strength
testing, and the recording/reporting of all test data.
105-8.8 Supervisory Personnel-Bridge Structures:
105-8.8.1 General: Provide supervisory personnel meeting the qualification
requirements only for the post-tensioned and movable bridge types detailed in this Article.
Submit qualifications to the Engineer at the pre-construction conference. Do not begin
Construction until the qualifications of supervisory personnel have been approved by the
Engineer.
105-8.8.2 Proof of License or Certification: Submit a copy of the Professional
Engineer license current and in force issued by the state in which registration is held. The license
must be for the field of engineering that the construction work involves such as Civil, Electrical
or Mechanical. Under certain circumstances Florida registration may be required.
Submit a copy of the license issued by the State of Florida for tradesmen
that require a license indicating that the license is in force and is current. Submit a copy of the
certification issued by the Instrumentation, Systems and Automation Society of America for each
Certified Control Systems Technician.
105-8.8.3 Experience Record: Submit the following information for supervisory
personnel to substantiate their experience record. The supervisor (project engineer,
superintendent/manager or foreman) seeking approval must provide a notarized certification
statement attesting to the completeness and accuracy of the information submitted. Provide the
following experience information for each individual seeking approval as a supervisor:
Project owners name and telephone number of an owners representative,
project identification number, state, city, county, highway number and feature intersected.
Provide a detailed description of each bridge construction experience, and
the level of supervisory authority during that experience. Report the duration in weeks, as well as
begin and end dates, for each experience period.
Provide the name, address and telephone number of an individual that can
verify that the experience being reported is accurate. This individual should have been an
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immediate supervisor unless the supervisor cannot be contacted in which case another individual
with direct knowledge of the experience is acceptable.
105-8.8.4 Concrete Post-Tensioned Segmental Box Girder Construction:
Ensure the individuals filling the following positions meet the minimum requirements as follows:
105-8.8.4.1 Project Engineer-New Construction: Ensure the Project
Engineer is a registered professional engineer with five years of bridge construction experience.
Ensure a minimum of three years of experience is in Segmental Box Girder Construction
Engineering and includes a minimum of one year in segmental casting yard operations and
related surveying, one year in segment erection and related surveying, including post-tensioning
and grouting of longitudinal tendons and a minimum of one year as the Project Engineer in
responsible charge of Segmental Box Girder Construction Engineering. Ensure this individual is
present at the site of construction, at all times while segmental box girder construction or
segment erection is in progress.
105-8.8.4.2 Project Engineer-Repair and Rehabilitation: Ensure the
Project Engineer is a registered Professional Engineer with five years of bridge construction
experience. Ensure a minimum of three years of experience is in Segmental Box Girder
Construction Engineering and includes one year of post-tensioning and grouting of longitudinal
tendons and a minimum of one year as the Project Engineer in responsible charge of Segmental
Box Girder rehabilitation engineering or Segmental Box Girder new construction engineering.
105-8.8.4.3 Project Superintendent/Manager-New Construction:
Ensure the Project Superintendent/Manager has a minimum of ten years of bridge construction
experience or is a registered professional engineer with five years of bridge construction
experience. Ensure that a minimum of three years of experience is in Segmental Box Girder
construction operations and includes a minimum of one year in the casting yard operations and
related surveying, one year in segment erection and related surveying including post-tensioning
and grouting of longitudinal tendons and a minimum of one year as the Project
Superintendent/Manager in responsible charge of Segmental Box Girder construction operations.
Ensure this individual is present at the site of construction, at all times while segmental box
girder construction or segment erection is in progress.
105-8.8.4.4 Project Superintendent/Manager-Repair and
Rehabilitation: Ensure the Project Superintendent/Manager has a minimum of five years of
bridge construction experience or is a registered professional engineer with three years of bridge
construction experience. Ensure that a minimum of two years of experience is in Segmental Box
Girder construction operations and includes a minimum of one year experience performing posttensioning and grouting of longitudinal tendons and a minimum of one year as the Project
Superintendent/Manager in responsible charge of Segmental Box Girder rehabilitation operations
or Segmental Box Girder new construction operations.
105-8.8.4.5 Foreman-New Construction: Ensure that the Foreman has a
minimum of five years of bridge construction experience with two years of experience in
Segmental Box Girder Operations and a minimum of one year as the foreman in responsible
charge of Segmental Box Girder new construction Operations. Ensure this individual is present
at the site of construction, at all times while segmental box girder construction or segment
erection is in progress.
105-8.8.4.6 Foreman-Repair and Rehabilitation: Ensure the Foremen
has a minimum of five years of bridge construction experience with two years of experience in
Segmental Box Girder Operations and a minimum of one year as the foreman in responsible
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charge of Segmental Box Girder rehabilitation operations or Segmental Box Girder new
construction operations.
105-8.8.4.7 Geometry Control Engineer/Manager: Ensure that the
Geometry Control Engineer/Manager for construction of cast-in-place box segments is a
Registered Professional Engineer with one year of experience, a non-registered Engineer with
three years of experience or a Registered Professional Land Surveyor with three years of
experience in geometry control for casting and erection of cast-in-place box segments. Credit for
experience in cast-in-place box girder geometry control will be given for experience in precast
box girder geometry control but not vice versa.
Ensure that the Geometry Control Engineer/Manager for precast
box segments is a Registered Professional Engineer with one year of experience or nonregistered with three years of experience in casting yard geometry control of concrete box
segments.
The Geometry Control Engineer/Manager must be responsible for
and experienced at implementing the method for establishing and maintaining geometry control
for segment casting yard operations and segment erection operations and must be experienced
with the use of computer programs for monitoring and adjusting theoretical segment casting
curves and geometry. This individual must be experienced at establishing procedures for
assuring accurate segment form setup, post-tensioning duct and rebar alignment and effective
concrete placement and curing operations as well as for verifying that casting and erection field
survey data has been properly gathered and recorded. Ensure this individual is present at the site
of construction, at all times while cast-in-place segmental box girder construction is in progress
or until casting yard operations and segment erection is complete.
105-8.8.4.8 Surveyor: Ensure that the Surveyor in charge of geometry
control surveying for box segment casting and/or box segment erection has a minimum of one
year of bridge construction surveying experience. Ensure this individual is present at the site of
construction, at all times while segmental box girder construction or segment erection is in
progress.
105-8.8.5 Movable Bridge Construction: Ensure the individual filling the
following positions meet the minimum requirements as follows:
105-8.8.5.1 Electrical Journeyman: Ensure the Electrical Journeyman
holds, an active journeyman electricians license and has at least five years experience in
industrial electrical work, or is a Certified Control Systems Technician. A Certified Control
Systems Technician will not be permitted to perform electrical power work including, but not
limited to, conduit and wire-way installation or power conductor connection. Ensure the
electrical journeyman has successfully completed the installation of one similar movable bridge
electrical system during the last three years.
105-8.8.5.2 Control Systems Engineer and Mechanical Systems
Engineer: Ensure the Control Systems Engineer and Mechanical Systems Engineer are both
registered Professional Engineers with a minimum of 10 years supervisory experience each in
movable bridge construction. Ensure the Engineers have working knowledge of the movable
bridge leaf motion control techniques, mechanical equipment and arrangements specified for this
project. Ensure that each Engineer has been in responsible control of the design and
implementation of at least three movable bridge electrical control and machinery systems within
the past 10 years of which, at least one of the three bridges was within the last three years.
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Ensure that a minimum of one of the three bridge designs incorporated the same type of leaf
motion control and machinery systems specified for this project.
105-8.8.6 Concrete Post-Tensioned Other Than Segmental Box Girder
Construction: Ensure the individual filling the following positions meet the minimum
requirements as follows:
105-8.8.6.1 Project Engineer: Ensure the Project Engineer is a registered
Professional Engineer with five years of bridge construction experience. Ensure that a minimum
of three years of experience is in concrete post-tensioned construction. Ensure that the three
years of experience includes experience in girder erection, safe use of cranes, stabilization of
girders; design of false work for temporary girder support, post-tensioning and grouting
operations, and a minimum of one year as the Project Engineer in responsible charge of posttensioning related engineering responsibilities.
105-8.8.6.2 Project Superintendent/Manager: Ensure the Project
Superintendent/Manager has a minimum of ten years of bridge construction experience or is a
registered Professional Engineer with five years of bridge construction experience and has a
minimum of three years of supervisory experience in girder erection, safe use of cranes,
stabilization of girders; design of falsework for temporary girder support post-tensioning,
grouting operations and a minimum of one year as the Project Superintendent/Manager in
responsible charge of post-tensioning related operations.
105-8.8.6.3 Foreman: Ensure the Foremen has a minimum of five years
of bridge construction experience with two years of experience in post-tensioning related
operations and a minimum of one year as the foreman in responsible charge of post-tensioning
related operations.
105-8.8.7 Post-Tensioning (PT) and Grouting Personnel Qualifications: Perform all
stressing and grouting operations in the presence of the Engineer and with personnel meeting the
qualifications of this article. Coordinate and schedule all PT and grouting activities to facilitate
inspection by the Engineer
105-8.8.7.1 Post-Tensioning: Perform all PT field operations under the direct
supervision of a Level II CTQP Qualified PT Technician who must be present at the site of the
post-tensioning work during the entire duration of the operation. For bridges having concrete
post-tensioned box or I girder construction, provide at least two CTQP qualified PT technicians,
Level I or II, on the work crew. The supervisor of the work crew, who must be a Level II CTQP
Qualified PT Technician, may also be a work crew member, in which case, the supervisor shall
count as one of the two CTQP qualified work crew members. For PT operations other then posttensioned box or I girder construction, perform all PT operations under the direct supervision of
a Level II CTQP Qualified PT Technician who must be present at the site of the PT work during
the entire duration of the operation.
105-8.8.7.2 Grouting: Perform all grouting field operations under the direct
supervision of a Level II CTQP Qualified Grouting Technician who must be present at the site of
the grouting work during the entire duration of the operation. For bridges having concrete posttensioned box or I girder construction, provide at least two CTQP qualified grouting technicians,
Level I or II, on the work crew. The supervisor of the work crew, who must be a Level II CTQP
Qualified Grouting Technician, may also be a work crew member, in which case, the supervisor
shall count as one of two CTQP qualified work crew members. For grouting operations other
then post-tensioned box or I girder construction, perform all grouting operations under the direct
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supervision of a Level II CTQP Qualified Grouting Technician who must be present at the site of
the grouting work during the entire duration of the operation.
Perform all vacuum grouting operations under the direct supervision of a
crew foreman who has been trained and has experience in the use of vacuum grouting equipment
and procedures. Submit the crew foremans training and experience records to the Engineer prior
to performing any vacuum grouting operation.
105-8.8.8 Failure to Comply with Bridge Qualification Requirements: Make
an immediate effort to reestablish compliance. If an immediate effort is not put forth as
determined by the Engineer, payment for the bridge construction operations requiring
supervisors to be qualified under this Specification will be withheld up to 60 days. Cease all
bridge construction and related activities (casting yard, etc.) if compliance is not met within
60 days, regardless of how much effort is put forth. Resume bridge construction operations only
after written approval from the Engineer stating that compliance is reestablished.
105-8.9 Prestressed Concrete Plant Quality Control Personnel: Ensure each
prestressed concrete plant has an onsite production manager, an onsite Plant Quality Control
Manager, a Plant engineer, and adequate onsite QC inspectors/technicians to provide complete
QC inspections and testing.
Ensure the Plant Manager for QC has at least five years of related experience and
a current PCI QC personnel Level III certification and a certificate of completion of Section 450
Specification examination. Ensure that the QC inspector/technician has current PCI QC
Technician/Inspector Level II certification and a certificate of completion of Section 450
Specification examination.
Ensure that the batch plant operators of the ready mixed concrete batch plants
meet the requirements of Section 9.2 of the Materials Manual. Ensure that the batch plant
operators of the onsite centrally mixed concrete plants meet the requirements of 105-8.11.1.4.2.
105-8.10 Signal Installation Inspector: Provide an inspector trained and certified by the
International Municipal Signal Association (IMSA) as a Traffic Signal Inspector to perform all
signal installation inspections. Use only Department approved signal inspection report forms
during the signal inspection activities. Ensure all equipment, materials, and hardware is in
compliance with Department Specifications and verify that all equipment requiring certification
is listed on the Departments Approved Product List (APL). Provide the completed signal
inspection report form(s), certified by the IMSA Traffic Signal Inspector to the Engineer.
The Departments approved inspection report forms are available at the following
URL: http://www.dot.state.fl.us/trafficoperations/ .
105-8.11 Pipe and Precast Concrete Products Manufacturing Facilities Quality
Control Personnel:
105-8.11.1 General: Obtain personnel certifications from Department accredited
training providers. The list of Department approved courses and their accredited providers is
available on the State Materials Office website.
105-8.11.2 Precast Concrete Drainage Structures, Precast Concrete Box
Culvert, Precast Concrete Pipe, Incidental Precast Concrete, and Flexible Pipe
Manufacturing Facilities Quality Control Personnel:
105-8.11.2.1 Level I Quality Control Inspectors: Ensure that the Level I
Inspectors have completed a minimum of a 12-hour, Department approved, Level I QC Inspector
training course in the respective work area. As an exception to this, ensure Flexible Pipe Level I
QC Inspectors have completed a minimum of an 8-hour, Department approved, Level I QC
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Flexible Pipe Inspector training course. For Incidental Precast Concrete, as an alternative to the
completion of the 12-hour training course, the Department will accept QC personnel meeting the
requirements of 105-8.11.2.4.1 and CTQP Concrete Field Technician level I certification or
Precast/Prestressed Concrete Institute (PCI) Quality Control Technician/Inspector Level II
certification.
105-8.11.2.2 Level II Quality Control Inspectors: Ensure that Level II
Inspectors have completed Department approved Level I QC Inspector training and a minimum
of a 5-hour, Department approved, Level II QC Inspector training course in the respective work
areas. For Incidental Precast Concrete, as an alternative to the completion of the 5-hour training
course, the Department will accept CTQP Concrete Field Technician Level II or PCI Quality
Control Level III certifications.
105-8.11.2.3 Plant Quality Control Manager: Ensure that QC Manager
has completed Department approved Level II QC Inspector training and has a minimum of 2
years construction related experience in the specific work area.
105-8.11.2.4 Additional Requirements for Quality Control Personnel
of Precast Concrete Drainage, Precast Concrete Box Culvert, and Incidental Precast
Concrete Manufacturing Facilities:
105-8.11.2.4.1 Testing Personnel: Ensure the personnel
performing plastic property tests have ACI Concrete Field Testing Technician-Grade I
certification. Ensure the personnel performing laboratory compressive strength testing have ACI
Concrete Laboratory Testing Technician-Grade 1 certification or ACI Concrete Strength Testing
Technician certification.
105-8.11. 2.4.2: Batch Plant Operator: Ensure the concrete batch
plant operator is qualified as a CTQP Concrete Batch Plant Operator. As an alternative to CTQP
qualification, the Department will accept the completion of a minimum of a 6-hour, Department
approved, Batch Plant Operator training course.
105-8.12 Structural Steel and Miscellaneous Metals Fabrication Facility Quality
Control Personnel: Ensure each fabrication facility has an onsite production manager, an onsite
facility manager for QC, a plant engineer, and on site QC inspectors/technicians to provide
complete QC inspections and testing.
Ensure that the Facility Manager for QC and QC inspectors/technicians meet the
certification requirements set forth in the latest version of AASHTO/NSBA Steel Bridge
Collaboration S 4.1, Steel Bridge Fabrication QC/QA Guide Specification, including the years of
experience required in Table 105-5 below. The Facility Manager for QC must meet the
requirements of Table 105-5 for every Structural Steel Member Type produced by a plant with
QC being managed by the Facility Manager for QC. The Facility Manager for QC will report
directly to the plant manager or plant engineer and must not be the plant production manager nor
report to or be the subordinate of the plant production manager. QC inspectors/technicians must
be the employees of, and must report directly to the Facility Manager for QC.
TABLE 105-5
Experience Requirements for QC Inspectors/Technicians
And Facility Manager for Quality Control
Minimum Years of Experience Required
Structural Steel Member Type
QC Inspector/Technician
Facility Manager for QC
Rolled beam bridges
1 year
3 years
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TABLE 105-5
Experience Requirements for QC Inspectors/Technicians
And Facility Manager for Quality Control
Minimum Years of Experience Required
Structural Steel Member Type
QC Inspector/Technician
Facility Manager for QC
Welded plate girders (I
2 years
4 years
sections, box sections, etc.)
Complex structures, such as
trusses, arches, cable stayed
3 years
5 years
bridges, and moveable bridges
Fracture critical (FC) members
3 years
5 years
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SECTION 107
LITTER REMOVAL AND MOWING
107-1 Description.
Provide pickup, removal and disposal of litter within the project limits, excluding any
areas identified in the Plans as landscaping in accordance with Section 580. Mow turf or
vegetation within the project limits, excluding any areas identified in the Plans as landscaping
areas in accordance with Section 580.
Litter, includes but is not limited to, bottles, cans, paper, tires, tire pieces, lumber, vehicle
parts, metal junk, and brush debris. Turf consists of planted grasses in accordance with Section
570. Vegetation consists of planted and natural grasses, weeds, and other natural vegetation
within the area to be mowed.
107-2 Operation.
107-2.1 Frequency: Begin litter removal and mowing when directed by the Engineer.
Continue per the mowing frequency stated in the Plans unless directed otherwise by the Engineer
until final acceptance in accordance with 5-11. Mow all areas to obtain a uniform height of
6 inches.
After final acceptance, perform litter removal and mowing until new turf is
established in accordance with 570-4 at no cost to the Department. Maintain turf and vegetation
height between 6 and 12 inches. Do not include seed stalk or wildflowers when measuring
height.
Perform litter removal prior to and in conjunction with mowing; however, the
Engineer may direct litter pickups in addition to those performed in conjunction with mowing.
Do not mow new turf until a healthy root system is established. In designated
wildflower areas, avoid cutting wildflowers when in bloom and when re-seeding.
107-2.2 General: Mow shoulders and medians concurrently so that not more than one
mile will be left partially mowed at the conclusion of the working day. Mow turf and vegetation
on slopes or around appurtenances concurrent with the mowing operation.
In areas saturated with standing water, mow or cut to the surface of the water
using hand labor or other specialized equipment when standard equipment will cause damage.
Do not remove turf or other vegetation cuttings from the right-of-way, or rake or
pick up the cuttings unless the cuttings are in the traveled ways, bike lanes, or sidewalk; are
obstructing drainage structures; or are the result of cleaning the equipment.
107-2.3 Limitations: Maintain traffic in accordance with Section 102. When mowing
within four feet of a travel lane, operate the equipment in the same direction of traffic, unless the
adjacent lane is closed to traffic due to construction operations.
Perform all work during daylight hours.
107-2.4 Disposal of Litter and Debris: During each litter removal cycle, bag and
remove all litter or piles at the end of each working day. Dispose of litter in accordance with
applicable local and state laws. Do not store or stockpile litter within the project limits.
107-3 Method of Measurement.
For each Litter Removal cycle, the quantity to be paid will be the area, in acres, from
which litter has been picked up, removed, and disposed, completed and accepted. The quantity
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will be determined by calculation using the lengths and widths based on the station to station
dimensions shown in the Plans.
For each Mowing cycle, the quantity to be paid will be the area, in acres, of mowing,
completed and accepted. The quantity will be determined by calculation using the lengths and
widths based on the station to station dimensions shown in the Plans.
107-4 Basis of Payment.
For litter removal, price and payment will be full compensation for all work specified in
this section.
For mowing, price and payment will be full compensation for all work specified in this
section.
No separate payment will be made for litter removal and mowing after final acceptance.
Payment will be made under:
Item No. 107 - 1Litter Removal - per acre.
Item No. 107 - 2 Mowing - per acre
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CLEARING CONSTRUCTION SITE
SECTION 110
CLEARING AND GRUBBING
110-1 Description.
Clear and grub within the areas of the roadway right-of-way and of borrow pits, sandclay base material pits, lateral ditches, and any other areas shown in the Plans to be cleared and
grubbed. Remove and dispose of all trees, stumps, roots and other such protruding objects,
buildings, structures, appurtenances, existing flexible asphalt pavement, and other facilities
necessary to prepare the area for the proposed construction. Remove and dispose of all product
and debris not required to be salvaged or not required to complete the construction.
Also, perform certain miscellaneous work the Engineer considers necessary for the
complete preparation of the overall project site, as follows:
(a) Plug any water wells that are encountered within the right-of-way and that are
to be abandoned.
(b) Level the terrain outside the limits of construction for purposes of facilitating
maintenance and other post-construction operations in accordance with 110-10.3.
(c) Trim trees and shrubs within the project right-of-way that are identified in the
Contract Documents.
Meet the requirements for such miscellaneous work as specified in 110-10.
110-2 Standard Clearing and Grubbing.
110-2.1 Work Included: Completely remove and dispose of all buildings, timber, brush,
stumps, roots, rubbish, debris, and all other obstructions resting on or protruding through the
surface of the existing ground and the surface of excavated areas, and all other structures and
obstructions necessary to be removed and for which other items of the Contract do not specify
the removal thereof, including septic tanks, building foundations, and pipes.
Perform Standard Clearing and Grubbing within the following areas:
(a) All areas where excavation is to be done, including borrow pits, lateral
ditches, right-of-way ditches, etc.
(b) All areas where roadway embankments will be constructed.
(c) All areas where structures will be constructed, including pipe culverts
and other pipe lines.
110-2.2 Depths of Removal of Roots, Stumps, and Other Debris: In all areas where
excavation is to be performed, or roadway embankments are to be constructed, remove roots and
other debris to a depth of 12 inches below the ground surface. Remove roots and other debris
from all excavated material to be used in the construction of roadway embankment or roadway
base. Plow the surface to a depth of at least 6 inches, and remove all roots thereby exposed to a
depth of at least 12 inches. Completely remove and dispose of all stumps within the roadway
right-of-way.
Remove all roots, etc., protruding through or appearing on the surface of the
completed excavation within the roadway area and for structures, to a depth of at least 12 inches
below the finished excavation surface.
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Remove or cut off all stumps, roots, etc., below the surface of the completed
excavation in borrow pits, material pits, and lateral ditches.
In borrow and material pits, do not perform any clearing or grubbing within 3 feet
inside the right-of-way line.
Within all other areas where Standard Clearing and Grubbing is to be performed
remove roots and other debris projecting through or appearing on the surface of the original
ground to a depth of 12 inches below the surface, but do not plow or harrow these areas.
110-2.3 Trees to Remain: As an exception to the above provisions, where so directed by
the Engineer, trim, protect, and leave standing desirable trees within the roadway area. Trim
branches of trees extending over the area occupied by the roadway as directed, to give a clear
height of 16 feet above the roadway.
110-2.4 Boulders: Remove any boulders encountered in the roadway excavation (other
than as permitted under the provisions of 120-7.2) or found on the surface of the ground. When
approved by the Engineer place boulders in neat piles inside the right of way. The Contractor
may stockpile boulders encountered in Department-furnished borrow areas, which are not
suitable for use in the embankment construction, within the borrow area.
110-3 Selective Clearing and Grubbing.
The Contractor shall remove and dispose of all vegetation, obstructions, etc., as provided
above except that, where so elected, the Contractor may cut roots, etc., flush with the ground
surface. Completely remove and dispose of stumps. Entirely remove undergrowth except in
specific areas designated by the Engineer to remain for aesthetic purposes. Trim, protect, and
leave standing desirable trees, with the exception of such trees as the Engineer may designate to
be removed in order to facilitate right-of-way maintenance. Remove undesirable or damaged
trees as so designated by the Engineer. Perform Selective Clearing and Grubbing only in areas so
designated in the Plans.
110-4 Protection of Property Remaining in Place.
Protect and do not displace property obstructions which are to remain in place, such as
buildings, sewers, drains, water or gas pipes, conduits, poles, walls, posts, bridges, etc.
110-5 Removal of Buildings.
110-5.1 Parts to be Removed: Completely remove all parts of the buildings, including
utilities, plumbing, foundations, floors, basements, steps, connecting concrete sidewalks or other
pavement, septic tanks, and any other appurtenances, by any practical manner which is not
detrimental to other property and improvements. Remove utilities to the point of connection to
the utility authoritys cut-in. After removing the sewer connections to the point of cut-in,
construct a concrete plug at the cut-in point, as directed by the Engineer, except where the utility
owners may elect to perform their own plugging. Contact the appropriate utility companies prior
to removal of any part of the building to ensure disconnection of services.
110-5.2 Removal by Others: Where buildings within the area to be cleared and grubbed
are so specified to be removed by others, remove and dispose of any foundations, curtain walls,
concrete floors, basements or other foundation parts which might be left in place after such
removal of buildings by others.
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110-6 Removal of Existing Structures.
110-6.1 Structures to be Removed: Remove and dispose of the materials from existing
structures. Remove the following: (1) those structures, or portions of structures, shown in the
Plans to be removed; (2) those structures, or portions of structures, found within the limits of the
area to be cleared and grubbed, and directed by the Engineer to be removed; (3) those structures,
or portion of structures, which are necessary to be removed in order to construct new structures;
and (4) other appurtenances or obstructions which may be designated in the Contract Documents
as to be included in an item of payment for the work under this Article.
Provide detailed schedule information to the Engineer 15 working days prior to
the commencement of any demolition or renovation of any structures, even if asbestos is not
found on the project, for the Engineers use in notifying the Department of Environmental
Protection (DEP) on DEP Form 62-257.900(1) Notice of Asbestos Renovation or Demolition.
110-6.2 Method of Removal:
110-6.2.1 General: Remove the structures in such a way so as to leave no
obstructions to any proposed new structures or to any waterways. Pull, cut off, or break off
pilings to the requirements of the permit or other Contract Documents, or if not specified, not
less than 2 feet below the finish ground line. In the event that the Plans indicate channel
excavation to be done by others, consider the finish ground line as the limits of such excavation.
For materials which are to remain the property of the Department or are to be salvaged for use in
temporary structures, avoid damage to such materials, and entirely remove all bolts, nails, etc.
from timbers to be so salvaged. Mark structural steel members for identification as directed.
110-6.2.2 Removal of Steel Members With Hazardous Coatings: Provide to
the Engineer for approval, a copy of the Contractors Lead in Construction Compliance
Program from the firm actually removing and disposing of these steel members before any
members are disturbed.
Vacuum power tool clean any coated steel member to bare metal as
defined by SSPC-SP11 a minimum of 4 inches either side of any area to be heated (torch cutting,
sawing, grinding, etc.) in accordance with 29 CFR 1926.354. Abrasive blasting is prohibited.
Provide air supplied respirators in accordance with 29 CFR 1926.62 and
29 CFR 1910.134.
110-6.3 Partial Removal of Bridges: On concrete bridges to be partially removed and
widened, remove concrete by manually or mechanically operated pavement breakers, by
concrete saws, by chipping hammers, or by hydro-demolition methods. Do not use explosives.
Where concrete is to be removed to neat lines, use concrete saws or hydro-demolition methods
capable of providing a reasonably uniform cleavage face. If the equipment used will not provide
a uniform cut without surface spalling, first score the outlines of the work with small trenches or
grooves. For all demolition methods, submit for review and approval of the Engineer, a
demolition plan that describes the method of removal, equipment to be used, types of rebar
splices or couplers, and method of straightening or cutting rebars. In addition, for hydrodemolition, describe the method for control of water or slurry runoff and measures for safe
containment of concrete fragments that are thrown out by the hydro-demolition machine.
110-6.4 Authority of U.S. Coast Guard: For structures in navigable waters, when
constructing the project under authority of a U.S. Coast Guard permit, the U.S. Coast Guard may
inspect and approve the work to remove any existing structures involved therein, prior to
acceptance by the Department.
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110-6.5 Asbestos Containing Materials (ACM) Not Identified Prior to the Work:
When encountering or exposing any condition indicating the presence of asbestos, cease
operations immediately in the vicinity and notify the Engineer.
Make every effort to minimize the disturbance of the ACM. Immediately provide
for the health and safety of all workers at the job site and make provisions necessary for the
health and safety of the public that may be exposed to any potentially hazardous conditions.
Provisions shall meet all applicable laws, rules or regulations covering hazardous conditions and
will be in a manner commensurate with the gravity of the conditions.
The Engineer will notify the District Contamination Assessment Coordinator who
will coordinate selecting and tasking the Departments Asbestos Contractor or Contamination
Assessment/Remediation Contractor (CAR). Provide access to the potential contamination area.
Preliminary investigation by the Asbestos/CAR Contractor will determine the course of action
necessary for site security and the steps necessary to resolve the contamination issue.
The Asbestos/CAR Contractor will delineate the contamination area(s), any
staging or holding area required. Coordinate with the Asbestos/CAR Contractor and the
Engineer to develop a work plan that will provide the Asbestos/CAR Contractors operations
schedule with projected completion dates for the final resolution of the contamination issue.
The Asbestos/CAR Contractor will maintain jurisdiction over activities inside any
outlined contaminated areas and any associated staging holding areas. The Asbestos/CAR
Contractor will be responsible for the health and safety of workers within the delineated areas.
Provide continuous access to these areas for the Asbestos/CAR Contractor and representatives of
regulatory or enforcement agencies having jurisdiction.
Both Contractors will use the schedule as a basis for planning the completion of
both work efforts. The Engineer may grant the Contract Time extensions according to the
provisions of 8-7.3.2.
Cooperate with the Asbestos/CAR Contractor to expedite integration of the
Asbestos/CAR Contractors operations into the construction project. The Prime Contractor is not
expected to engage in routine construction activities involving asbestos containing materials.
Adjustments to quantities or to Contract unit prices will be made according to work additions or
reductions on the part of the Prime Contractor in accordance with 4-3.
The Engineer will direct the Prime Contractor when operations may resume in the
affected area.
110-7 Removal of Existing Pavement.
Remove and dispose of existing rigid portland cement concrete pavement, sidewalk,
slope pavement, ditch pavement, curb, and curb and gutter etc., where shown in the Plans or
ordered by the Engineer to be removed or where required because of the construction operations.
Retaining walls, drainage structures and flexible asphalt pavement are not included in the work
under this Article.
110-8 Ownership of Materials.
Except as may be otherwise specified in the Contract Documents, the Contractor shall
take ownership of all buildings, structures, appurtenances, and other materials removed by him
and shall dispose of them in accordance with 110-9.
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110-9 Disposal of Materials.
110-9.1 General: Either stack materials designated to remain the property of the
Department in neat piles within the right-of-way or load onto the Departments vehicles.
Dispose of timber, stumps, brush, roots, rubbish, and other objectionable material
resulting from clearing and grubbing in areas and by methods meeting the applicable
requirements of all Local, State and Federal regulations. Do not block waterways by the disposal
of debris.
110-9.2 Burning Debris: Where burning of such materials is permitted, perform all such
burning in accordance with the applicable laws, ordinances, and regulations. Perform all burning
at locations where trees and shrubs adjacent to the cleared area will not be harmed.
110-9.3 Timber and Crops: The Contractor may sell any merchantable timber, fruit
trees, and crops that are cleared under the operations of clearing and grubbing for his own
benefit, subject to the provisions of 7-1.2, which may require that the timber, fruit trees, or crops
be burned at or near the site of their removal, as directed by the Engineer. The Contractor is
liable for any claims which may arise pursuant to the provisions of this Subarticle.
110-9.4 Disposal of Treated Wood: Treated wood, including that which comes from
bridge channel fender systems, must be handled and disposed of properly during removal.
Treated wood should not be cut or otherwise mechanically altered in a manner that would
generate dust or particles without proper respiratory and dermal protection. The treated wood
must be disposed of in at least a lined solid waste facility or through recycling/reuse. Treated
wood shall not be disposed by burning or placement in a construction and demolition (C&D)
debris landfill. All compensation for the cost of removal and disposal of treated wood will be
included in the Cost of Removal of Existing Structures.
110-9.5 Hazardous Materials/Waste: Handle, transport and dispose of hazardous
materials in accordance with all Local, State and Federal requirements including the following:
a. SSPC Guide 7
b. Federal Water Pollution Control Act, and
c. Resource Conservation and Recover Act (RCRA).
Accept responsibility for the collection, sampling, classification, packaging,
labeling, accumulation time, storage, manifesting, transportation, treatment and disposal of
hazardous waste, both solid and liquid. Separate all solid and liquid waste and collect all liquids
used at hygiene stations and handle as hazardous materials/waste. Obtain written approval from
the Engineer for all hazardous materials/waste stabilization methods before implementation.
Obtain an EPA/FDEP Hazardous Waste Identification Number
(EPA/FDEP ID Number) before transporting and/or disposal of any hazardous materials/waste.
List the Department as the generator of all hazardous materials/waste.
Submit the following for the Engineers approval before transporting, treatment or
disposal of any hazardous materials/waste:
a. Name, address and qualifications of the transporter,
b. Name, address and qualifications of the treatment facility,
c. Proposed treatment and/or disposal of all Hazardous Materials/Waste.
Transport all hazardous materials/waste in accordance with applicable
40 CFR 263 Standards. Provide a copy of all completed Hazardous Materials/Waste
manifest/bills of lading to the Engineer within 21 days of each shipment.
110-9.5.1 Steel Members With Hazardous Coating: Dispose of steel members
with hazardous coating in one of the following manners:
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(a) Deliver the steel members and other hazardous waste to a licensed
recycling or treatment facility capable of processing steel members with hazardous coating.
(b) Deliver the steel members with hazardous coating to a site designated
by the Engineer for use as an offshore artificial reef. Deliver any other hazardous materials/waste
to a licensed hazardous materials/waste recycling treatment facility.
Dismantle and/or cut steel members to meet the required dimensions of
the recycling facility, treatment facility or offshore artificial reef agency.
All compensation for the cost of removal and disposal of hazardous
materials/waste will be included in the Cost of Removal of Existing Structures.
110-9.5.2 Certification of Compliance: Furnish two copies of Certification of
Compliance from the firm actually removing and disposing of the hazardous materials/waste
stipulating, the hazardous materials/waste has been handled, transported and disposed of in
accordance with this Specification. The Certification of Compliance shall be attested to by a
person having legal authority to bind the company.
Maintain all records required by this Specification and ensure these
records are available to the Department upon request.
110-10 Miscellaneous Operations.
110-10.1 Water Wells Required to be Plugged: Fill or plug all water wells within the
right-of-way, including areas of borrow pits and lateral ditches, that are not to remain in service,
in accordance with applicable Water Management District rules or the Department of
Environmental Protection regulations.
Cut off the casing of cased wells at least 12 inches below the ground line or
12 inches below the elevation of the finished excavation surface, whichever is lower. Water
wells, as referred to herein, are defined either as artesian or non-artesian, as follows:
(a) An artesian well is an artificial hole in the ground from which water
supplies may be obtained and which penetrates any water-bearing rock, the water in which is
raised to the surface by natural flow or which rises to an elevation above the top of the waterbearing bed. Artesian wells are further defined to include all holes drilled as a source of water
that penetrate any water-bearing beds that are a part of the artesian water system of Florida, as
determined by representatives of the applicable Water Management District.
(b) A non-artesian (water-table) well is a well in which the source of water
is an unconfined aquifer. The water in a non-artesian well does not rise above the source bed.
When the Plans do not indicate whether a non-flowing well is artesian or nonartesian, obtain this information from the Engineer.
110-10.2 Landscape Areas: When certain areas of the right-of-way, outside of the limits
of construction, are shown in the Plans or designated by the Engineer to be landscaped, either
under the construction Contract or at a later time, remove undesirable trees, stumps,
undergrowth, and vegetation, as directed, and preserve and trim natural growth and trees as
directed by the Engineer.
110-10.3 Leveling Terrain: Within the areas between the limits of construction and the
outer limits of clearing and grubbing, fill all holes and other depressions, and cut down all
mounds and ridges. Make the area of a sufficient uniform contour so that the Departments
subsequent mowing and cutting operations are not hindered by irregularity of terrain. Perform
this work regardless of whether the irregularities were the result of construction operations or
existed originally.
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110-10.4 Mailboxes: When the Contract Documents require furnishing and installing
mailboxes, permit each owner to remove the existing mailbox. Work with the Local Postmaster
to develop a method of temporary mail service for the period between removal and installation of
the new mailboxes. Install the mailboxes in accordance with the Design Standards.
110-11 Method of Measurement.
110-11.1 Clearing and Grubbing: When direct payment is provided in the Contract, the
quantity to be paid for will be the lump sum quantity.
110-11.2 Removal of Existing Structures: When direct payment is provided in the
Contract, the quantity to be paid for will be the lump sum quantity or quantities for the specific
structures removed, as designated.
110-11.3 Removal of Existing Pavement: Payment for removal of flexible asphalt
pavement is included in the Lump Sum price for Clearing and Grubbing. When a separate item
for Removal of Existing Pavement is provided, the quantity to be paid for will be the number of
square yards of existing pavement of the types listed in 110-7, acceptably removed and disposed
of, as specified. The quantity will be determined by actual measurement along the surface of the
pavement before its removal. Measurements for appurtenances which have irregular surface
configurations, such as curb and gutter, steps, and ditch pavement, will be the area as projected
to an approximate horizontal plane. Where the removal of pavement areas is necessary only for
the construction of box culverts, pipe culverts, storm sewers, inlets, manholes, etc., these areas
will not be included in the measurements.
110-11.4 Plugging Water Wells: When direct payment is provided in the Contract, the
quantity to be paid for will be the number of water wells plugged, for each type of well (artesian
or non-artesian).
110-11.5 Mailboxes: When direct payment is provided in the Contract, the quantity to be
paid for will be the number of mailboxes acceptably furnished and installed.
110-11.6 Delivery of Salvageable Material to the Department When direct payment is
provided in the Contract, the quantity to be paid for will be the Lump Sum quantity for delivery
of salvageable materials to the Department as indicated in the Plans.
110-11.7 General: In each case, except as provided below, where no item of separate
payment for such work is included in the proposal, all costs of such work will be included in the
various scheduled items in the Contract, or under specific items as specified herein below or
elsewhere in the Contract.
110-12 Basis of Payment.
110-12.1 Clearing and Grubbing:
110-12.1.1 Lump Sum Payment: Price and payment will be full compensation
for all clearing and grubbing required for the roadway right-of-way and for lateral ditches,
channel changes, or other outfall areas, and any other clearing and grubbing indicated, or
required for the construction of the entire project, including all necessary hauling, furnishing
equipment, equipment operation, furnishing any areas required for disposal of debris, leveling of
terrain and the landscaping work of trimming, etc., as specified herein, except for any areas
designated to be paid for separately or to be specifically included in the costs of other work
under the Contract.
Where construction easements are specified in the Plans and the limits of
clearing and grubbing for such easements are dependent upon the final construction
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requirements, no adjustment will be made in the lump sum price and payment, either over or
under, for variations from the limits of the easement defined in the Plans.
110-12.1.2 When No Direct Payment is Provided: When no item for clearing
and grubbing is included in the proposal, the Contractor shall include the cost of any work of
clearing and grubbing which is necessary for the proper construction of the project in the
Contract price for the structure or other item of work for which such clearing and grubbing is
required.
The Contractor shall include the cost of all clearing and grubbing which
might be necessary in pits or areas from which base material is obtained in the Contract price for
the base in which such material is used. The clearing and grubbing of areas for obtaining
stabilizing materials, where required only for the purpose of obtaining materials for stabilizing,
will not be paid for separately.
110-12.2 Removal of Existing Structures: Price and payment will be full compensation
for all work of removal and disposal of the designated structures.
When direct payment for the removal of existing structures is not provided in the
proposal, the Contractor shall include the cost of removing all structures in the Contract price for
clearing and grubbing or, if no item of clearing and grubbing is included, in the compensation for
the other items covering the new structure being constructed.
110-12.3 Removal of Existing Pavement: Price and payment will be full compensation
for performing and completing all the work of removal and satisfactory disposal.
When no separate item for this work is provided and no applicable item of
excavation or embankment covering such work (as provided in 120-13.1) is included, the
Contractor shall include the costs of this work in the Contract price for the item of clearing and
grubbing or for the pipe or other structure for which the pavement removal is required.
110-12.4 Plugging Water Wells: Price and payment will be full compensation for each
type of well acceptably plugged.
If a water well requiring plugging is encountered and the Contract contains no
price for plugging wells of that specific type, the plugging of such well will be paid for as
unforeseeable work.
110-12.5 Mailboxes: Price and payment will be full compensation for all work and
materials required, including supports and numbers.
110-12.6 Delivery of Salvageable Material to the Department: Price and payment will
be full compensation for all work required for delivery of the materials to the Department.
110-12.7 Payment Items: Payment will be made under:
Item No. 110- 1Clearing and Grubbing - lump sum.
Item No. 110- 3Removal of Existing Structures - lump sum.
Item No. 110- 4Removal of Existing Pavement - per square yard.
Item No. 110- 5Plugging Water Wells (Artesian) - each.
Item No. 110- 6Plugging Water Wells (Non-Artesian) - each.
Item No. 110- 7Mailbox (Furnish and Install) - each.
Item No. 110- 86Delivery of Salvageable Material to FDOT - lump sum.
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EARTHWORK AND RELATED OPERATIONS
SECTION 120
EXCAVATION AND EMBANKMENT
120-1 Description.
120-1.1 General: Excavate and construct embankments as required for the roadway,
ditches, channel changes and borrow material. Use suitable excavated material or authorized
borrow to prepare subgrades and foundations. Construct embankments in accordance with
Standard Index 505. Compact and dress excavated areas and embankments.
For excavation and backfilling of structures, comply with the requirements
of Section 125. Excavate material for clearing and grubbing in accordance with the requirements
of Section 110. Material displaced by the storm sewer or drainage structure system is not
included in the earthwork quantities shown in the Plans.
120-1.2 Unidentified Areas of Contamination: When encountering or exposing any
abnormal condition indicating the presence of contaminated materials, cease operations
immediately in the vicinity and notify the Engineer. The presence of tanks or barrels; discolored
earth, metal, wood, ground water, etc.; visible fumes; abnormal odors; excessively hot earth;
smoke; or other conditions that appear abnormal may indicate the presence of contaminated
materials and must be treated with extreme caution.
Make every effort to minimize the spread of contamination into uncontaminated
areas. Immediately provide for the health and safety of all workers at the job site and make
provisions necessary for the health and safety of the public that may be exposed to any
potentially hazardous conditions. Ensure provisions adhere to all applicable laws, rules or
regulations covering potentially hazardous conditions and will be in a manner commensurate
with the gravity of the conditions.
The Engineer will notify the District Contamination Impact Coordinator (DCIC)
who will coordinate selecting and tasking the Departments Contamination
Assessment/Remediation Contractor (CAR). Provide access to the potentially contaminated area.
Preliminary investigation by the CAR Contractor will determine the course of action necessary
for site security and the steps necessary under applicable laws, rules, and regulations for
additional assessment and/or remediation work to resolve the contamination issue.
The CAR Contractor will delineate the contamination area(s), any staging or
holding area required, and, in cooperation with the Prime Contractor and Engineer, develop a
work plan that will provide the CAR Contractors operations schedule with projected completion
dates for the final resolution of the contamination issue.
The CAR Contractor will maintain jurisdiction over activities inside any outlined
contaminated areas and any associated staging holding areas. The CAR Contractor will be
responsible for the health and safety of workers within the delineated areas. Provide continuous
access to these areas for the CAR Contractor and representatives of regulatory or enforcement
agencies having jurisdiction.
Both Contractors will use the schedule as a basis for planning the completion of
both work efforts. The Engineer may grant the Contract Time extensions according to the
provisions of 8-7.3.2.
Cooperate with the CAR Contractor to expedite integration of the CAR
Contractors operations into the construction project. The Prime Contractor is not expected to
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engage in routine construction activities, such as excavating, grading, or any type of soil
manipulation, or any construction processes required if handling of contaminated soil, surface
water or ground water is involved. All routine construction activities requiring the handling of
contaminated soil, surfacewater or groundwater will be by the CAR Contractor. Adjustments to
quantities or to Contract unit prices will be made according to work additions or reductions on
the part of the Prime Contractor in accordance with 4-3.
The Engineer will direct the Prime Contractor when operations may resume in the
affected area.
120-2 Classifications of Excavation.
120-2.1 General: The Department may classify excavation specified under this Section
for payment as any of the following: (1) Regular Excavation, (2) Subsoil Excavation, (3) Lateral
Ditch Excavation, and (4) Channel Excavation.
If the proposal does not show Subsoil Excavation or Lateral Ditch Excavation as
separate items of payment, include such excavation under the item of Regular Excavation.
If the proposal shows Lateral Ditch Excavation as a separate item of payment, but
does not show Channel Excavation as a separate item of payment, include such excavation under
the item of Lateral Ditch Excavation. Otherwise, include Channel Excavation under the item of
Regular Excavation.
120-2.2 Regular Excavation: Regular Excavation includes roadway excavation and
borrow excavation, as defined below for each.
120-2.2.1 Roadway Excavation: Roadway Excavation consists of the excavation
and the utilization or disposal of all materials necessary for the construction of the roadway,
ditches, channel changes, etc., except as may be specifically shown to be paid for separately and
that portion of the lateral ditches within the limits of the roadway right-of-way as shown in the
Plans.
120-2.2.2 Borrow Excavation: Borrow Excavation consists of the excavation
and utilization of material from authorized borrow pits, including only material that is suitable
for the construction of roadway embankments or of other embankments covered by the Contract.
A Cost Savings Initiative Proposal submittal based on using borrow
material from within the project limits will not be considered.
120-2.3 Subsoil Excavation: Subsoil Excavation consists of the excavation and disposal
of muck, clay, rock, or any other material that is unsuitable in its original position and that is
excavated below the finished grading template. For stabilized bases and sand bituminous road
mixes, consider the finished grading template as the top of the finished base, shoulders and
slopes. For all other bases and rigid pavement, consider the finished grading template as the
finished shoulder and slope lines and bottom of completed base or rigid pavement. For pond and
ditches that identify the placement of a blanket material, consider the finished grading template
as the bottom of the blanket material. Subsoil Excavation also consists of the excavation of all
suitable material within the above limits as necessary to excavate the unsuitable material.
Consider the limits of Subsoil Excavation indicated in the Plans as being particularly variable, in
accordance with the field conditions actually encountered.
The quantity of material required to replace the excavated material and to raise
the elevation of the roadway to the bottom of the template will be paid for under Embankment or
Borrow Excavation (Truck Measure).
120-2.4 Lateral Ditch Excavation: Lateral Ditch Excavation consists of all excavation
of inlet and outlet ditches to structures and roadway, changes in channels of streams, and ditches
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parallel to the roadway right-of-way. Dress lateral ditches to the grade and cross-section shown
in the Plans.
120-2.5 Channel Excavation: Channel Excavation consists of the excavation and
satisfactory disposal of all materials from the limits of the channel as shown in the Plans.
120-3 Preliminary Soils Investigations.
When the Plans contain the results of a soil survey, do not assume such data is a
guarantee of the depth, extent, or character of material present.
120-4 Removal of Unsuitable Materials and Existing Roads.
120-4.1 Subsoil Excavation: Where muck, rock, clay, or other material within the limits
of the roadway is unsuitable in its original position, excavate such material to the cross-sections
shown in the Plans or indicated by the Engineer, and backfill with suitable material. Shape
backfill material to the required cross-sections. Where the removal of plastic soils below the
finished earthwork grade is required, meet a construction tolerance, from the lines shown in the
plans as the removal limits, of plus or minus 0.2 feet in depth and plus or minus 6 inches (each
side) in width.
120-4.2 Construction over Existing Old Road: Where a new roadway is to be
constructed over an old one, plow or scarify the old road, and break it up full width, regardless of
height of fill. If the Plans provide that paving materials may be incorporated into the fill,
distribute such material in a manner so as not to create voids. Recompact the old road meeting
the requirements of 120-10.2.
120-4.3 Obliterating Old Road: Where the Plans call for obliteration of portions of an
old road outside of the proposed new roadway, obliterate such sections of the old road by
grading to fill ditches and to restore approximately the original contour of the ground or a
contour which produces a pleasing appearance.
120-5 Disposal of Surplus and Unsuitable Material.
120-5.1 Ownership of Excavated Materials: Dispose of surplus and excavated
materials as shown in the Plans or, if the Plans do not indicate the method of disposal, take
ownership of the materials and dispose of them outside the right-of-way.
120-5.2 Disposal of Muck on Side Slopes: As an exception to the provisions of 120-5. 1,
when approved by the Engineer, in rural undeveloped areas, the Contractor may place muck (A8 material) on the slopes, or store it alongside the roadway, provided there is a clear distance of
at least 6 feet between the roadway grading limits and the muck, and the Contractor dresses the
muck to present a neat appearance. In addition, the Contractor may also dispose of this material
by placing it on the slopes in developed areas where, in the opinion of the Engineer, this will
result in an aesthetically pleasing appearance and will have no detrimental effect on the adjacent
developments. Where the Engineer permits the disposal of muck or other unsuitable material
inside the right-of-way limits, do not place such material in a manner which will impede the
inflow or outfall of any channel or side ditches. The Engineer will determine the limits adjacent
to channels within which such materials may be disposed.
120-5.3 Disposal of Paving Materials: Unless otherwise noted, take ownership of
paving materials, such as paving brick, asphalt block, concrete slab, sidewalk, curb and gutter,
etc., excavated in the removal of existing pavements, and dispose of them outside the right-ofway. If the materials are to remain the property of the Department, place them in neat piles as
directed. Existing limerock base that is removed may be incorporated in the stabilized portion of
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the subgrade. If the construction sequence will allow, incorporate all existing limerock base into
the project as allowed by the Contract Documents.
120-5.4 Disposal Areas: Where the Contract Documents require disposal of excavated
materials outside the right-of-way, and the disposal area is not indicated in the Contract
Documents, furnish the disposal area without additional compensation.
Provide areas for disposal of removed paving materials out of sight of the project
and at least 300 feet from the nearest roadway right-of-way line of any State-maintained road. If
the materials are buried, disregard the 300 foot limitation.
120-6 Borrow.
120-6.1 Materials for Borrow: Do not open borrow pits until the Engineer has approved
their location.
Do not provide borrow materials that are polluted as defined in Chapter 376 of the
Florida Statutes (oil of any kind and in any form, gasoline, pesticides, ammonia, chlorine, and
derivatives thereof, excluding liquefied petroleum gas) in concentrations above any local, State,
or Federal standards.
Prior to placing any borrow material that is the product of soil incineration,
provide the Engineer with a copy of the Certificate of Materials Recycling and Post Burn
Analysis showing that the material is below all allowable pollutant concentrations.
120-6.2 Furnishing of Borrow Areas:
To obtain the Engineers approval to use an off-site construction activity area that
involves excavation such as a borrow pit or local aggregate pit, request in writing, a review for cultural resources involvement. Send the request to the Division of Historical Resources (DHR),
Department of State, State Historic Preservation Officer, Tallahassee,FL. As a minimum, include
in the request the Project Identification Number, the County, a description of the property with
Township, Range, Section, etc., the dimensions of the area to be affected, and a location map. Do
not start any work at the off-site construction activity area prior to receiving clearance from the
DHR that no additional research is warranted.
For certain locations, the DHR will require a Cultural Resources Assessment
Survey before approval can be granted. When this is required, secure professional archaeological
services to complete an historical and archaeological survey report. Submit the report to the
DHR with a copy to the Department. The Engineer will determine final approval or rejection of
off-site construction activity areas based on input from the DHR.
Before receiving approval or before use of borrow areas, obtain written clearance
from the engineer concerning compliance with the Federal Endangered Species Act and other
Wildlife Regulations as specified in 7-1.4 and Section 4(f) of the USDOT Act as specified in 71.8.
The Department will adjust Contract Time in accordance with 8-7 for any
suspension of operations required to comply with this Article. The Department will not accept
any monetary claims due to delays or loss of off-site construction activity areas.
Except where the Plans specifically call for the use of a particular borrow or
dredging area, the Contractor may substitute borrow or dredging areas of his own choosing
provided: (1) the Engineer determines the materials from such areas meet the Departments
standards and other requirements for stability for use in the particular sections of the work in
which it is to be placed, and (2) the Contractor absorbs any increase in hauling or other costs.
Stake the corners of the proposed borrow area and provide the necessary equipment along with
an operator in order for the Engineer to investigate the borrow area. The Engineer will determine
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test locations, collect samples, and perform tests to investigate the proposed borrow area based
on soil strata and required soil properties. The Engineer will approve use of materials from the
proposed area based on test results and project requirements. Final acceptance of materials will
be based on Point of Use Test as described in 6-1.2.4.
Before using any borrow material from any substitute areas, obtain the Engineers
approval, in writing, for the use of the particular areas, and, where applicable, ensure that the
Engineer has cross-sectioned the surface. Upon such written approval by the Engineer, consider
the substitute areas as designated borrow areas.
When furnishing the dredging or borrow areas, supply the Department with
evidence that the necessary permits, rights, or waivers for the use of such areas have been
secured.
Do not excavate any part of a Contractor furnished borrow area which is less than
300 feet from the right-of-way of the project or any State Road until the Engineer has approved a
plan for landscaping and restoring the disturbed area. Perform this landscaping and land
restoration at no expense to the Department, prior to final acceptance of the project. Do not
provide a borrow area closer than 25 feet to the right-of-way of any state road. In Department
furnished borrow pits, do not excavate material within 5 feet of adjacent property lines.
Upon completion of excavation, neatly shape, dress, grass, vegetate, landscape,
and drain all exposed areas including haul roads, as necessary so as not to present an
objectionable appearance.
Meet the requirements of Section 104 when furnishing borrow areas, regardless of
location.
120-6.3 Borrow Material for Shoulder Build-up: When so indicated in the Plans,
furnish borrow material with a specific minimum bearing value, for building up of existing
shoulders. Blend materials as necessary to achieve this specified minimum bearing value prior to
placing the materials on the shoulders. Take samples of this borrow material at the pit or blended
stockpile. Include all costs of providing a material with the required bearing value in the Contract
unit price for borrow material.
120-6.4 Haul Routes for Borrow Pits: Provide and maintain, at no expense to the
Department, all necessary roads for hauling the borrow material. Where borrow area haul roads
or trails are used by others, do not cause such roads or trails to deteriorate in condition.
Arrange for the use of all non-public haul routes crossing the property of any
railroad. Incur any expense for the use of such haul routes. Establish haul routes which will
direct construction vehicles away from developed areas when feasible, and keep noise from
hauling operations to a minimum. Advise the Engineer in writing of all proposed haul routes.
120-6.5 Authorization for Use of Borrow: When the item of Borrow Excavation is
included in the Contract, use borrow only when sufficient quantities of suitable material are not
available from roadway and drainage excavation, to properly construct the embankment,
subgrade, and shoulders, and to complete the backfilling of structures. Do not use borrow
material until so ordered by the Engineer, and then only use material from approved borrow pits.
120-7 Materials for Embankment.
120-7.1 Use of Materials Excavated From the Roadway and Appurtenances: Assume
responsibility for determining the suitability of excavated material for use on the project in
accordance with the applicable Contract Documents. Consider the sequence of work and
maintenance of traffic phasing in the determination of the availability of this material.
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120-7.2 General Requirements for Embankment Materials: Construct embankments
of acceptable material including reclaimed asphalt pavement (RAP), reclaimed concrete
aggregate (RCA) and portland cement concrete rubble, but containing no muck, stumps, roots,
brush, vegetable matter, rubbish, reinforcement bar or other material that does not compact into a
suitable and enduring roadbed. Do not use RAP or RCA in the top 3 feet of slopes and shoulders
that are to be grassed or have other type of vegetation established.
Remove all waste material designated as undesirable. Use material in
embankment construction in accordance with plan details or as the Engineer directs.
Complete the embankment using maximum particle sizes (in any dimension) as
follows:
In top 12 inches: 3 1/2 inches (in any dimension).
12 to 24 inches: 6 inches (in any dimension).
In the depth below 24 inches: not to exceed 12 inches (in any dimension)
or the compacted thickness of the layer being placed, whichever is less.
Spread all material so that the larger particles are separated from each other to
minimize voids between them during compaction. Compact around these rocks in accordance
with 120-9.2.
When and where approved by the Engineer, the Contractor may place larger rocks
(not to exceed 18 inches in any dimension) outside the one to two slope and at least 4 feet or
more below the bottom of the base. Compact around these rocks to a firmness equal to that of the
supporting soil. Construct grassed embankment areas in accordance with 120-9.2.6. Where
constructing embankments adjacent to bridge end bents or abutments, do not place rock larger
than 3 1/2 inches in diameter within 3 feet of the location of any end-bent piling.
120-7.3 Materials Used at Pipes, Culverts, etc.: Construct embankments over and
around pipes, culverts, and bridge foundations with selected materials.
120-8 Embankment Construction.
120-8.1 General: Construct embankments in sections of not less than 300 feet in length
or for the full length of the embankment. Perform work in accordance with an approved Quality
Control Plan meeting the requirements of 105-3.
For construction of mainline pavement lanes, turn lanes, ramps, parking lots,
concrete box culverts and retaining wall systems, a LOT is defined as a single lift of finished
embankment not to exceed 500 feet.
For construction of shoulder-only areas, bike/shared use paths, and sidewalks
areas, a LOT is defined as 2,000 feet or one Days Production, whichever is greater.
Isolated compaction operations will be considered as separate LOTS. For multiple
phase construction, a LOT shall not extend beyond the limits of the phase.
120-8.2 Dry Fill Method:
120-8.2.1 General: Construct embankments to meet compaction requirements in
Article 120-9 and in accordance with the acceptance program requirements in 120-10. Restrict
the compacted thickness of the last embankment lift to 6 inches maximum.
120-8.2.1.1 For A-3, and A-2-4 Materials with up to 15% fines:
Construct the embankment in successive layers with lifts up to a maximum compacted thickness
of 12 inches. Ensure the percentage of fines passing the No. 200 US Standard sieve in the A-2-4
material does not exceed 15%.
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120-8.2.1.2 For A-1, Plastic materials (As designated in Design
Standard Index 505) and A-2-4 Materials with greater than 15% fines: Construct the
embankment in successive layers with lifts up to a maximum compacted thickness of 6 inches.
Alternately, for A-1, Plastic material and A-2-4 Materials with
greater than 15% fines, construct embankments using thick lift construction in successive layers
of not more than 12 inches compacted thickness, after having demonstrated with a successful test
section, the possession and control of compacting equipment sufficient to achieve density
required by 120-10.2 for the full depth of a thicker lift, and if the Engineer approves the
compaction effort. Notify the Engineer prior to beginning construction of a test section.
Construct a test section of the length of one full LOT. Perform five QC tests at random locations
within the test section. All five QC tests and a Department Verification test must meet the
density required by 120-10.2. Identify the test section with the compaction effort and soil
classification in the Density Log Book. In case of a change in compaction effort or soil
classification, failing QC test or when the QC tests cannot be verified, construct a new test
section. The Contractor may elect to place material in 6 inches compacted thickness at any time.
Construct all layers approximately parallel to the centerline profile of the road.
The Engineer reserves the right to terminate the Contractors use of
thick lift construction. Whenever the Engineer determines that the Contractor is not achieving
satisfactory results, revert to the 6 inch compacted lifts.
As far as practicable, distribute traffic over the work during the
construction of embankments so as to cover the maximum area of the surface of each layer.
Construct embankment in the dry whenever normal dewatering
equipment and methods can accomplish the needed dewatering.
120-8.2.1.3 Equipment and Methods: Provide normal dewatering
equipment including, but not limited to, surface pumps, sump pumps and trenching/digging
machinery. Provide normal dewatering methods including, but not limited to, constructing
shallow surface drainage trenches/ditches, using sand blankets, sumps and siphons.
When normal dewatering does not adequately remove the water,
the Engineer may require the embankment material to be placed in the water or on low swampy
ground in accordance with 120-9.2.3.
120-8.2.2 Placing in Unstable Areas: Where depositing the material in water, or
on low swampy ground that will not support the weight of hauling equipment, construct the
embankment by dumping successive loads in a uniformly distributed layer of a thickness not
greater than necessary to support the hauling equipment while placing subsequent layers. Once
sufficient material has been placed so that the hauling equipment can be supported, construct the
remaining portion of the embankment in layers in accordance with the applicable provisions of
120-9.2.2 and 120-9.2.4.
120-8.2.3 Placing on Steep Slopes: When constructing an embankment on a
hillside sloping more than 20 degrees from the horizontal, before starting the fill, deeply plow or
cut into steps the surface of the original ground on which the embankment is to be placed.
120-8.2.4 Placing Outside Standard Minimum Slope: Where material that is
unsuitable for normal embankment construction is to be used in the embankment outside the
standard minimum slope (approximately one to two), place such material in layers of not more
than 18 inches in thickness, measured loose. The Contractor may also place material which is
suitable for normal embankment, outside such standard minimum slope, in 18 inch layers.
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Maintain a constant thickness for suitable material placed within and outside the standard
minimum slope, unless placing in a separate operation.
120-8.3 Hydraulic Method:
120-8.3.1 Method of Placing: When the hydraulic method is used, as far as
practicable, place all dredged material in its final position in the embankment by such method.
Place and compact any dredged material that is rehandled, or moved and placed in its final
position by any other method, as specified in 120-9.2. The Contractor may use baffles or any
form of construction he may select provided the slopes of the embankments are not steeper than
indicated in the Plans. Remove all timber used for temporary bulkheads or baffles from the
embankment, and fill and thoroughly compact the holes thus formed. When placing fill on
submerged land, construct dikes prior to beginning of dredging, and maintain the dikes
throughout the dredging operation.
120-8.3.2 Excess Material: Do not use excess material placed outside the
prescribed slopes, below the normal high-water level, to raise the fill. Remove only the portion
of this material required for dressing the slopes.
120-8.3.3 Protection of Openings in Embankment: Leave openings in the
embankments at the bridge sites. Remove any material which invades these openings or existing
channels without additional compensation to provide the same depth of channel as existed before
the construction of the embankment. Do not excavate or dredge any material within 200 feet of
the toe of the proposed embankment.
120-8.4 Reclaimed Asphalt Pavement (RAP) Method:
120-8.4.1 General: Use only RAP material: 1) stored at facilities with an
approved Florida Department of Environmental Protection Stormwater permit; or, 2) transferred
directly from a milling project to the Department project. Certify the source if RAP material is
from an identifiable Department project. Do not use RAP material in the following areas:
1) Construction areas that are below the seasonal high groundwater table elevation; 2) MSE Wall
backfill; 3) underneath MSE Walls or 4) The top 6 inches of embankment.
Prior to placement, submit documentation to the Engineer for his approval,
outlining the proposed location of the RAP material.
120-8.4.2 Soil and RAP Mixture: Place the RAP material at the location and
spread uniformly, using approved methods to obtain a maximum layer thickness of 4 inches. Mix
this 4 inches maximum layer of RAP with a loose soil layer of 8 to 10 inches thickness. After
mixing, meet all Embankment Utilization requirements of Index 505 for the location used. Do
not mix RAP in the uppermost 12 inches in order to comply with 120-8.2.1. The total RAP and
other embankment material shall not exceed 12 inches per lift after mixing and compaction if the
contractor can demonstrate that the density of the mixture can be achieved. Perform mixing
using rotary tillers or other equipment meeting the approval of the Engineer. The Engineer will
determine the order in which to spread the two materials. Mix both materials to the full depth.
Ensure that the finished layer will have the thickness and shape required by the typical section.
Demonstrate the feasibility of this construction method by successfully completing a 500-footlong test section. For embankment construction, meet the requirements of 120-8. For compaction
requirements of the soil and RAP mixture, meet the requirements of 120-9.
120-8.4.3 Alternate Soil and RAP Layer Construction: Construct soil in 6 to
12 inch compacted lifts and RAP in alternate layers with 6 inch maximum compacted lifts. Use
soil with a minimum LBR value of 40 to prevent failure during compaction of the overlying RAP
layer. Demonstrate the feasibility of this construction method by successfully completing a 500-
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foot-long test section. For compaction requirements of both soil and RAP, meet the requirements
of 120-9.
120-9 Compaction Requirements.
120-9.1 Moisture Content: Compact the materials at a moisture content such that the
specified density can be attained. If necessary to attain the specified density, add water to the
material, or lower the moisture content by manipulating the material or allowing it to dry, as is
appropriate.
120-9.2 Compaction of Embankments:
120-9.2.1 General: Uniformly compact each layer, using equipment that will
achieve the required density, and as compaction operations progress, shape and manipulate each
layer as necessary to ensure uniform density throughout the embankment.
120-9.2.2 Compaction Over Unstable Foundations: Where the embankment
material is deposited in water or on low swampy ground, and in a layer thicker than 12 inches (as
provided in 120-8.2.2), compact the top 6 inches (compacted thickness) of such layer to the
density as specified in 120-10.2.
120-9.2.3 Compaction Where Plastic Material Has Been Removed: Where
unsuitable material is removed and the remaining surface is of the A-4, A-5, A-6, or A-7 Soil
Groups (see AASHTO M-145), as determined by the Engineer, compact the surface of the
excavated area by rolling with a sheepsfoot roller exerting a compression of at least 250 psi on
the tamper feet, for the full width of the roadbed (subgrade and shoulders). Perform rolling
before beginning any backfill, and continue until the roller feet do not penetrate the surface more
than 1 inch. Do not perform such rolling where the remaining surface is below the normal water
table and covered with water. Vary the procedure and equipment required for this operation at
the discretion of the Engineer.
120-9.2.4 Compaction of Material To Be Used In Base, Pavement, or
Stabilized Areas: Do not compact embankment material which will be incorporated into a
pavement, base course, or stabilized subgrade, to be constructed as a part of the same Contract.
120-9.2.5 Compaction of Grassed Shoulder Areas: For the upper 6-inch layer
of all shoulders which are to be grassed, since no specific density is required, compact only to
the extent directed.
120-9.2.6 Compaction of Grassed Embankment Areas: For the outer layer of
all embankments where plant growth will be established, do not compact. Leave this layer in a
loose condition to a minimum depth of 6 inches for the subsequent seeding or planting
operations.
120-9.3 Compaction for Pipes, Culverts, etc.: Compact the backfill of trenches to the
densities specified for embankment or subgrade, as applicable, and in accordance with the
requirements of 125-9.2.
Thoroughly compact embankments over and around pipes, culverts, and bridges
in a manner which will not place undue stress on the structures, and in accordance with the
requirements of 125-9.2.
120-9.4 Compaction of Subgrade: If the Plans do not provide for stabilizing, compact
the subgrade (as defined in 1-3) in both cuts and fills, to the density specified in 120-10.2. For
undisturbed soils, do not apply density requirements where constructing narrow widening strips
or paved shoulders 5 feet or less in width.
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Where trenches for widening strips are not of sufficient width to permit the use of
standard compaction equipment, perform compaction using vibratory rollers, trench rollers, or
other type compaction equipment approved by the Engineer.
Maintain the required density until the base or pavement is placed on the
subgrade.
120-10 Acceptance Program.
120-10.1 General Requirements:
120-10.1.1 Initial Equipment Comparison: Before initial production, perform a
comparison test using the Quality Control, Verifications and Independent Assurance gauges.
Unless the Engineer instructs, do not perform the initial equipment comparison more than once
per project. When comparing the computed dry density of one nuclear gauge to a second gauge,
ensure that the difference between the two computed dry densities does not exceed 2 lb/ft3
between gauges from the same manufacturer, and 3 lb/ft3 between gauges from different
manufacturers. Repair or replace any Quality Control gauge that does not compare favorably
with the IA gauge.
Perform a comparison analysis between the Quality Control nuclear gauge
and the Verification nuclear gauge any time a nuclear gauge or repaired nuclear gauge is first
brought to the project. Repair and replace any Quality Control gauge that does not compare
favorably with the Verification gauge at any time during the remainder of the project. Calibrate
all Quality Control gauges annually.
120-10.1.2 Initial Production Lot: Before construction of any other LOT,
prepare a 500-foot initial control section consisting of one full LOT in accordance with the
approved Quality Control Plan for the project. Notify the Engineer at least 24 hours prior to
production of the initial control section. Perform all QC tests required in 120-10.1.4. When the
initial Quality Control test results pass specifications, the Engineer will perform a Verification
test to verify compliance with the specifications. Do not begin constructing another LOT until
successfully completing the initial production LOT. The Engineer will notify the Contractor of
the initial production lot approval within three working days after receiving the Contractors
Quality Control data when test results meet the following conditions:
Quality Control tests must meet the specifications.
Verification test must meet the specifications.
Difference between Quality Control and Verification computed Dry
Density results shall meet the requirements of 120-10.1.1.
If Verification test result fails the density requirements of 120-10.2,
correct the areas of non-compliance. The Quality Control and Verification tests will then be
repeated. The Engineer will reject the Contractors Quality Control Plan after three unsuccessful
Verification attempts. Submit a revised Quality Control Plan to the Engineer for approval.
120-10.1.3 Density over 105%: When a QC computed dry density results in a
value greater than 105% of the applicable Proctor maximum dry density, the Engineer will
perform an Independent Verification density test within 5 feet. If the Independent Verification
density results in a value greater than 105%, the Engineer will investigate the compaction
methods, examine the applicable Standard Proctor Maximum Density and material description.
The Engineer may collect and test an Independent Verification Standard Proctor Maximum
Density sample for acceptance in accordance with the criteria of 120-10.2.
120-10.1.4 Quality Control Tests:
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120-10.1.4.1 Standard Proctor Maximum Density Determination:
Determine the Quality Control standard Proctor maximum density and optimum moisture
content by sampling and testing the material in accordance with the specified test method listed
in 120-10.2.
120-10.1.4.2 Density Testing Requirements: Ensure compliance to the
requirements of 120-10.2 by Nuclear Density testing in accordance with FM 1-T 238. Determine
the in-place moisture content for each density test. Use Florida Method FM 1-T 238, FM 5-507
(Determination of Moisture Content by Means of a Calcium Carbide Gas Pressure Moisture
Tester), or ASTM D-4643 (Laboratory Determination of Moisture Content of Granular Soils By
Use of a Microwave Oven) for moisture determination.
120-10.1.4.3 Soil Classification: Perform soil classification tests on the
sample collected in 120-10.1.4.1, in accordance with AASHTO T-88. Classify soils in
accordance with AASHTO M-145 in order to determine compliance with embankment
utilization requirements. Unless required by the Engineer, do not test or classify materials for
stabilized subgrade or base.
120-10.1.5 Department Verification: The Engineer will conduct a Verification
test(s) in order to accept all materials and work associated with 120-10.1.4. The Engineer will
verify the Quality Control results if they meet the Verification Comparison Criteria, otherwise
the Engineer will implement Resolution procedures.
The Engineer will select test locations, including Station, Offset, and Lift,
using a Random Number generator based on the Lots under consideration. Each Verification test
evaluates all work represented by the Quality Control testing completed in those LOTs.
In addition to the Verification testing, the Engineer may perform
additional Independent Verification (IV) testing. The Engineer will evaluate and act upon the IV
test results in the same manner as Verification test results.
When the project requires less than four Quality Control tests per material
type, the Engineer reserves the right to accept the materials and work through visual inspection.
120-10.1.6 Reduced Testing Frequency: When no Resolution testing is required
for 12 consecutive verified LOTs, or if required, the QC test data was upheld, reduce the QC
density testing to one test every two LOTs by identifying the substantiating tests in the Density
Log Book and notifying the Engineer in writing prior to starting reduced frequency of testing.
Generate random numbers based on the two LOTs under consideration. When Quality Control
test frequency is reduced to one every two LOTs, obtain the Engineers approval to place more
than one LOT over an untested LOT. Assure similar compaction efforts for the untested LOTs. If
the Verification test fails, and Quality Control test data is not upheld by Resolution testing, the
Quality Control testing will revert to the original frequency of one Quality Control test per LOT.
Do not apply reduced testing frequency in construction of shoulder-only areas, bike/shared use
paths and sidewalks.
120-10.1.7 Payment for Resolution Tests: If the Resolution laboratory results
compare favorably with the Quality Control results, the Department will pay for Resolution
testing. No additional compensation, either monetary or time, will be made for the impacts of
any such testing.
If the Resolution laboratory results do not compare favorably with the
Quality Control results, the costs of the Resolution testing will be deducted from monthly
estimates. No additional time will be granted for the impacts of any such testing.
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120-10.2 Acceptance Criteria: Obtain a minimum Quality Control (QC) density of
100% of the standard Proctor maximum density as determined by AASHTO T-99, Method C,
with the following exceptions: 1) embankment constructed by the hydraulic method as specified
in 120-8.3; 2) material placed outside the standard minimum slope as specified in 120-8.2.4; and
3) other areas specifically excluded herein.
120-10.3 Additional Requirements:
120-10.3.1 Frequency: Conduct QC sampling and testing at a minimum
frequency listed in the table below. The Engineer will perform Verification sampling and tests at
a minimum frequency listed in the table below.
Test Name
Quality Control
Verification
Verification of
Shoulder-Only Areas,
Bike/Shared Use Paths,
and Sidewalks
Standard Proctor
Maximum Density
One per soil type
One per soil type
One per soil type
Density
One per LOT
Soil Classification
One per Standard
Proctor Maximum
Density
One per four LOTS and
for wet conditions, the
first lift not affected by
water
One per Standard
Proctor Maximum
Density
One per two LOTs
One per Standard
Proctor Maximum
Density
120-10.3.2 Test Selection and Reporting: Determine test locations including
Stations and offsets, using the random number generator approved by the Engineer. Do not use
note pads or work sheets to record data for later transfer to the Density Log Book. Notify the
Engineer upon successful completion of Quality Control testing on each LOT.
120-10.4 Verification Comparison Criteria and Resolution Procedures:
120-10.4.1 Standard Proctor Maximum Density Determination: The Engineer
will verify the Quality Control results if the results compare within 4.5 lb/ft3 of the Verification
test result. Otherwise, the Engineer will take one additional sample of material from the soil type
in question. The State Materials Office or an AASHTO accredited laboratory designated by the
State Materials Office will perform Resolution testing. The material will be sampled and tested
in accordance with AASHTO T-99, Method C.
The Engineer will compare the Resolution Test results with the Quality
Control test results. If all Resolution Test results are within 4.5 lb/ft3 of the corresponding
Quality Control test results, the Engineer will use the Quality Control test results for material
acceptance purposes for each LOT with that soil type. If the Resolution Test result is not within
4.5 lb/ft3 of the Contractors Quality Control test, the Verification Test result will be used for
material acceptance purposes.
120-10.4.2 Density Testing: When a Verification or Independent Verification
density test fails the Acceptance Criteria, retest the site within a 5 feet radius and the following
actions will be taken:
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1. If the Quality Control retest meets the Acceptance Criteria and meets
the 120-10.1.1 criteria when compared with the Verification or Independent Verification test, the
Engineer will accept those LOTs.
2. If the Quality Control retest does not meet the Acceptance Criteria and
compares favorably with the Verification or Independent Verification test, rework and retest the
LOT. The Engineer will re-verify those LOTs.
3. If the Quality Control retest and the Verification or Independent
Verification test do not compare favorably, complete a new comparison analysis as defined in
120-10.1.1. Once acceptable comparison is achieved, retest the LOTs. The Engineer will perform
new verification testing. Acceptance testing will not begin on a new LOT until the Contractor
has a gauge that meets the comparison requirements.
Record Quality Control test results in the density log book on
approved Department forms provided by the Engineer. Submit the original, completed density
log book to the Engineer at final acceptance.
120-10.4.3 Soil Classification: The Engineer will verify the Quality Control
results if the Verification results identify matching soil classifications. Otherwise, the Engineer
will take one additional sample of material from the soil type in question. The State Materials
Office or an AASHTO accredited laboratory designated by the State Materials Office will
perform Resolution testing. The material will be sampled and tested in accordance with
AASHTO T-88.
The Engineer will compare the Resolution Test results with the Quality
Control test results. If the Resolution test matches the Quality Control classification, the
Engineer will use the Quality Control classification for material acceptance purposes. If the
Resolution Test result does not match the Contractors Quality Control classification, the
Verification Test result will be used for material acceptance purposes.
120-11 Maintenance and Protection of Work.
While construction is in progress, maintain adequate drainage for the roadbed at all times.
Maintain a shoulder at least 3 feet wide adjacent to all pavement or base construction in order to
provide support for the edges.
Maintain all earthwork construction throughout the life of the Contract, and take all
reasonable precautions to prevent loss of material from the roadway due to the action of wind or
water. Repair, at no expense to the Department, except as otherwise provided herein, any slides,
washouts, settlement, subsidence, or other mishap which may occur prior to final acceptance of
the work. Perform maintenance and protection of earthwork construction in accordance with
Section 104.
Maintain all channels excavated as a part of the Contract work against natural shoaling or
other encroachments to the lines, grades, and cross-sections shown in the Plans, until final
acceptance of the project.
120-12 Construction.
120-12.1 Construction Tolerances: Shape the surface of the earthwork to conform to
the lines, grades, and cross-sections shown in the Plans. In final shaping of the surface of
earthwork, maintain a tolerance of 0.3 foot above or below the plan cross-section with the
following exceptions:
1. Shape the surface of shoulders to within 0.1 foot of the plan cross-section.
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2. Shape the earthwork to match adjacent pavement, curb, sidewalk, structures,
etc.
3. Shape the bottom of ditches so that the ditch impounds no water.
4. When the work does not include construction of base or pavement, shape the
entire roadbed (shoulder point to shoulder point) to within 0.1 foot above or below the plan
cross-section.
Ensure that the shoulder lines do not vary horizontally more than 0.3 foot from
the true lines shown in the Plans.
120-12.2 Operations Adjacent to Pavement: Carefully dress areas adjacent to
pavement areas to avoid damage to such pavement. Complete grassing of shoulder areas prior to
placing the final wearing course. Do not manipulate any embankment material on a pavement
surface.
When shoulder dressing is underway adjacent to a pavement lane being used to
maintain traffic, exercise extreme care to avoid interference with the safe movement of traffic.
120-13 Method of Measurement.
120-13.1 General: When payment for excavation is on a volumetric basis, the quantity to
be paid for will be the volume, in cubic yards, calculated by the method of average end areas,
unless the Engineer determines that another method of calculation will provide a more accurate
result. The material will be measured in its original position by field survey or by
photogrammetric means as designated by the Engineer, unless otherwise specified under the
provisions for individual items.
Where subsoil excavation extends outside the lines shown in the Plans or
authorized by the Engineer including allowable tolerances, and the space is backfilled with
material obtained in additional authorized roadway or borrow excavation, the net fill, plus
shrinkage allowance, will be deducted from the quantity of roadway excavation or borrow
excavation to be paid for, as applicable.
The quantity of all material washed, blown, or placed beyond the authorized
roadway cross-section will be determined by the Engineer and will be deducted from the quantity
of roadway excavation or borrow excavation to be paid for, as applicable.
Subsoil Excavation that extends outside the lines shown in the Plans or authorized
by the Engineer including allowable tolerances will be deducted from the quantity to be paid for
as subsoil excavation.
120-13.2 Roadway Excavation: The measurement will include only the net volume of
material excavated between the original ground surface and the surface of the completed
earthwork, except that the measurement will also include all unavoidable slides which may occur
in connection with excavation classified as roadway excavation.
The pay quantity will be the plan quantity provided that the excavation was
accomplished in substantial compliance with the plan dimensions and subject to the provisions of
9-3.2 and 9-3.4. On designated 3-R Projects, regular excavation will be paid for at the Contract
lump sum price provided that the excavation was accomplished in substantial compliance with
the plan dimension.
120-13.3 Borrow Excavation: Measurement will be made on a loose volume basis, as
measured in trucks or other hauling equipment at the point of dumping on the road. If
measurement is made in vehicles, level the material to facilitate accurate measurement.
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Unsuitable material excavated from borrow pits where truck measurement is
provided for and from any borrow pits furnished by the Contractor, will not be included in the
quantity of excavation to be paid for.
120-13.4 Lateral Ditch Excavation: The measurement will include only material
excavated within the lines and grades indicated in the Plans or as directed by the Engineer. The
measurement will include the full station-to-station length shown in the Plans or directed by the
Engineer and acceptably completed. Excavation included for payment under Section 125 will not
be included in this measurement.
The pay quantity will be the plan quantity provided that the excavation was
accomplished in substantial compliance with the plan dimensions and subject to the provisions of
9-3.2 and 9-3.4.
120-13.5 Channel Excavation: The measurement will include only material excavated
within the lines and grades indicated in the Plans or in accordance with authorized plan changes.
The measurement will include the full station-to-station length shown in the Plans including any
authorized changes thereto.
If shoaling occurs subsequent to excavation of a channel and the Engineer
authorized the shoaled material to remain in place, the volume of any such material remaining
within the limits of channel excavation shown in the Plans will be deducted from the measured
quantity of channel excavation.
120-13.6 Subsoil Excavation: The measurement will include only material excavated
within the lines and grades indicated in the Plans (including the tolerance permitted therefore) or
as directed by the Engineer.
When no item for subsoil excavation is shown in the proposal but subsoil
excavation is subsequently determined to be necessary, such unanticipated subsoil excavation
will be paid for as provided in 4-4.
120-13.7 Embankment: The quantity will be at the plan quantity.
Where payment for embankment is not to be included in the payment for the
excavation, and is to be paid for on a cubic yard basis for the item of embankment, the plan
quantities to be paid for will be calculated by the method of average end areas unless the
Engineer determines that another method of calculation will provide a more accurate result. The
measurement will include only material actually placed above the original ground line, within the
lines and grades indicated in the Plans or directed by the Engineer. The length used in the
computations will be the station-to-station length actually constructed. The original ground line
used in the computations will be as determined prior to placing of embankment subject to the
provisions of 9-3.2, and no allowance will be made for subsidence of material below the surface
of the original ground.
If there are authorized changes in plan dimensions or if errors in plan quantities
are detected, plan quantity will be adjusted as provided in 9-3.2.
Where the work includes excavation of unsuitable material below the finished
grading template or original ground line, whichever is lower as defined in 120-3.3, the original
ground line is defined as the surface prior to beginning excavation, except that this surface is not
outside the permissible tolerance of lines and grades for subsoil excavation as indicated in the
Plans or as directed by the Engineer. Any overrun or underrun of plan quantity for subsoil
excavation which results in a corresponding increase or decrease in embankment will be
considered as an authorized plan change for adjustment purposes as defined in 9-3.2.2.
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No payment will be made for embankment material used to replace unsuitable
material excavated beyond the lines and grades shown in the Plans or ordered by the Engineer.
In no case will payment be made for material allowed to run out of the
embankment on a flatter slope than indicated on the cross-section. The Contractor shall make his
own estimate on the volume of material actually required to obtain the pay section.
120-14 Basis of Payment.
120-14.1 General: Prices and payments for the various work items included in this
Section will be full compensation for all work described herein, including excavating, dredging,
hauling, placing, and compacting; dressing the surface of the earthwork; maintaining and
protecting the complete earthwork; and hauling.
The Department will not allow extra compensation for any rehandling of
materials.
The Department will compensate for the cost of grassing or other permanent
erosion control measures directed by the Engineer as provided in the Contract for similar items
of roadway work.
120-14.2 Excavation:
120-14.2.1 Items of Payment: When no classification of material is indicated in
the Plans, and bids are taken only on regular excavation, the total quantity of all excavation
specified under this Section will be paid for at the Contract unit price for regular excavation.
When separate classifications of excavation are shown in the proposal, the
quantities of each of the various classes of materials so shown will be paid for at the Contract
unit prices per cubic yard for regular excavation, lateral ditch excavation, subsoil excavation, and
channel excavation, as applicable, and any of such classifications not so shown will be included
under the item of regular excavation (except that if there is a classification for lateral ditch
excavation shown and there is no classification for channel excavation, any channel excavation
will be included under the item of lateral ditch excavation). As an exception, on designated
projects, regular excavation will be paid for at the Contract lump sum price.
120-14.2.2 Basic Work Included in Payments: Prices and payments will be full
compensation for all work described under this Section, except for any excavation, or
embankment which is specified to be included for payment under other items. Such prices and
payments will include hauling; any rehandling that may be necessary to accomplish final
disposal as shown in the Plans; the dressing of shoulders, ditches and slopes; removal of trash,
vegetation, etc., from the previously graded roadway where no item for clearing and grubbing is
shown in the Plans; and compacting as required.
120-14.2.3 Additional Depth of Subsoil Excavation: Where subsoil excavation
is made to a depth of 0 to 5 feet below the depth shown on the Contract Plans, such excavation
will be paid for at the unit price bid.
Where subsoil excavation is made to a depth greater than 5 feet, and up to
15 feet, deeper than the depth shown on the Contract Plans, such excavation will be paid for at
the unit price bid plus 25% of such unit price. Additional extra depth, more than 15 feet below
such plan depth, will be considered as a change in the character of the work and will be paid for
as unforeseeable work.
Where no subsoil excavation is shown in a particular location on the
original plans, payment for extra depth of subsoil will begin 5 feet below the lowest elevation on
the grading template.
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120-14.2.4 Borrow Excavation: When the item of borrow excavation is included
in the Contract, price and payment will also include the cost of furnishing the borrow areas and
any necessary clearing and grubbing thereof, the removal of unsuitable material that it is
necessary to excavate in order to obtain suitable borrow material, and also the costs incurred in
complying with the provisions of 120-6.3.
120-14.2.5 Materials Excluded from Payment for the Excavation: No payment
as excavation will be made for any excavation covered for payment under the item of
embankment.
No payment will be made for the excavation of any materials which are
used for purposes other than those shown in the Plans or designated by the Engineer. No
payment will be made for materials excavated outside the lines and grades given by the
Engineer, unless specifically authorized by the Engineer; except that, in the operations of
roadway excavation, all slides and falls of insecure masses of material beyond the regular slopes
and not due to lack of precaution on the part of the Contractor will be paid for at the Contract
unit price for the material involved. The removal of slides and falls of material classified as
lateral ditch excavation or as subsoil excavation will not be paid for separately, but will be
included in the Contract unit price for the pay quantity of these materials, measured as provided
in 120-14.
120-14.3 Embankment:
120-14.3.1 General: Price and payment will be full compensation for all work
specified in this Section, including all material for constructing the embankment; all excavating,
dredging, pumping, placing and compacting of material for constructing the embankment
complete; dressing of the surface of the roadway, maintenance and protection of the completed
earthwork, and the removal of rubbish, vegetation, etc., from the roadway, where no clearing and
grubbing of the area is specified in the Plans. Also, such price and payment, in each case, will
specifically include all costs of any roadway, lateral ditch, or channel excavation, unless such
excavation is specifically shown to be paid for separately, regardless of whether the materials are
utilized in the embankment.
120-14.3.2 Excluded Material: No payment will be made for the removal of
muck or overburden from the dredging or borrow areas. No payment will be made for
embankment material used to replace muck or other unsuitable material excavated beyond the
lines and grades shown in the Plans or ordered by the Engineer.
120-14.3.3 Clearing and Grubbing: No payment will be made for any clearing
and grubbing of the borrow or dredging areas. Where no clearing and grubbing of such areas is
specified in the Plans, the cost of any necessary clearing and grubbing will be included in the
Contract unit or lump sum price for Embankment.
120-14.3.4 Cost of Permits, Rights, and Waivers: Where the Contractor
provides borrow or dredging areas of his own choosing, the cost of securing the necessary
permits, rights or waivers will be included in the Contract price for embankment.
120-14.4 Payment Items: Payment will be made under:
Item No. 120- 1Regular Excavation - per cubic yard.
Item No. 120- 2Borrow Excavation - per cubic yard.
Item No. 120- 3Lateral Ditch Excavation - per cubic yard.
Item No. 120- 4Subsoil Excavation - per cubic yard.
Item No. 120- 5Channel Excavation - per cubic yard.
Item No. 120- 6Embankment - per cubic yard.
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Item No. 120- 71-
Regular Excavation (3-R Projects) - lump sum.
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SECTION 121
FLOWABLE FILL
121-1 Description.
Furnish and place flowable fill as an alternative to compacted soil as approved by the
Engineer. Applications for conventional flowable fill include beddings; encasements; closures
for tanks and pipes; and general backfill for trenches, embankments and walls. Applications for
cellular concrete flowable fill include beddings; encasements; closures for tanks and pipes; and
general backfill for embankments and walls.
121-2 Materials.
Meet the following requirements:
Fine Aggregate* ..................................................Section 902
Portland Cement (Types I, II, or III) ...................Section 921
Water ...................................................................Section 923
Admixtures** ......................................................Section 924
Fly Ash, Slag and other Pozzolanic Materials ....Section 929
Preformed Foam............................................... ASTM C 869
*Any clean fine aggregate with 100% passing a 3/8 inch mesh sieve and not more
than 15% passing a No. 200 sieve may be used.
**High air generators or foaming agents may be used in lieu of conventional air
entraining admixtures and shall be added at jobsite and mixed in accordance with the
manufacturers recommendation.
121-3 Mix Design.
Conventional flowable fill is a mixture of portland cement, fly ash, fine aggregate,
admixture and water. Flowable fill contains a low cementitious content for reduced strength
development. Cellular concrete flowable fill is a low density concrete made with cement, water
and preformed foam to form a hardened closed cell foam material. Cellular concrete flowable fill
may also contain fine aggregate, fly ash, slag and admixtures.
Submit mix designs to the Engineer for approval. The following are suggested mix guides
for excavatable, non-excavatable and cellular concrete flowable fill:
Cement
Pozzolans or Slag
Water
Air**
28 Day Compressive Strength**
Unit Weight **
Fine Aggregate
Excavatable
75-100 lb/yd3
None
*
5-35%
Maximum 100 psi
90-110 lb/ft3
***
Non-Excavatable
75-150 lb/yd3
150-600 lb/yd3
*
5-15%
Minimum 125 psi
100-125 lb/ft3
***
Cellular Concrete
Min 150 lb/yd3
Optional
*
****
Minimum 80 psi
20-80 lb/ft3
Optional
*Mix designs shall produce a consistency that will result in a flowable self-leveling product at time of placement.
**The requirements for percent air, compressive strength and unit weight are for laboratory designs only and are not intended for
jobsite acceptance requirements.
***Fine Aggregate shall be proportioned to yield 1 yd3.
****In cellular concrete, preformed foam shall be proportioned at the job site to yield 1 yd3 in accordance with the design
requirements.
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121-4 Production and Placing.
Use flowable fill manufactured at a production facility that meets the requirements of
347-3. Deliver flowable fill using concrete construction equipment. Revolution counter are
waived. Place flowable fill by chute, pumping or other methods approved by the Engineer.
Tremie flowable fill through water. Cellular concrete flowable fill may not be placed within
three feet of the bottom elevation for roadway base courses.
121-5 Construction Requirements.
Use straps, soil anchors or other approved means of restraint to ensure correct alignment
when flowable fill is used as backfill for pipe or where flotation or misalignment may occur.
Protect flowable fill from freezing for a period of 36 hours after placement.
Place flowable fill to the designated fill line without vibration or other means of
compaction. Do not place flowable fill during inclement weather, e.g. rain or ambient
temperatures below 40F. Take all necessary precautions to prevent any damages caused by the
hydraulic pressure of the fill during placement prior to hardening. Provide the means to confine
the material within the designated space.
121-6 Acceptance.
Acceptance of flowable fill will be based on the following documentation and a
minimum temperature of flowable fill at the point of delivery of 50F.
Furnish a delivery ticket to the Engineer for each load of flowable fill delivered to the
worksite. Ensure that each ticket contains the following information:
(1) Project designation,
(2) Date,
(3) Time,
(4) Class and quantity of flowable fill,
(5) Actual batch proportions,
(6) Free moisture content of aggregates,
(7) Quantity of water withheld.
Leave the fill undisturbed until the material obtains sufficient strength. Sufficient
strength is 35 psi penetration resistance as measured using a hand held penetrometer in
accordance with ASTM C-403. Provide a hand held penetrometer to measure the penetration
resistance of the hardened flowable fill.
121-7 Basis of Payment.
When the item of flowable fill is included in the Contract, payment will be made at the
Contract unit price per cubic yard. Such price and payment will include all cost of the mixture, in
place and accepted, determined as specified above. No measurement and payment will be made
for material placed outside the neat line limits or outside the adjusted limits, or for unused or
wasted material.
Payment will be made under:
Item No. 121- 70Flowable Fill - per cubic yard.
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SECTION 125
EXCAVATION FOR STRUCTURES AND PIPE
125-1 Description.
Excavate for bridge foundations, box culverts, pipe culverts, storm sewers and all other
pipe lines, retaining walls, headwalls for pipe culverts and drains, catch basins, drop inlets,
manholes, and similar structures. Construct and remove cofferdams, sheeting, bracing, etc.;
pump or otherwise dewater foundations; remove and dispose of any existing structures or
portions of structures not covered by other items in the Contract, including foundations,
abutments, piers, wings, and all other materials, obstructions, etc., found necessary to clear the
site for the proposed work; backfill, dispose of surplus material, and perform final cleaning, as
may be necessary for the proper execution of the work. This Section does not include excavation
for bases or pavements, curbs, curb and gutter, valley gutter, ditch pavement, or rubble gutter.
Perform work in accordance with an approved Quality Control (QC) Plan meeting the
requirements of 105-3.
125-1.1 Trench Excavation Safety System and Shoring, Special (Trench
Excavation): When performing trench excavation in excess of 5 feet in depth, comply with the
Occupational Safety and Health Administrations (OSHA) trench safety standards, 29 C.F.R.,
s. 1926.650, Subpart P, and all subsequent revisions or updates adopted by the Department of
Labor and Employment Security. Ensure that trench boxes are wide enough to accommodate
compaction and density testing.
Submission of bid and subsequent execution of the Contract will serve as
certification that all trench excavation in excess of 5 feet in depth will be in compliance with
Section 553.62, Florida Statutes.
Consider all available geotechnical information available when designing the
trench excavation safety system.
Consider these and any more stringent trench safety standards as minimum
Contract requirements.
125-2 Classification.
Consider all materials excavated as unclassified and as excavation regardless of the
material encountered.
125-3 Cofferdams.
125-3.1 Construction:
125-3.1.1 Methods: Construct all foundations by open excavation, and shore,
brace, or protect the foundation openings with cofferdams. Provide cofferdams or cribs for
foundation construction below the bottom of the footings. Provide sufficient clearance in the
cofferdam interiors to permit construction of forms and inspection of their exteriors, and for
pumping equipment.
125-3.1.2 Protection of Concrete: Construct cofferdams to protect green
concrete against damage from a sudden rising of the water and to prevent damage by erosion. Do
not leave timber or bracing in cofferdams or cribs that extend into the substructure masonry
except where permitted in writing by the Engineer.
125-3.1.3 Placing in the Dry: For placing footings in the dry, the Engineer may
require cofferdam sheeting to be driven to an elevation 6 feet below the elevation of the bottom
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of the footings and require sufficient pumping equipment to dewater and maintain the cofferdam
in a comparatively dry condition.
125-3.1.4 Working Drawings: For substructure work, submit drawings showing
the proposed method of cofferdam construction and other details left to choice or not fully shown
in the Plans. Obtain the Engineers approval of the type and clearance of cofferdams, insofar as
such details affect the character of the finished work. For other details of design that do not affect
the character of the finished work, assume responsibility for the successful construction of the
work. Retain a Professional Engineer, registered in the State of Florida, to prepare the above
construction drawing, and keep a signed and sealed copy on hand at the site at all times. On
completion of the work, furnish the Department with as-built drawings on permanent
reproducible material as noted in 5-1.4.1.
125-3.2 Removal: Unless otherwise provided, remove cofferdams or cribs, with all
sheeting and bracing, after completion of the substructure without disturbing or marring the
finished masonry.
125-4 Excavation.
125-4.1 Requirements for all Excavation: Excavate foundation pits to permit the
placing of the full widths and lengths of footings shown in the Plans, with full horizontal beds.
Do not round or undercut corners or edges of footings. Perform all excavation to foundation
materials, satisfactory to the Engineer, regardless of the elevation shown in the Plans. Perform all
excavation in stream beds to a depth at least 4 feet below the permanent bed of the stream, unless
a firm footing can be established on solid rock before such depth is reached, and excavate to such
additional depth as may be necessary to eliminate any danger of undermining. Wherever rock
bottom is secured, excavate in such manner as to allow the solid rock to be exposed and prepared
in horizontal beds for receiving the masonry. Remove all loose and disintegrated rock or thin
strata. Have the Engineer inspect and approve all foundation excavations prior to placing
masonry.
125-4.2 Earth Excavation:
125-4.2.1 Foundation Material other than the Rock: When masonry is to rest
on an excavated surface other than rock, take special care to avoid disturbing the bottom of the
excavation, and do not remove the final foundation material to grade until just before placing the
masonry. In case the foundation material is soft or mucky, the Engineer may require excavation
to a greater depth and to backfill to grade with approved material.
125-4.2.2 Foundation Piles: Where foundation piles are used, complete the
excavation of each pit before driving the piles. After the driving is completed, remove all loose
and displaced material, leaving a smooth, solid, and level bed to receive the masonry.
125-4.2.3 Removal of Obstructions: Remove boulders, logs, or any unforeseen
obstacles encountered in excavating. Compensation will be in accordance with the requirements
of 4-3.4.
125-4.3 Rock Excavation: Clean all rock and other hard foundation material, remove all
loose material, and cut all rock to a firm surface. Either level, step vertically and horizontally, or
serrate the rock, as may be directed by the Engineer. Clean out all seams, and fill them with
concrete or mortar.
125-4.4 Pipe Trench Excavation: Excavate trenches for pipe culverts and storm sewers
to the elevation of the bottom of the pipe and to a width sufficient to provide adequate working
room. Remove soil not meeting the classification specified as suitable backfill material in
125-8.3.2.2, to a depth of 4 inches below the bottom of the pipe elevation. Remove rock,
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boulders or other hard lumpy or unyielding material to a depth of 12 inches below the bottom of
the pipe elevation. Remove muck or other soft material to a depth necessary to establish a firm
foundation. Where the soils permit, ensure that the trench sides are vertical up to at least the midpoint of the pipe.
For pipe lines placed above the natural ground line, place and compact the
embankment, prior to excavation of the trench, to an elevation at least 2 feet above the top of the
pipe and to a width equal to four pipe diameters, and then excavate the trench to the required
grade.
For pipe trenches utilizing trench boxes, ensure that the trench box used is of
sufficient width to permit thorough tamping of bedding material under and around the pipes as
specified in 125-8.1.6.
Do not disturb the installed pipe and its embedment when moving trench boxes.
Move the trench box carefully to avoid excavated wall displacement or damage. As the trench
box is moved, fill any voids left by the trench box and continuously place and compact the
backfill material adjacent to and all along the side of the trench box walls to fill any voids
created by the trench box.
125-5 Preservation of Channel.
125-5.1 General: Unless shown in the Plans, do not excavate outside of caissons, cribs,
cofferdams, or sheet piling, and do not disturb the natural stream bed adjacent to the structure. If
excavating or dredging at the site of the structure before sinking caissons, cribs, or cofferdams,
complete the foundation and backfill all such excavations to the original ground surface or other
required elevation, with material satisfactory to the Engineer.
125-5.2 Removal of Excavated Materials: Do not allow materials that are deposited
adjacent to the stream area to infiltrate the water areas. Leave the stream in its original condition.
125-6 Disposal of Surplus.
Use suitable excavated materials for backfilling over or around the structure. Dispose of
unsuitable materials. Meet the disposal requirements pertaining to water pollution contained in
Section 104 and in 7-1.1.
125-7 Pumping.
Pump from the interior of any foundation enclosure in such manner as to preclude the
possibility of any portion of the concrete materials being carried away. Do not pump while
placing concrete, or for a period of at least 24 hours thereafter, unless using a suitable pump
separated from the concrete work by a watertight wall.
125-8 Backfilling.
125-8.1 General Requirements for Structures and Pipe:
125-8.1.1 General: Backfill in the dry whenever normal dewatering equipment
and methods can accomplish the needed dewatering. A LOT is defined as one lift of backfill
material placement, not to exceed 500 feet in length or a single run of pipe connecting two
successive structures, whichever is less. Backfill for structures and plastic or metal pipe
compacted in one operation will be considered as separate LOTs within the cover zone. Backfill
around structures compacted separately from the pipe will be considered as separate LOTs.
Backfill on each side of the pipe for the first lift will be considered a separate LOT. Backfill on
opposite sides of the pipe for the remaining lifts will be considered separate LOTs, unless the
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same compactive effort is applied. Same compactive effort is defined as the same type of
equipment (make and model) making the same number of passes on both sides of the pipe. For
multiple phase backfill, a LOT shall not extend beyond the limits of the phase.
When placing backfill within trench box each lift of backfill is considered
a LOT. Placement of backfill within trench box limits will be considered a complete operation
before trench box is moved for next backfill operation. When the trench box is moved for next
backfill operation this will start new LOTs for each lift. Follow the density testing frequency in
125-9.3.1.
125-8.1.2 Equipment and Methods: Provide normal dewatering equipment
including, but not limited to, surface pumps, sump pumps, wellpoints and header pipe and
trenching/digging machinery. Provide normal dewatering methods including, but not limited to,
constructing shallow surface drainage trenches/ditches, using sand blankets, perforated pipe
drains, sumps and siphons.
125-8.1.3 Backfill Materials: Backfill to the original ground surface or subgrade
surface of openings made for structures, with a sufficient allowance for settlement. The Engineer
may require that the material used for this backfill be obtained from a source entirely apart from
the structure. Use only material accepted by the Engineer.
Do not allow heavy construction equipment to cross over culvert or storm
sewer pipes until placing and compacting backfill material to the finished earthwork grade or to
an elevation at least 4 feet above the crown of the pipe.
125-8.1.4 Use of A-7 Material: In the backfilling of trenches, A-7 material may
be used from a point 12 inches above the top of the pipe up to the elevation shown in the Design
Standards as the elevation for undercutting of A-7 material.
125-8.1.5 Time of Placing Backfill: Do not place backfill against any masonry or
concrete abutment, wingwall, or culvert until the Engineer has given permission to do so, and in
no case until the masonry or concrete has been in place seven days or until the specified 28 day
compressive strength occurs.
125-8.1.6 Placement and Compaction: Place the material in horizontal layers
not exceeding 6 inches compacted thickness, in depth above water level, behind abutments,
wingwalls and end bents or end rest piers, under the haunches of the pipes and around box
culverts and all structures including pipe culverts. When the backfill material is deposited in
water, compact as specified in 125-8.2.5 and 125-8.3.4.
The Contractor may elect to place material in thicker lifts of no more than
12 inches compacted thickness above the Soil Envelope if he can demonstrate with a successful
test section that density can be achieved. Notify the Engineer prior to beginning construction of a
test section. Construct a test section of the length of one LOT. Perform five QC tests at random
locations within the test section. All five tests must meet the density required by 125-9.2 and be
verified by the Department. Identify the test section with the compaction effort and soil
classification in the Logbook. In case of a change in compaction effort or soil classification,
construct a new test section. When a QC test fails the requirements of 125-9.2 or when the QC
tests cannot be verified, construct a new test section. The Contractor may elect to place material
in 6 inches compacted thickness at any time.
125-8.2 Additional Requirements for Structures Other than Pipe:
125-8.2.1 Density: Where the backfill material is deposited in water, obtain a
12 inch layer of comparatively dry material, thoroughly compacted by tamping, before verifying
the layer and density requirements. Meet the requirements of 125-9.2.
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125-8.2.2 Box Culverts: For box culverts over which pavement is to be
constructed, compact around the structure to an elevation not less than 12 inches above the top of
the structure, using rapid-striking mechanical tampers.
125-8.2.3 Other Limited Areas: Compact in other limited areas using
mechanical tampers or approved hand tampers, until the cover over the structure is at least
12 inches thick. When hand tampers are used, deposit the materials in layers not more than
4 inches thick using hand tampers suitable for this purpose with a face area of not more than
100 square inches. Take special precautions to prevent any wedging action against the masonry,
and step or terrace the slope bounding the excavation for abutments and wingwalls if required by
the Engineer.
125-8.2.4 Culverts and Piers: Backfill around culverts and piers on both sides
simultaneously to approximately the same elevation.
125-8.2.5 Compaction Under Wet Conditions: Where wet conditions do not
permit the use of mechanical tampers, compact using hand tampers. Use only A-3 material for
the hand tamped portions of the backfill. When the backfill has reached an elevation and
condition such as to make the use of the mechanical tampers practical, perform mechanical
tamping in such manner and to such extent as to transfer the compaction force into the sections
previously tamped by hand.
125-8.3 Additional Requirements for Pipe 15 Inches Inside Diameter or Greater:
125-8.3.1 General: Trenches for pipe may have up to four zones that must be
backfilled.
Lowest Zone: The lowest zone is backfilled for deep undercuts up to
within 4 inches of the bottom of the pipe.
Bedding Zone: The zone above the lowest zone is the bedding zone.
Usually it will be the backfill which is the 4 inches of soil below the bottom of the pipe. When
rock or other hard material has been removed to place the pipe, the bedding zone will be the
12 inches of soil below the bottom of the pipe.
Cover Zone: The next zone is backfill that is placed after the pipe has been
laid and will be called the cover zone. This zone extends to 12 inches above the top of the pipe.
The cover zone and the bedding zone are considered the Soil Envelope for the pipe.
Top Zone: The top zone extends from 12 inches above the top of the pipe
to the base or final grade.
125-8.3.2 Material:
125-8.3.2.1 Lowest Zone: Backfill areas undercut below the bedding zone
of a pipe with coarse sand, or other suitable granular material, obtained from the grading
operations on the project, or a commercial material if no suitable material is available.
125-8.3.2.2 Soil Envelope: In both the bedding zone and the cover zone
of the pipe, backfill with materials classified as A-1, A-2, or A-3. Material classified as A-4 may
be used if the pipe is concrete pipe.
125-8.3.2.3 Top Zone: Backfill the area of the trench above the soil
envelope of the pipe with materials allowed on Design Standards, Index No. 505.
125-8.3.3 Compaction:
125-8.3.3.1 Lowest Zone: Compact the soil in the lowest zone to
approximately match the density of the soil in which the trench was cut.
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125-8.3.3.2 Bedding Zone: If the trench was not undercut below the
bottom of the pipe, loosen the soil in the bottom of the trench immediately below the
approximate middle third of the outside diameter of the pipe.
If the trench was undercut, place the bedding material and leave it
in a loose condition below the middle third of the outside diameter of the pipe. Compact the
outer portions to meet the density requirements of the acceptance criteria. Place the material in
lifts no greater than 6 inches (compacted thickness).
125-8.3.3.3 Cover Zone: Before placing the cover zone material, lay pipe
according to Section 430. Excavate for pipe bells before laying pipe. Place the material in 6 inch
layers (compacted thickness), evenly deposited on both sides of the pipe, and compact with
mechanical tampers suitable for this purpose. Hand tamp material below the pipe haunch that
cannot be reached by mechanical tampers. Meet the requirements of in 125-9.2.
125-8.3.3.4 Top Zone: Place the material in layers not to exceed
12 inches in compacted thickness. Meet the requirements of the density acceptance criteria.
125-8.3.4 Backfill Under Wet Conditions: Where wet conditions are such that
dewatering by normal pumping methods would not be effective, the procedure outlined below
may be used when specifically authorized by the Engineer in writing. The Department will pay
for any select material which is not available from the grading as Unforeseeable Work. The
Department will not pay for select material that might be used by the Contractor for his own
convenience instead of dewatering.
The Department will permit the use of granular material below the
elevation at which mechanical tampers would be effective, but only material classified as A-3.
Place and compact the material using timbers or hand tampers until the backfill reaches an
elevation such that its moisture content will permit the use of mechanical tampers. When the
backfill has reached such elevation, use normally acceptable backfill material. Compact the
material using mechanical tampers in such manner and to such extent as to transfer the
compacting force into the material previously tamped by hand.
The Department will permit the use of coarse aggregate below the
elevation at which mechanical tampers would be effective. Use coarse aggregate as specified in
Section 901 for Aggregate Size Number 89, 8, 78, 7, 68, 6, or 57. Place the coarse aggregate
such that it will be stable and firm. Fully wrap the aggregate with a layer of Type D-4 filter
fabric, as specified on Design Standards, Index No. 199. Do not place coarse aggregate within
4 feet of the ends of the trench or ditch. Use normally accepted backfill material at the ends.
125-9 Acceptance Program.
125-9.1 General Requirements: Meet the requirements of 120-10, except replace the
requirements of 120-10.1.6 with 125-9.1.1, 120-10.2 with 125-9.2, 120-10.3 with 125-9.3, and
120-10.4 with 125-10.
125-9.1.1 Reduced Testing Frequency: When no resolution testing is required
for six consecutive LOTs, or if required, the QC test data was upheld, reduce the QC density
testing to one test every two Lots by identifying the substantiating tests in the Density Log Book
and notifying the Engineer in writing prior to starting reduced frequency of testing. Generate
random numbers based on the two LOTs under consideration. When QC test frequency is
reduced to one every two LOTs, obtain the Engineers approval to place more than one LOT
over an untested LOT. Assure similar compaction efforts for the untested sections. If the
Verification test fails, and QC test data is not upheld by Resolution testing the QC testing will
revert to the original frequency.
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125-9.2 Acceptance Criteria:
125-9.2.1 Density: Obtain a minimum QC density in any LOT of 100% of the
Standard Proctor maximum density as determined by AASHTO T99, Method C, or the
requirements of 125-8.3.3.1 when applicable. For metal and plastic pipe, compact the backfill in
the cover zone to a density of at least 95% of the Standard Proctor maximum density as
determined by AASHTO T99, Method C.
125-9.2.2 Exceptions to Structures and Pipe Density Requirements: Compact
the backfill to a firmness approximately equal to that of the soil next to the pipe trench in
locations outside the plane described by a two (horizontal) to one (vertical) slope downward
from the roadway shoulder line or the back of curb as applicable. Apply 125-9.2.1 when
compacting side-drain pipe backfill under driveways serving a property that is not a single
residential lot.
125-9.3 Additional Requirements:
125-9.3.1 Frequency: Conduct QC Standard Proctor maximum density sampling
and testing at a minimum frequency of one test per soil type. The verification test will be at a
minimum of one test per soil type:
Test Name
Standard Proctor
Maximum Density
Quality Control
Verification
One per soil type
One per soil type
Density
One per LOT
Soil Classification
One per Standard Proctor
Maximum density
One per four consecutive LOTs
and for wet conditions, the first
lift not affected by water
One per Standard Proctor
Maximum density
125-10 Verification Comparison Criteria and Resolution Procedures.
125-10.1 Standard Proctor Maximum Density Determination: The Engineer will
verify the QC results if the results compare within 4.5 PCF of the verification test result.
Otherwise, the Engineer will take one additional sample of material from the soil type in
question. The State Materials Office or an AASHTO accredited laboratory designated by the
State Materials Office will perform resolution testing. The material will be sampled and tested in
accordance with AASHTO T99, Method C.
The Engineer will compare the resolution test result with the QC test results. If
the resolution test result is within 4.5 PCF of the corresponding QC test results, the Engineer
will use the QC test results for material acceptance purposes for each LOT with that soil type. If
the resolution test result is not within 4.5 PCF of the Contractors QC test, the verification test
result will be used for material acceptance purposes.
125-10.2 Density Testing: When a verification or independent verification density test
fails the acceptance criteria, retest the site within a 5 feet radius and the following actions will be
taken:
1. If the QC retest meets the acceptance criteria and compares favorably with the
verification or independent verification test, the Engineer will accept those LOTs.
2. If the QC retest does not meet the acceptance criteria and compares favorably
with the verification or independent verification test, rework and retest the LOT. The Engineer
will re-verify those LOTs.
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3. If the QC retest and the verification or independent verification test do not
compare favorably, complete a new equipment-comparison analysis as defined in 120-10.1.2.
Once acceptable comparison is achieved, retest the LOTs. The Engineer will perform new
verification testing. Acceptance testing will not begin on a new LOT until the Contractor has a
gauge that meets the comparison requirements.
125-10.3 Soil Classification: Meet the requirements of 120-10.4.3.
125-11 Site Restoration.
Wherever the existing site is disturbed solely for the purpose of constructing or removing
box culverts, pipe culverts, storm sewers, inlets, manholes, etc., completely replace and restore
the site to the Engineers satisfaction, without additional compensation.
125-12 Cleaning Up.
Upon completion of the work, leave the structure and all adjacent areas in a neat and
presentable condition, clear up all temporary structures, rubbish and surplus materials and leave
the space under the structure unobstructed and in such shape that drift will not collect nor scour
or be induced. Pile all material from existing structures that have been removed neatly on the
bank, unless otherwise directed by the Engineer. Pull false work piling unless the Engineer
permits it to be cut or broken off in which case it will be cut or broken off at least 2 feet below
the ground line or stream bed.
125-13 Method of Measurement.
When direct payment for excavation for structures is provided in the proposal, and such
payment is on a unit basis, such excavation will be measured in its original position by the crosssection method to determine the amount of material. The cubic yard volume of excavation used
as a basis of payment will then be that material actually removed below the original ground line
or stream bed, but not including that shown in the Plans to be paid for either as regular
excavation, subsoil excavation, lateral ditch excavation or channel excavation, or which is
included in the item for grading, and except that no payment will be made for material removed
in excavating for footings or foundations outside of an area which is bounded by vertical planes
12 inches outside of the limits of the footing and parallel thereto. For pipe trenches the width
used to be in the calculation shall be the diameter of the pipe, plus 24 inches.
125-14 Basis of Payment.
125-14.1 When No Direct Payment Provided: When direct payment for excavation for
structures is not provided for in the proposal, all work specified in this Section, other than as
specified in 125-14.3 through 125-14.7, shall be included in the Contract price for the concrete or
for other items covering the applicable structure.
125-14.2 Direct Payment: When direct payment for work under this Section is provided,
the Contract price per cubic yard (measured as provided in 125-13), as shown in the proposal,
shall be full compensation for all the work specified in this Section, except such work as is
specifically stipulated to be paid for separately, in 125-14.3 through 125-14.7.
125-14.3 Excavation Below Plan Grade: When excavation of material below plan grade
is called for in the Plans or authorized by the Engineer, and payment for Excavation for
Structures is on a cubic yard basis, the material excavated below plan grade will be included in
the measurement for this item.
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Payment for the material used for the backfill will be made as specified in
125-14.7.
125-14.4 Strengthening Foundations: The work of strengthening the foundations (as
provided in 125-4.2) shall be paid for as provided in 4-4, unless such work is covered by a bid
item.
125-14.5 Backfilling for Additional Support: The work of providing additional support
by backfilling with sand or other satisfactory material, where called for by the Engineer (as
specified in 125-8), shall be paid for as provided in 4-4.
125-14.6 Removal and Replacement of Existing Pavement: For pavement, curb, etc.,
which is removed only in order to construct pipe culverts or storm sewers, as specified in 125-11,
all costs of such removal and replacement shall be included in the costs of the pipe or other
structure for which it is removed, unless otherwise provided for in the contract.
125-14.7 Removal and Replacement of Material Unsuitable for Backfill: When it
cannot reasonably be anticipated from information contained in the Plans, that material
excavated for the structure will be unsuitable for use as backfill, and such material proves to be
unsuitable for this use, the work of disposing of such material away from the site will be paid for
as Unforeseeable Work, and the work of bringing in substitute material for the backfill will be
paid for as specified for the particular case shown below:
(a) No additional payment will be made for backfill materials obtained from
surplus material available from the normal excavation or grading operations.
(b) When the necessary material is not available from the normal excavation or
grading operations, and the Contract includes an item for borrow excavation, backfill material
authorized to be obtained from designated borrow areas will be included in the volume of borrow
excavation to be paid for.
(c) When the necessary material is not available from the normal excavation or
grading operations and no separate item for borrow excavation is included in the Contract, any
backfill material obtained by increasing the volume of excavation within the roadway right of
way will be measured and paid for as regular excavation subject to the provisions of 9-3.2.2.
(d) When authorization is given for obtaining the material from outside the right
of way and from other than designated borrow areas, such excavation will be paid for as
unforeseeable work.
(e) Where pipe bedding is provided, as specified in 125-8, by the use of select
granular material, the quantity of such select material obtained either as commercial material or
from material from the grading operations other than in the immediate vicinity of the pipe to be
bedded, as authorized by the Engineer, will be paid for at the Contract price per cubic yard for
select bedding material. No payment for this material will be made for material available from
the excavation for the pipe culvert or from other material available from the grading operations
at a location not sufficiently remote as to require loading on trucks.
125-14.8 Pay Items: Payment for the work under this Section, when provided for
directly, shall be made under:
Item No. 125- 1Excavation for Structures - per cubic yard.
Item No. 125- 3Select Bedding Material - per cubic yard.
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SECTION 145
GEOSYNTHETIC REINFORCEMENT
145-1 Description.
This Section specifies the construction requirements for geosynthetics used in: (1)
geosynthetic reinforced soil slopes, and (2) geosynthetic reinforced foundations constructed on
soft in-situ soils. Furnish and place geosynthetics and any associated facing material or drainage
blankets.
145-2 Responsibility.
Construct the geosynthetic reinforced feature, including materials, method, and
installation based on information provided in the Contract Documents and the geosynthetic
suppliers recommendations. Provide shop drawings depicting the details and distribution of the
selected geosynthetics which are required to meet the design shown in the Plans and in
accordance with the requirements contained in the Departments Plans Preparation Manual
(PPM) and Design Standards, Index No. 501 for these items. Alternate designs optimizing the
selected geosynthetic materials may be submitted.
For alternate designs, provide complete design calculations and details which include:
plan view, elevation view, and details in accordance with the Contract Documents. These shall
show the extent, number of layers of geosynthetic reinforcement, minimum properties of each
geosynthetic reinforcement layer, vertical spacing of geosynthetic reinforcement, orientation of
geosynthetic facing details, details at special structures or obstructions, typical construction
sequence, and top and bottom elevations of the geosynthetic reinforcement. Calculations shall be
submitted to substantiate the design meets the requirements of Chapter 31 of the PPM and in
accordance with the Contract Plans. As a minimum these shall clearly show the derivation of
reinforcement requirements (i.e., type, spacing, length, etc.) and determination of all design
parameters and factors. All plans and calculations are to be signed and sealed by a Professional
Engineer registered in the State of Florida.
145-3 Materials.
145-3.1 Geosynthetic Materials: Use primary and secondary reinforcing elements
consisting of a regular array of tensile elements that have sufficient reinforcement strength to
perform the prime functions of reinforcement and which are listed on Design Standards, Index
No. 501.
Deliver geosynthetic materials (including facing and drainage elements) to the job
site in unopened shipping packages labeled with the suppliers name and product name. During
shipping and storage, protect the geosynthetic from physical damage, debris and from
temperatures greater than 140F. Follow the suppliers recommendations regarding protection
from direct sunlight. At the time of installation, the Engineer will reject the material if it has
defects, tears, punctures, flaws, deterioration, or other damage. However, if approved by the
Engineer, the Contractor may repair torn or punctured sections by placing a patch over the
damaged area. Replace or repair any rejected geosynthetic at no additional expense to the
Department.
145-3.2 Backfill Materials: Use only free draining backfill material in the reinforced fill
volume as shown in the Plans meeting the following gradation limits as determined in
accordance with AASHTO T27 and FM 1 T-011:
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Sieve Size
3-1/2 inches
3/4 inch
No. 4
No. 40
No. 100
No. 200
Percent Passing
100
70 to 100
30 to 100
15 to 100
5 to 65
0 to 15
Do not use backfill material containing more than 2.0% by weight of organic
material, as determined by FM 1-T 267 and by averaging the test results for three randomly
selected, representative samples from each stratum or stockpile of a particular material. Consider
the stratum or stockpile unsuitable for construction of the reinforced fill volume if an individual
test value exceeds 3.0%.
Use backfill with a maximum plasticity index of six as determined by
AASHTO T90, and a maximum liquid limit of 15 as determined by AASHTO T89. Use backfill
materials with a pH between 4.5 and 10.0. When metal pipes or other metal items are embedded
in the backfill, use backfill with a pH between 6.0 and 10.0. Do not use soil cement or lime
stabilized backfill unless approved by the Engineer.
Submit a copy of certified test results and a certificate of compliance certifying
that the fill material meets the above requirements to the Engineer for review and approval prior
to delivering the backfill to the site. Use a Department-approved testing laboratory for all testing.
Submit an alternate design, prepared in accordance with 145-2, when backfill meeting alternate
gradation limits is proposed.
145-4 Construction.
145-4.1 General: Obtain from the geosynthetic supplier, technical instructions, guidance
in preconstruction activities, and on-site technical assistance during construction. Submit a copy
of any instructions provided by the supplier to the Engineer prior to beginning installation.
145-4.2 Reinforced Soil Slopes:
145-4.2.1 Preparation: Remove all existing vegetation and all unsuitable
foundation materials. Prepare the foundation in accordance with Section 110, except as noted
herein.
Proof roll the graded area with a vibratory roller weighing a minimum of
8 tons or a sheepsfoot roller, where appropriate, exerting a compression of at least 250 pounds
psi on the tamper foot for at least five passes in the presence of the Engineer or as directed by the
Engineer. Remove and replace any soft or loose foundation subsoils that are, in the opinion of
the Engineer, incapable of sustaining the required proof rolling, in accordance with Section 125.
Provide proof rolled ground surfaces which are uniform, smooth, and free
of abrupt changes in slope, debris, and irregularities that might damage the reinforcement.
Promptly repair and restore to their original condition any areas outside the limits of disturbance
shown in the Plans which are damaged as part of this work at no expense to the Department.
Make every possible effort to avoid such damage.
145-4.2.2 Geosynthetic Placement: Place the geosynthetics at the proper
elevation, location and orientation as shown in the Plans. In general, place the geosynthetics used
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for slope stabilization such that its primary direction of tensile strength is perpendicular to the
plan face of the slope. Pull the geosynthetic material tight, and secure it as necessary to lay flat
against the soil prior to fill placement.
Place adjacent rolls of geosynthetic to maintain 100% horizontal coverage
at the face of the slope. When placing geosynthetic for curved embankments, do not allow less
than 50% horizontal coverage or an unreinforced horizontal spacing greater than 3 feet at the end
of the reinforcement farthest from the face of the slope. Do not allow vertical spacing of the
geosynthetic layers to exceed the spacing shown on the shop drawings.
Do not make any splices or seams in the primary direction of tensile
strength in the geosynthetic without approval of the Engineer. When splices in the primary
direction are approved, make splices full width of the geosynthetic strip by using a similar
material with similar strength. Use a splice mechanism that allows a minimum of 95% load
transfer from piece to piece of geosynthetic. Make only one splice per length of geosynthetic. Do
not place splices within 6 feet of the slope face, within 6 feet below top of slope, or horizontally
adjacent to another splice.
Place only that amount of geosynthetic material, including facing and
drainage material, which will be covered in a single days production.
Do not operate equipment directly on the geosynthetics. Operate
equipment such that no turning movements occur on the areas where geosynthetic is in place
with less than 12 inches of fill cover. Fill and compact ruts of more than 3 inches in depth as
they develop.
145-4.2.3 Backfill Placement: Maintain uniform moisture content of the backfill
material prior to and during compaction throughout each layer of material. Use backfill material
having a placement moisture content within 2% on the dry side of optimum. Do not place wet
backfill with moisture content greater than optimum in the fill. Spread backfill material over the
geosynthetic in the direction of geosynthetic overlaps. Do not stockpile backfill materials on the
installed geosynthetics. Avoid construction procedures or equipment which, in the opinion of the
Engineer, will cause excessive mudwaving.
Compact the backfill using either smooth wheel or rubber tire rollers. Do
not use sheepsfoot, grid rollers, or other types of equipment employing a foot. At the end of each
days operation, slope the backfill surface in order to permit runoff of rainwater away from the
slope face, or provide some other positive drainage.
Place and compact the backfill material in accordance with Section 120 to
obtain a density in each soil layer of at least 95% of the maximum density as determined by
AASHTO T180.
145-4.2.3.1 Optional Acceptance Criteria for A-3 and A-2-4 Materials:
Obtain a minimum density of 100% of the maximum dry density as determined by
AASHTO T99. The combined width from both reinforced fill volume and retained fill material
may be considered the same LOT in accordance with 120-8.1, if both volumes comprise the
same material and both are compacted with the same procedure, lift thickness, equipment and
compacting effort.
145.4.2.4 Repairs: Replace geosynthetic reinforcement damaged during or after
installation at no expense to the Department. Repair geosynthetics damaged during or after
installation only after the supplier establishes that the interior and exterior stability is not
affected and after obtaining the Engineers approval. Make such repairs as follows:
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Remove all backfill material from the damaged area of the reinforcement
geosynthetic plus an additional 4 feet in all directions beyond the limits of damage. Place a patch
consisting of the same material as the reinforcement geosynthetic over the damaged area.
Overlap the undamaged reinforcement geosynthetic with the patch a minimum of 3 feet in all
directions. Then replace and compact backfill material in accordance with 145-4.2.3.
145-4.3 Reinforced Foundations Constructed on Soft In-Situ Soils:
145-4.3.1 Preparation: For some applications involving reinforcement of soft
insitu soils, the Engineer may require that some vegetation be left in place. If directed in the
Plans or by the Engineer, cut trees to within 6 inches of the ground line, and leave the stumps in
place. Remove fallen trunks, limbs, etc. greater than 3 inches in diameter.
145-4.3.2 Backfill Placement: Meet the requirements of 145-4.2.3.
145-4.3.3 Geosynthetic Placement: Position and orient the geosynthetics over
prepared surfaces. Place a geotextile filter of a type recommended by the designer of the
geosynthetic system under the reinforcement geosynthetic. Cut and overlap geosynthetics as
necessary to accommodate curves. Overlap or join ends and sides of adjacent geosynthetic
courses as shown in the Plans and in accordance with 145-4.2.2. Make any overlaps in
geosynthetics in the same direction that covering embankment will be spread. Take care to
ensure that the geosynthetic sections do not separate at overlaps during construction. Pull the
geosynthetic material tight by hand to a tension that removes all slack.
145-4.3.4 Repairs: Meet the requirements of 145-4.2.4.
145-5 Certification.
Furnish certification from the supplier, at least ten days prior to placement, that the
products used are the same products listed on Design Standards, Index No. 501, are in
accordance with the project design requirements and is recommended by the supplier for use at
this location.
Acceptance of furnished material will be based on the suppliers certification and visual
inspection by the Engineer.
145-6 Method of Measurement.
145-6.1 Geosynthetic Reinforced Soil Slopes: The quantity to be paid for will be the
plan area, in square feet, of the projected vertical height of the slope face, measured from the top
of slope to the proposed final ground line at the toe of slope and from the beginning to end limits
as shown in the Plans, regardless of the length or number of layers of geosynthetic within the
reinforced volume and including any reinforcement required below the toe of slope elevation.
145-6.2 Geosynthetic Reinforced Foundations over Soft Soils: The quantity to be paid
for will be the plan area, in square yards, of the embankment to be reinforced as shown in the
Plans, regardless of the length or number of layers of geosynthetic within the reinforced soil
volume, and including any reinforcement required below the original ground elevation.
145-7 Basis of Payment.
145-7.1 Geosynthetic Reinforced Soil Slopes: Price and payment will be full
compensation for all work, materials, and services specified in this Section, including design and
shop drawings, geosynthetic materials, facing materials and/or treatment, installation, testing,
and required submittals. The cost and placement of all backfill material will be included in the
pay quantity for embankment or borrow excavation, as applicable.
189
145-7.2 Geosynthetic Reinforced Foundations over Soft Soils: Price and payment will
be full compensation for all work, materials, and services specified in this Section, including
geosynthetic materials, geotextile filter materials, facing materials, drainage materials,
installation, testing, and required submittals. The cost and placement of all backfill will be
included in the pay quantity for embankment or borrow excavation, as applicable.
145-7.3 Payment Items: Payment will be made under:
Item No. 145- 1Geosynthetic Reinforced Soil Slopes - per square foot.
Item No. 145- 2Geosynthetic Reinforced Foundations over Soft Soils - per
square yard.
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SECTION 160
STABILIZING
160-1 Description.
Stabilize designated portions of the roadbed to provide a firm and unyielding subgrade,
having the required bearing value specified in the Plans. Perform work in accordance with an
approved Quality Control Plan meeting the requirements of Section 105.
160-2 Materials.
160-2.1 Commercial Material: Meet the requirements of Section 914.
160-2.2 Local Material: Meet the requirements of Section 914.Test material from each
source, or if authorized by the Engineer, test blended materials. Submit test results to the
Engineer at least 14 days prior to the stabilization operation.
160-2.3 Existing Base: When the material from an existing base is used as all, or a
portion, of the stabilizing additives, no further testing is required unless directed by the Engineer.
160-2.4 Granular Subbase: The Engineer may allow, at no additional cost to the
Department, the substitution of 6 inches of Granular Subbase meeting the requirements of 290-2
and 290-3, when 12 inches of Stabilization requiring a Limerock Bearing Ratio (LBR) value
of 40 is specified.
160-3 Construction Methods.
160-3.1 General: Prior to the beginning of stabilizing operations, construct the area to be
stabilized to an elevation such that, upon completion of stabilizing operations, the completed
stabilized subgrade will conform to the lines, grades, and cross-section shown in the Plans. Prior
to spreading any additive stabilizing material, bring the surface of the roadbed to a plane
approximately parallel to the plane of the proposed finished surface.
Construct mainline pavement lanes, turn lanes, ramps, parking lots, concrete box
culverts and retaining wall systems meeting the requirements of 120-8.1, except replace
Embankment with Subgrade.
Construct shoulder-only areas, sidewalk, and bike/shared use path areas meeting
the requirements of 120-8.1 except replace Embankment with Subgrade and meet the
acceptance criteria of 160-4.2.
Isolated mixing operations will be considered as separate LOTs. Curbpads and
shoulders compacted separately shall be considered separate LOTs. Isolated compaction
operations will be considered as separate LOTs. For multiple phase construction, a LOT shall not
extend beyond the limits of the phase.
160-3.2 Application of Stabilizing Material: After substantially completing the roadbed
grading operations, determine the type and quantity (if any) of stabilizing material necessary for
compliance with the bearing value requirements. Notify the Engineer of the approximate
quantity to be added before spreading. When additive stabilizing materials are required, spread
the material uniformly over the area to be stabilized.
160-3.2.1 Sampling and Testing of Local Material: Randomly select locations
for sampling using a random number generator approved by the Engineer in accordance with
FM 1-T 267 and test at the minimum frequency listed in the table below before mixing. The
Engineer will reject the material for failing QC test results. The Engineer will sample for
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Verification and Resolution testing at the minimum frequency listed in the table below. The
Engineer will perform Verification tests at the minimum frequency listed in the table below.
Test Name
Quality Control
Verification
Resolution
Liquid Limit (LL), Plastic
Index (PI), and Organic
Content
One per two LOTs
One per eight
LOTs
One per eight LOTs
160-3.2.1.1 Verification Comparison Criteria and Resolution
Procedures: If the QC and the Departments Verification tests meet the requirements of
Section 914 then the Engineer will accept the corresponding LOTs. Otherwise, the Engineer will
submit the Resolution sample to the State Materials Office or an AASHTO accredited laboratory
designated by the State Materials Office to perform Resolution testing.
If the Resolution Test results meet the requirements of Section 914 then the
Engineer will accept the LOTs in question. Otherwise remove the material and apply new
material meeting the requirements of Section 914 and retest in accordance with 160-3.2.
160-3.3 Mixing: Perform mixing using rotary tillers, a plant or other equipment meeting
the approval of the Engineer. The subgrade may be mixed in one course if the equipment and
method of construction provides the uniformity, particle size limitation, compaction and other
desired results of 160-4. Thoroughly mix the area to be stabilized throughout the entire depth and
width of the stabilizing limits.
Perform the mixing operations, as specified, (either in place or in a plant)
regardless of whether the existing soil, or any select soils placed within the limits of the
stabilized sections, have the required bearing value without the addition of stabilizing materials.
160-3.4 Maximum Particle Size of Mixed Materials: At the completion of the mixing,
ensure that the gradation of the material within the limits of the area being stabilized is such that
97% will pass a 3 1/2 inch sieve and that the material does not have a plasticity index greater
than eight or liquid limit greater than 30. Remove any materials not meeting the plasticity
requirements from the stabilized area. Break down or remove from the stabilized area materials,
including clay lumps or lumps made of clay-size particles (any particle size 2 microns or less),
not meeting the gradation requirements.
160-3.5 Bearing Value: Meet the bearing value requirements for the subgrade in
accordance with 160-4.
160-3.6 Compaction: After completing the mixing operations and satisfying the
requirements for bearing value, uniformity, and particle size. Compact the materials at a moisture
content permitting the specified compaction in 160-4.2.3. If the moisture content of the material
is improper for attaining the specified density, either add water or allow the material to dry until
reaching the proper moisture content for the specified compaction.
160-3.7 Finish Grading: Shape the completed stabilized subgrade to conform with the
finished lines, grades, and cross-section indicated in the Plans. Check the subgrade using
elevation stakes or other means approved by the Engineer.
160-3.8 Requirements for Condition of Completed Subgrade: After completing the
stabilizing and compacting operations, ensure that the subgrade is firm and substantially
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unyielding to the extent that it will support construction equipment and will have the bearing
value required by the Plans.
Remove all soft and yielding material, and any other portions of the subgrade
which will not compact readily, and replace it with suitable material so that the whole subgrade
is brought to line and grade, with proper allowance for subsequent compaction.
160-3.9 Maintenance of Completed Subgrade: After completing the subgrade as
specified above, maintain it free from ruts, depressions, and any damage resulting from the
hauling or handling of materials, equipment, tools, etc. The Contractor is responsible for
maintaining the required density until the subsequent base or pavement is in place including any
repairs, replacement, etc., of curb and gutter, sidewalk, etc., which might become necessary in
order to recompact the subgrade in the event of underwash or other damage occurring to the
previously compacted subgrade. Perform any such recompaction at no expense to the
Department. Construct and maintain ditches and drains along the completed subgrade section.
160-4 Acceptance Program.
160-4.1 General Requirements: Meet the requirements of 120-10, except use 160-4.2
instead of 120-10.2, 160-4.3 instead of 120-10.3, and 160-4.4 instead of 120-10.4.
160-4.2 Acceptance Criteria:
160-4.2.1 Bearing Value Requirements:
160-4.2.1.1 General: Within the entire limits of the width and depth of the
areas to be stabilized, obtain the required minimum bearing value for each LOT. For any area
where the bearing value obtained is deficient from the value indicated in the Plans, in excess of
the tolerances established herein, spread and mix additional stabilizing material in accordance
with 160-3.3. Perform this reprocessing for the full width of the roadway being stabilized and
longitudinally for a distance of 50 feet beyond the limits of the area in which the bearing value is
deficient.
Determine the quantity of additional stabilizing material to be used
in reprocessing.
160-4.2.1.2 Under-tolerances in Bearing Value Requirements: The
under-tolerances are allowed for the following specified Bearing Values:
Specified Bearing Value
LBR 40
LBR 35
LBR 30 (and under)
Under-tolerance
5.0
4.0
2.5
The following unsoaked bearing value requirement is based on tests performed on
samples obtained after completing mixing operations:
Specified Bearing Value
LBR 40
Unsoaked Bearing Value Required
LBR 43
Under-tolerance
0.0
160-4.2.2 Mixing Depth Requirements: Do not exceed individual plan depth
thickness by more than 2 inches or exceed LOT-average depth thickness by more than 1 inch
measured to the nearest 0.25 inch. No undertolerance of mixing depth is allowed.
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As an exception to the above mixing requirements, where the subgrade is
of rock, the Engineer may waive the mixing operations (and the work of stabilizing), and the
Department will not pay for stabilization for such sections of the roadway.
160-4.2.3 Density Requirements:
160-4.2.3.1 General: Within the entire limits of the width and depth of the
areas to be stabilized, other than as provided in 160-4.2.3.2, obtain a minimum density at any
location of 98% of the Modified Proctor maximum density as determined by FM 1-T 180,
Method D.
160-4.2.3.2 Exceptions to Density Requirements: The Contractor need
not obtain the minimum density specified in 160-4.2.3.1 if within the following limits:
(a) The width and depth of areas which are to be subsequently
incorporated into a base course under the same contract.
(b) The upper 6 inches of areas to be grassed under the same
contract. Compact these areas to a reasonably firm condition as directed by the Engineer.
160-4.2.4 Frequency: Conduct QC sampling and testing at a minimum frequency
listed in the table below. The Engineer will perform Verification sampling and tests at a
minimum frequency listed in the table below.
Test Name
Quality Control
Verification
Modified Proctor
Maximum Density
Density
Stabilizing Mixing
Depth
One per two
consecutive LOTs
One per LOT
Three per 500 feet
One per eight
consecutive LOTs
One per four LOTs
LBR
Gradation, LL/PI &
Soil Classification
(Local materials)
Verification for
Shoulder-Only,
Bike/Shared Use Path
and Sidewalk
Construction
One per four LOTs
One per two LOTs
Witness one per LOT
Witness one per LOT
One per two
consecutive LOTs
One per eight
consecutive LOTs
One per four LOTs
Not Required
One per eight
consecutive LOTs
One per four LOTs
160-4.3 Additional Requirements:
160-4.3.1 Quality Control Testing:
160-4.3.1.1 Bearing Values: Test the Stabilized Subgrade sample
collected in 160-4.3.1.3. Determine the LBR in accordance with FM 5-515 and 160-4.2.4.
160-4.3.1.1.1 Unsoaked LBR: If Unsoaked LBR is desired,
submit request for approval to the Engineer. Upon approval by the Engineer to consider the use
of Unsoaked LBR, randomly sample and test from three locations in the initial Lot for both
Soaked and Unsoaked LBR in accordance with FM 5-515. Ensure all of the tests demonstrate the
material achieves the LBR values in 160-4.2.1.2. Continue testing Unsoaked LBR at the
frequency shown in 160-4.2.4. Discontinue Unsoaked LBR testing if any unsatisfactory QC LBR
test result is obtained or resolution determines an unsatisfactory LBR.
194
160-4.3.1.2 Mixing Depths: Meet required plan mixing-depths by
measuring from the proposed Final Grade Line. Determine test locations, including Stations and
Offsets, using the Random Number generator approved by the Department. Notify the Engineer
a minimum of 24 hours before checking mixing depths. Record results on forms supplied by the
Department.
160-4.3.1.3 Modified Proctor Maximum Density Requirement: Collect
enough material to split and create three separate samples. Determine test locations, including
Stations and Offsets, using the Random Number generator approved by the Department for the
two LOTs under consideration. Retain the Verification and Resolution samples for the
Department until the Engineer accepts the LOTs represented by the samples.
160-4.3.2 Department Verification Tests:
160-4.3.2.1 Bearing Value & Soil Classification: The Engineer will
collect a sample at a location other than the location where the sample was collected in 1604.3.1.3, and test the Stabilized Subgrade for determination of the LBR in accordance with
FM 5-515. The Engineer will select test locations, including Stations and Offsets, using a
Random Number generator, based on the LOTs under consideration.
If Local Material is used for stabilizing, the Engineer will
determine compliance with embankment utilization requirements and 160-3.4 by testing and
classifying the Stabilized Subgrade in accordance with AASHTO T88 and AASHTO M 145 at
the frequency shown in 160-4.2.4.
160-4.3.2.1.1 Unsoaked LBR: The Engineer will sample
and test the initial LOT for one soaked and one unsoaked LBR if consideration of the Unsoaked
LBR has been approved.
160-4.3.2.2 Mixing Depth: The Engineer will witness the Contractors
mixing depth checks to ensure compliance with 160-4.2.2. The Engineer will select test
locations, including Stations and Offsets, using a Random Number generator.
160-4.3.2.3 Modified Proctor Maximum Density: The Engineer will
randomly select one of the retained split samples and test in accordance with FM 1-T 180,
Method D.
160-4.4 Verification Comparison Criteria and Resolution Procedures:
160-4.4.1 Bearing Value & Soil Classification: If the Departments Verification
test meets the requirements of 160-4.2.1 and embankment utilization requirements, the Engineer
will accept the corresponding LOTs. Otherwise, the Engineer will collect an additional sample in
the same LOT the Verification sample was obtained. The State Materials Office or an AASHTO
accredited laboratory designated by the State Materials Office will perform Resolution testing on
the additional sample. The material will be sampled and tested in accordance with FM 5-515. If
Local Material is used for stabilization, the sample will be tested in accordance with
AASHTO T-88, and AASHTO M-145.
If the Resolution Testing results meet the requirements of 160-4.2.1 and
embankment utilization requirements then the Engineer will accept the LOTs in question.
Otherwise reprocess the corresponding LOTs in accordance with 160-3 and retest in accordance
with 160-4.3.1.1.
160-4.4.2 Mixing Depth Thickness: The Department will witness the mixing
depth checks.
1. If the depth checks meet the requirements of 160-4.2.2 the Engineer
will accept that 500-foot section.
195
2. If the depth checks confirm shallow depth, re-mix the 500-foot section
to an appropriate Depth and re-measure in accordance with 160-4.3.1.2. The Engineer will repeat
the witness process.
3. If the depth checks confirm extra deep mixing, conduct an additional
QC density test after compaction for the bottom 12 inches of the subgrade for that 500-foot
section in addition to a QC density test for the top 12 inches. The additional Density test must
meet the requirements of 160-4.2.3.
160-4.4.3 Modified Proctor Maximum Density Determination: The Engineer
will compare the Verification test results of 160-4.3.2.3 to the corresponding Quality Control test
results. If the test result is within 4.5 lb/ft3 of the QC test result, the LOTs will be verified.
Otherwise, the Engineer will collect the Resolution split sample corresponding to the
Verification sample tested. The State Materials Office or an AASHTO accredited laboratory
designated by the State Materials Office will perform Resolution testing. The material will be
sampled and tested in accordance with FM 1-T 180, Method D.
The Engineer will compare the Resolution Test results with the Quality
Control test results. If the Resolution Test result is within 4.5 lb/ft3 of the corresponding Quality
Control test result, the Engineer will use the Quality Control test results for material acceptance
purposes for each corresponding pair of LOTs. If the Resolution test result is not within 4.5 lb/ft3
of the corresponding Quality Control test, the Engineer will collect the remaining Verification
split samples for testing. Verification Test results will be used for material acceptance purposes
for the LOTs in question.
160-4.4.4 Density: When a Verification or Independent Verification density test
does not meet 160-4.2.3 (Acceptance Criteria), retest at a site within a 5 feet radius of the
Verification test location and observe the following:
1. If the Quality Control retest meets the Acceptance Criteria and
compares favorably with the Verification or Independent Verification test, the Engineer will
accept the LOTs in question.
2. If the Quality Control retest does not meet the Acceptance Criteria and
compares favorably with the Verification or Independent Verification test, rework and retest the
material in that LOT. The Engineer will re-verify the LOTs in question.
3. If the Quality Control retest and the Verification or Independent
Verification test do not compare favorably, complete a new equipment-comparison analysis as
defined in 120-10.1.2. Once acceptable comparison is achieved, retest the LOTs. The Engineer
will perform new verification testing. Acceptance testing will not begin on a new LOT until the
Contractor has a gauge that meets the comparison requirements.
160-5 Method of Measurement.
The quantity to be paid for will be the plan quantity, in square yards, completed and
accepted.
160-6 Basis of Payment.
Price and payment will constitute full compensation for all work and materials specified
in this Section, including furnishing, spreading and mixing of all stabilizing material required
and any reprocessing of stabilization areas necessary to attain the specified bearing value. The
Department will make full payment for any areas where the existing subgrade materials meet the
design bearing value requirements without the addition of stabilizing additives, as well as areas
196
where the Contractor may elect to place select high-bearing materials from other sources within
the limits of the stabilizing.
If the item of borrow excavation is included in the Contract, any stabilizing materials
obtained from designated borrow areas will be included in the pay quantity for borrow
excavation.
Payment will be made under:
Item No. 160- 4Stabilization - per square yard.
197
SECTION 162
PREPARED SOIL LAYER
162-1 Description.
162-1.1 Finish Soil Layer: Unless otherwise called for in the Plans, prepare a 6 inch
thick layer of existing soil mixed with imported material, if necessary, to achieve the pH and
organic matter levels required in Section 987, that is favorable to turf and ground cover growth
over areas of the project which are to be seeded, seeded and mulched, or planted, by mixing in an
organic material, compost, or commercially available soil amendments. Prepare finish soil layer
in areas to be sodded, when called for in the Plans.
162-1.2 Organic Soil Layer: When required by a permit, prepare a 6 inch thick layer of
organic soil, at locations shown in the Plans.
162-1.3 Blanket Material: When required by a permit, place a layer of blanket material
at the locations and to the depth shown in the Plans.
162-2 Materials.
162-2.1 Finish Soil Layer and Organic Soil Layer: Meet the requirements of
Section 987.
162-2.2 Blanket Material: Meet the material classification shown in the Plans and
Design Standards, Index No. 505.
162-3 Ownership of Surplus Materials.
The Department will retain ownership of all materials suitable for construction of the
prepared soil layer until the final job requirements have been fulfilled. Unless otherwise shown
in the Contract Documents, upon final acceptance, Contractor shall take ownership of any
surplus materials and dispose of in accordance with 120-5.
Where temporary storage of apparent surplus materials within the right-of-way may be
impractical, the materials may be stockpiled outside the right-of-way in areas provided by the
Contractor until needed on the project or declared surplus. With the Engineers written approval,
the Contractor may dispose of excess material with the stipulation that any portion required to
fulfill job requirements will be replaced with equally suitable material at no cost to the
Department.
No extra compensation is allowed for any rehandling involved under the provisions of
this Subarticle.
162-4 Construction Methods.
Construct the surface of the earthwork to such lines and elevations that will provide a
surface conforming to the plan lines and elevations upon completion of the prepared soil
operations. Leave the surface of the earthwork in a roughened and loose condition. Prevent
contamination of the materials by other construction operations. Remove and replace all
materials which fail to meet the required soil classification or become contaminated after
placement, and correct any slippage of this material at no cost to the Department. Spread the
appropriate material uniformly over areas to receive treatment.
162-4.1 Finish Soil Layer: After spreading, mix the material with the underlying soil to
a combined depth of 6 inches, unless otherwise called for in the Plans. Continue mixing to
provide a uniform finish soil layer true to line and grade.
162-4.2 Organic Soil Layer: Spread materials to the depth of 6 inches.
198
162-4.3 Blanket Material: Place the blanket material to the depth shown in the plans.
162-5 Acceptance Testing.
The Engineer reserves the right to waive or reduce testing requirements for shoulder
treatment projects as defined in the Design Standards, Index No. 105.
Immediately after completion of construction operations, sample and test the prepared
soil layer at a testing laboratory qualified under 6-9. Take random samples at a minimum of one
sample per 2,500 square yards of prepared surface. When the source of added material changes,
the Engineer will require an additional sample. Test results will be averaged for each
10,000 square yards to determine specification compliance. The Engineer reserves the right to
take and test additional samples to determine specification compliance. For failing samples, take
and test additional samples, as directed by the Engineer, to delineate areas that need re-treatment.
Perform re-treatment at no additional cost to the Department. Perform additional testing of
retreated areas, at locations directed by the Engineer, to determine specification compliance.
Provide copies of all test results to the Engineer.
162-5.1 Finish Soil Layer: Test sampled material for organic matter content, pH,
primary macronutrients (N, P K) and secondary macronutrients (S, Ca, Mg) content. Acquire
from the soil testing laboratory fertilizer recommendations for the specific plants to be grown in
the area. Do not seed, seed and mulch, or place sod until acceptable values for organic content
and pH are obtained in accordance with the requirements of 987-1.
162-5.2 Organic Soil Layer: Test sampled material for organic matter content in
accordance with the requirements of 987-1.
162-5.3 Blanket Material: Test blanket material for depth in accordance with the Plans
and for soil classification in accordance with AASHTO M145. Add materials as necessary to
achieve the required depth.
162-6 Method of Measurement.
The quantities to be paid for will be the plan quantity for the following items meeting the
requirements of this Section, completed and accepted:
(1) The area, in square yards, of finish soil layer.
(2) The area, in square yards, of organic soil layer.
(3) The area, in square yards, of blanket material.
162-7 Basis of Payment.
Prices and payments will be full compensation for completing all work specified in this
Section, including furnishing, hauling, and placing materials to the lines and grades shown in the
Plans.
Payment will be made under:
Item No. 162- 1Prepared Soil Layer - per square yard.
199
SECTION 175
CRACKING AND RESEATING EXISTING
CONCRETE PAVEMENT
175-1 Description.
Perform controlled cracking of concrete pavement and reseating of the cracked slabs, by
rolling, tamping, etc., on the underlying subgrade to provide a firm base for asphalt concrete
surfacing.
175-2 Equipment.
175-2.1 For Cracking: Provide pneumatic or gravity-type breakers, or other specifically
approved equipment that ensures controlled cracking to the size and extent of uniformity, etc.,
specified. Control the fall of gravity-type breakers by leads so that the fall will be straight and
vertical. Use hammers for both pneumatic and gravity-type breakers of a type that will crack the
concrete cleanly and not punch or unnecessarily shatter the concrete.
175-2.2 For Reseating Provide vibratory compacting equipment or traffic rollers. Use
traffic rollers that weigh at least 15 tons.
175-3 Construction Requirements.
175-3.1 Protection of New Construction and Adjacent Structures: Perform cracking
and reseating work prior to beginning all new construction which this work might endanger or
disturb. Perform cracking and reseating in a manner that will not damage any existing structures
which are to remain, and repair any damage to such structures that this work causes by this work
at no expense to the Department.
175-3.2 Cracking and Seating: For the cracked slabs, make clean fractures, as near
vertical as practicable. Do not punch the pieces into the subgrade, but firmly seat them thereon,
to as uniform a contour as is practicable.
175-3.3 Special Requirements for Asphalt-Surfaced Pavement: Where the existing
concrete pavement is covered with an asphalt surface, remove the asphalt surfacing (after the
cracking operation) on test areas approximately 10 by 10 feet, at locations selected by the
Engineer, in order to determine if the required results are being obtained in the cracking
operations. Prepare at least one such test area for each day's operation, and prepare additional
areas if deemed necessary by the Engineer.
175-3.4 Dimensions of Slabs: Ensure that the cracked slabs have no dimension greater
than 3 feet. In the event that the required results in the cracking are not being obtained, adjust the
spacing of blows or the height of drop of the blows as necessary to obtain the required results
with the equipment being used.
175-4 Method of Measurement.
The quantity to be paid for will be the plan quantity, in square yards, of existing concrete
pavement acceptably cracked and reseated on the subgrade.
175-5 Basis of Payment.
Price and payment will be full compensation for performing and completing all work
specified in this Section.
Payment will be made under:
200
Item No. 175- 1-
Reseating Concrete Pavement - per square yard.
201
BASE COURSES
SECTION 200
ROCK BASE
200-1 Description.
Construct a base composed of base rock. Perform work in accordance with an approved
Quality Control Plan meeting the requirements of 105-3.
200-2 Materials.
Meet the requirements of either Section 911, 913, 913A or 915 for the particular type of
base to be constructed. The Contractor may use more than one source of base rock on a single
Contract provided that a single source is used throughout the entire width and depth of a section
of base. Obtain approval from the Engineer before placing material from more than one source.
Place material to ensure total thickness single source integrity at any station location of the base.
Intermittent placement or blending of sources is not permitted. Base rock may be referred to
hereinafter as rock.
Do not use any of the existing base that is removed to construct the new base.
200-3 Equipment.
Use mechanical rock spreaders, equipped with a device that strikes off the rock uniformly
to laying thickness, capable of producing even distribution. For crossovers, intersections and
ramp areas; roadway widths of 20 feet or less; the main roadway area when forms are used and
any other areas where the use of a mechanical spreader is not practicable; the Contractor may
spread the rock using bulldozers or blade graders.
200-4 Transporting Rock.
Transport the rock to its point of use, over rock previously placed, if practicable, and
dump it on the end of the preceding spread. Hauling and dumping on the subgrade will be
permitted only when, in the Engineers opinion, these operations will not be detrimental to the
subgrade.
200-5 Spreading Rock.
200-5.1 Method of Spreading: Spread the rock uniformly. Remove all segregated areas
of fine or coarse rock and replace them with properly graded rock.
200-5.2 Number of Courses: When the specified compacted thickness of the base is
greater than 6 inches, construct the base in multiple courses of equal thickness. Individual
courses shall not be less than 3 inches. The thickness of the first course may be increased to bear
the weight of the construction equipment without disturbing the subgrade.
If, through field tests, the Contractor can demonstrate that the compaction
equipment can achieve density for the full depth of a thicker lift, and if approved by the
Engineer, the base may be constructed in successive courses of not more than 8 inches
compacted thickness.
The Engineer will base approval on results of a test section constructed using the
Contractors specified compaction effort. Notify the Engineer prior to beginning construction of
a test section. Construct a test section of the length of one LOT. Perform five QC density tests at
random locations within the test section. At each test site, test the bottom 6 inches in addition to
202
the entire course thickness. All QC tests and a Department Verification test must meet the
density required by 200-7.2.1. Identify the test section with the compaction effort and thickness
in the Logbook. Remove the materials above the bottom 6 inches, at no expense to the
Department. The minimum density required on the thicker lift will be the average of the five
results obtained on the thick lift in the passing test section. Maintain the exposed surface as close
to undisturbed as possible; no further compaction will be permitted during the test preparation.
If unable to achieve the required density, remove and replace or repair the test section to comply
with the specifications at no additional expense to the Department. The Contractor may elect to
place material in 6 inches compacted thickness at any time.
Once approved, a change in the source of base material will require the construction
of a new test section. Do not change the compaction effort once the test section is approved. The
Engineer will periodically verify the density of the bottom 6 inches during thick lift operations.
The Engineer may terminate the use of thick lift construction and instruct the
Contractor to revert to the 6 inches maximum lift thickness if the Contractor fails to achieve
satisfactory results or meet applicable specifications.
200-5.3 Rock Base for Shoulder Pavement: Unless otherwise permitted, complete all
rock base shoulder construction at any particular location before placing the final course of
pavement on the traveled roadway. When dumping material for the construction of a rock base
on the shoulders, do not allow material capable of scarring or contaminating the pavement
surface on the adjacent pavement. Immediately sweep off any rock material that is deposited on
the surface course.
200-6 Compacting and Finishing Base.
200-6.1 General: Construct mainline pavement lanes, turn lanes, ramps, parking lots,
concrete box culverts and retaining wall systems meeting the requirements of 120-8.1, except
replace embankment with base.
Construct shoulder-only areas, bike/shared use paths, and sidewalks. Meet the
requirements of 120-8.1 except replace embankment with base meeting the acceptance
criteria of 200-7.2. Shoulders compacted separately shall be considered separate LOTs.
200-6.1.1 Single Course Base: After spreading, scarify the entire surface, then
shape the base to produce the required grade and cross-section, free of scabs and laminations,
after compaction.
200-6.1.2 Multiple Course Base: Clean the first course of foreign material, then
blade and bring it to a surface cross-section approximately parallel to the finished base. Before
spreading any material for the upper courses, allow the Engineer to make density tests for the
lower courses to determine that the required compaction has been obtained. After spreading the
material for the top course, scarify finish and shape its surface to produce the required grade and
cross-section, free of scabs and laminations, after compaction.
200-6.2 Moisture Content: When the material does not have the proper moisture content
to ensure the required density, wet or dry it as required. When adding water, uniformly mix it in
to the full depth of the course that is being compacted. During wetting or drying operations,
manipulate, as a unit, the entire width and depth of the course that is being compacted.
200-6.3 Thickness Requirements: Within the entire limits of the length and width of the
finished base, meet the specified plan thickness in accordance with the requirements of 2007.3.1.2.
200-6.4 Correction of Defects:
203
200-6.4.1 Contamination of Base Material: If, at any time, the subgrade
material becomes mixed with the base course material, dig out and remove the mixture, and
reshape and compact the subgrade. Then replace the materials removed with clean base material,
and shape and compact as specified above. Perform this work at no expense to the Department.
200-6.4.2 Cracks and Checks: If cracks or checks appear in the base, either
before or after priming, which, in the opinion of the Engineer, would impair the structural
efficiency of the base, remove the cracks or checks by rescarifying, reshaping, adding base
material where necessary, and recompacting.
200-6.5 Compaction of Widening Strips: Where base construction consists of widening
strips and the trench width is not sufficient to permit use of standard base compaction equipment,
compact the base using vibratory compactors, trench rollers or other special equipment which
will achieve the density requirements specified herein.
When multiple course base construction is required, compact each course prior to
spreading material for the overlaying course.
200-7 Acceptance Program.
200-7.1 General Requirements: Meet the requirements of 120-10, except use 200-7.2
instead of 120-10.2, 200-7.3 instead of 120-10.3 and 200-7.4 instead of 120-10.4.
200-7.2 Acceptance Criteria:
200-7.2.1 Density: Within the entire limits of the width and depth of the base,
obtain a minimum density in any LOT of 98% of modified Proctor maximum density as
determined by FM 1-T 180, Method D. For shoulder only areas and bike/shared use paths, obtain
a minimum density of 95% of the modified Proctor maximum density as determined by FM 1T 180, Method D.
200-7.2.2 Frequency: Conduct QC sampling and testing at a minimum frequency
listed in the table below. The Engineer will perform Verification sampling and tests at a
minimum frequency listed in the table below.
Mainline Pavement Lanes, Turn Lanes, Ramps, Parking Lots, Concrete Box Culverts and
Retaining Wall Systems
Test Name
Quality Control
Verification
Modified Proctor
One per eight consecutive
One per 16 consecutive LOTs
Maximum Density
LOTs
Density
One per LOT
One per four LOTs
Roadway Surface
Ten per LOT
Witness
Roadway Thickness
Three per LOT
Witness
Shoulder-Only, Bike/Shared Use Path and Sidewalk Construction
Test Name
Quality Control
Verification
Modified Proctor
One per two LOTs
One per four LOTs
Maximum Density
Density
One per LOT
One per two LOTs
Surface
Thickness
Five per 500 feet
Three per 1000 consecutive feet
204
Witness
Witness
200-7.3 Additional Requirements:
200-7.3.1 Quality Control Testing:
200-7.3.1.1 Modified Proctor Maximum Density Requirement: Collect
enough material to split and create three separate samples and retain two for the Engineers
Verification and Resolution testing until the Engineer accepts the 16 LOTs represented by the
samples.
200-7.3.1.2 Depth and Surface Testing Requirements: Notify the
Engineer a minimum of 24 hours before checking base depths and surface checking. Determine
test locations including Stations and Offsets, using the Random Number generator approved by
the Department. Do not perform depth and surface checks until the Engineer is present to
witness. Enter test results into the Departments database. Perform thickness check on the
finished base or granular subbase component of a composite base. Provide traffic control,
coring/boring equipment, and an operator for the coring/boring equipment. Traffic control is to
be provided in accordance with the standard maintenance of traffic requirements of the Contract.
The thickness is considered deficient, if the measured depth is over
1/2 inch less than the specified thickness. Correct all deficient areas of the completed base by
scarifying and adding additional base material. As an exception, if authorized by the Department,
such areas may be left in place without correction and with no payment.
Check the finished surface of the base course with a template cut to
the required crown and with a 15 foot straightedge laid parallel to the centerline of the road.
Correct all irregularities greater than 1/4 inch to the satisfaction of the Engineer by scarifying
and removing or adding rock as required, and recompact the entire area as specified
hereinbefore.
200-7.3.1.3 Surface & Thickness Reduced Testing Frequency: When
no Resolution testing is required for 12 consecutive verified LOTs, or if required, the QC test
data was upheld, reduce the QC surface and/or thickness checks to one half the minimum
requirements as stated in 200-7.2.2 (eg. Reduce frequency from ten per LOT to ten per two
LOTs) by identifying the substantiating tests and notifying the Engineer in writing prior to
starting reduced frequency of testing. If the Verification test fails, and Quality Control test data is
not upheld by Resolution testing the Quality Control testing will revert to the original frequency
of 200-7.2.2. The results of the Independent Verification testing will not affect the frequency of
the Quality Control testing.
200-7.3.2 Department Verification Tests:
200-7.3.2.1 Maximum Density: The Engineer will randomly select one of
the remaining two split samples and test in accordance with FM 1-T 180, Method D.
200-7.3.2.2 Thickness and Surface Testing Requirements: The
Department will witness the base depth and surface checks to ensure compliance with 2007.3.1.2. If the QC test results are not deficient as defined in 200-7.3.1.2, the LOT or 500-foot
section will be accepted. If the QC test results are deficient, resolve deficiencies in accordance
with 200-7.3.1.2. Repeat acceptance testing. Provide traffic control, coring/boring equipment,
and an operator for the coring/boring equipment.
200-7.4 Verification Comparison Criteria and Resolution Procedures:
200-7.4.1 Modified Proctor Maximum Density: The Engineer will compare the
Verification test results of 200-7.3.2.1 to the corresponding Quality Control test results. If the
test result is within 4.5 lb/ft3 of the QC test result, the LOTs will be verified. Otherwise, the
Engineer will collect the Resolution split sample corresponding to the Verification sample tested.
205
The State Materials Office or an AASHTO accredited laboratory designated by the State
Materials Office will perform Resolution testing. The material will be sampled and tested in
accordance with FM 1-T 180, Method D.
The Engineer will compare the Resolution Test results with the Quality
Control test results. If the Resolution Test result is within 4.5 lb/ft3 of the corresponding Quality
Control test result, the Engineer will use the Quality Control test results for material acceptance
purposes for each corresponding set of LOTs. If the Resolution test result is not within 4.5 lb/ft3
of the corresponding Quality Control test, the Engineer will collect the remaining Verification
split sample for testing. Verification Test results will be used for material acceptance purposes
for the LOTs in question.
200-7.4.2 Density: When a Verification or Independent Verification density test
does not meet the requirements of 200-7.2.1 (Acceptance Criteria), retest at a site within a 5 feet
radius of the Verification test location and observe the following:
1. If the Quality Control retest meets the Acceptance Criteria and
compares favorably with the Verification or Independent Verification test, the Engineer will
accept the LOTs in question.
2. If the Quality Control retest does not meet the Acceptance Criteria and
compares favorably with the Verification or Independent Verification test, rework and retest the
material in that LOT. The Engineer will re-verify the LOTs in question.
3. If the Quality Control retest and the Verification or Independent
Verification test do not compare favorably, complete a new equipment-comparison analysis as
defined in 120-10.1.1. Once acceptable comparison is achieved, retest the LOTs. The Engineer
will perform new verification testing. Acceptance testing will not begin on a new LOT until the
Contractor has a gauge that meets the comparison requirements.
200-7.4.3 Thickness and Surface Testing Requirements: Resolve deficiencies
in accordance with 200-7.3.1.2.
200-8 Priming and Maintaining.
200-8.1 Priming: Apply the prime coat only when the base meets the specified density
requirements and when the moisture content in the top half of the base does not exceed the
optimum moisture of the base material. At the time of priming, ensure that the base is firm,
unyielding and in such condition that no undue distortion will occur.
200-8.2 Maintaining: Maintain the true crown and template, with no rutting or other
distortion, while applying the surface course.
200-9 Calculations for Average Thickness of Base.
For bases that are not mixed in place, the Engineer will determine the average thickness
from the measurements specified in 200-10.1, calculated as follows:
(a) When the measured thickness is more than 1/2 inch greater than the design
thickness shown on the typical cross-section in the Plans, it will be considered as the design
thickness plus 1/2 inch.
(b) Average thickness will be calculated per typical cross-section for the entire job
as a unit.
(c) Any areas of base left in place with no payment will not be included in the
calculations.
206
(d) Where it is not possible through borings to distinguish the base materials from
the underlying materials, the thickness of the base used in the measurement will be the design
thickness.
200-10 Method of Measurement.
200-10.1 General: The quantity to be paid for will be the plan quantity, adjusted as
specified below.
200-10.2 Authorized Normal Thickness Base: The surface area of authorized normal
thickness base to be adjusted will be the plan quantity as specified above, omitting any areas not
allowed for payment under the provisions of 200-6.3 and omitting areas which are to be included
for payment under 200-10.3. The adjustment shall be made by adding or deducting, as
appropriate, the area of base represented by the difference between the calculated average
thickness, determined as provided in 200-9, and the specified normal thickness, converted to
equivalent square yards of normal thickness base.
200-10.3 Authorized Variable Thickness Base: Where the base is constructed to a
compacted thickness other than the normal thickness as shown on the typical section in the Plans,
as specified in the Plans or ordered by the Engineer for providing additional depths at culverts or
bridges, or for providing transitions to connecting pavements, the volume of such authorized
variable thickness compacted base will be calculated from authorized lines and grades, or by
other methods selected by the Engineer, converted to equivalent square yards of normal
thickness base for payment.
200-11 Basis of Payment.
Price and payment will be full compensation for all the work specified in this Section,
including correcting all defective surface and deficient thickness, removing cracks and checks as
provided in 200-6.4.2, the prime coat application as directed in 300-8, and the additional rock
required for crack elimination.
Payment shall be made under:
Item No. 285- 7Optional Base - per square yard.
207
SECTION 204
GRADED AGGREGATE BASE
204-1 Description.
Construct a base course composed of graded aggregate.
204-2 Materials.
Use graded aggregate material, produced from Department approved sources, which
yields a satisfactory mixture meeting all the requirements of these Specifications after it has been
crushed and processed as a part of the mining operations.
The Contractor may furnish the material in two sizes of such gradation that, when
combined in a central mix plant pugmill, the resultant mixture meets the required specifications.
Use graded aggregate base material of uniform quality throughout, substantially free
from vegetable matter, shale, lumps and clay balls, and having a Limerock Bearing Ratio value
of not less than 100. Use material retained on the No. 10 sieve composed of aggregate meeting
the following requirements:
Soundness Loss, Sodium, Sulfate: AASHTO T104 .................. 15%
Percent Wear: AASHTO T96 (Grading A)
Group 1 Aggregates ....................................................... 45%
Group 2 Aggregates ....................................................... 65%
Group 1: This group of aggregates is composed of limestone, marble, or dolomite.
Group 2: This group of aggregates is composed of granite, gneiss, or quartzite.
Use graded aggregate base material meeting the following gradation:
Sieve Size
2 inch
1 1/2 inch
3/4 inch
3/8 inch
No. 4
No. 10
No. 50
No. 200
Percent by Weight Passing
100
95 to 100
65 to 90
45 to 75
35 to 60
25 to 45
5 to 25
0 to 10
For Group 1 aggregates, ensure that the fraction passing the No. 40 sieve has a Plasticity
Index (AASHTO T90) of not more than 4.0 and a Liquid Limit (AASHTO T89) of not more
than 25, and contains not more than 67% of the weight passing the No. 200 sieve.
For Group 2 aggregates, ensure that the material passing the No. 10 sieve has a sand
equivalent (AASHTO T176) value of not less than 28.
The Contractor may use graded aggregate of either Group 1 or Group 2, but only use one
group on any Contract. (Graded aggregate may be referred to hereinafter as aggregate.)
204-3 Equipment.
Provide equipment meeting the requirements of 200-3.
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204-4 Transporting Aggregate.
Transport aggregate as specified in 200-4.
204-5 Spreading Aggregate.
Spread aggregate as specified in 200-5.
204-6 Compacting and Finishing Base.
204-6.1 General: Meet the requirements of 200-7.1 with density requirements of 2046.3.
204-6.1.1 Single-Course Base: Construct as specified in 200-6.1.1.
204-6.1.2 Multiple-Course Base: Construct as specified in 200-6.1.2.
204-6.2 Moisture Content: Meet the requirements of 200-6.2.
204-6.3 Density Requirements: After attaining the proper moisture conditions,
uniformly compact the material to a density of not less than 100% of the maximum density as
determined by FM 1-T 180. Ensure that the minimum density that will be acceptable at any
location outside the traveled roadway (such as intersections, crossovers, turnouts, etc.) is 98% of
the maximum density.
204-6.4 Density Tests: Meet the requirements of 200-7.2.
204-6.5 Correction of Defects: Meet the requirements of 200-6.4.
204-6.6 Dust Abatement: Minimize the dispersion of dust from the base material during
construction and maintenance operations by applying water or other dust control materials.
204-7 Testing Surface.
Test the surface in accordance with the requirements of 200-7.
204-8 Priming and Maintaining.
Meet the requirements of 200-8.
204-9 Thickness Requirements.
Meet the requirements of 285-6.
204-10 Calculations for Average Thickness of Base.
Calculations for determining the average thickness of base will be made in accordance
with 285-7.
204-11 Method of Measurement.
204-11.1 General: The quantity to be paid for will be the area, in square yards,
completed and accepted.
204-11.2 Authorized Normal Thickness Base: The surface area of authorized normal
thickness base will be calculated as specified in 9-1.3, omitting any areas not allowed for
payment under the provisions of 204-9 and omitting areas which are to be included for payment
under 204-11.3. The area for payment, of authorized normal thickness base, will be the surface
area determined as provided above, adjusted by adding or deducting, as appropriate, the area of
base represented by the difference between the calculated average thickness, determined as
provided in 204-10, and the specified normal thickness, converted to equivalent square yards of
normal thickness base.
204-11.3 Authorized Variable Thickness Base: As specified in 200-10.3.
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204-12 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including dust abatement, correcting all defective surface and deficient thickness, removing
cracks and checks and the additional aggregate required for such crack elimination.
Payment will be made under:
Item No. 285- 7Optional Base - per square yard.
210
SECTION 210
REWORKING LIMEROCK BASE
210-1 Description.
Rework (or rework and widen) the existing rock base, by adding new limerock material
as required by the Plans. Construct adjacent turnouts, entirely with new limerock.
210-2 Materials.
Meet the limerock material requirements as specified in Section 911 if new limerock is
needed. The Contractor may use limerock of either Miami Oolite or Ocala Formation but only
use limerock of one formation on any Contract.
210-3 Equipment.
Provide equipment meeting the requirements of 200-3.
210-4 Existing Bituminous Surfaces.
210-4.1 Asphalt Concrete: Remove asphalt concrete surfaces from the base prior to
excavating trenches or scarifying the rock. Dispose of removed materials as specified in 120-5.
210-4.2 Bituminous Surface Treatment: Remove and dispose of existing bituminous
surface treatment only when specifically specified in the Plans. Otherwise, the Contractor may
mix the existing bituminous surfacing in with the existing limerock material.
210-5 Trenches and Subgrade.
Where widening the existing base, excavate trenches along the edges of the existing
pavement to the width and depth indicated in the Plans. Excavate the trenches before scarifying
the existing base. Shape, compact, and maintain the subgrade of the trenches and turnouts as
specified in 120-9, except that when stabilization of the subgrade is not included in the Plans, do
not compact the trenches unless the native underlying material has been disturbed. Dispose of all
excavated materials as specified in 120-5.
210-6 Spreading, Shaping, and Compacting Rock.
210-6.1 General: Scarify and disk, or otherwise loosen the existing base to such extent
that no pieces larger than 3 1/2 inches in greatest dimension remain bonded together. Then,
spread the material to the full width of the proposed new base course and to a grade and crosssection roughly parallel to the finished grade. Meet the requirements of 200-7.1.
210-6.2 Widening Strips: Where the widening strips are not of sufficient width to permit
the use of standard compaction equipment, compact the rock in accordance with 200-6.5.
210-6.3 Construction Sequence: Do not spread any material for the upper course until
the Engineer has made the density tests on the lower course and has determined that the specified
compaction requirements have been met. Then, construct the second course of new limerock in
accordance with the requirements of 200-5 through 200-7.
210-7 Priming and Maintaining.
Meet the requirements of 200-8.
211
210-8 Method of Measurement.
210-8.1 Base: The quantity to be paid for will be the plan quantity, in square yards,
completed and accepted, including the areas of widened base and of turnouts constructed of new
limerock material.
210-8.2 Limerock Material: The quantity to be paid for will be the number of cubic
yards of only the new limerock material actually placed in the road and accepted. The quantity
will be determined by measurement in loose volume, in truck bodies, at the point of dumping on
the road, with proper deduction for all materials wasted, left in trucks or otherwise not actually
used in the road. For this purpose, level the material in the truck bodies to facilitate accurate
measurement.
210-9 Basis of Payment.
Prices and payments will be full compensation for performing all work specified in this
Section including prime coat application as specified in 300-7, except all earthwork required for
this work, and the work of removal and disposal of the existing bituminous surfaces, if required,
as indicated in the Plans.
When the plans do not provide for direct payment for such work, the cost will be
included in the Contract unit price for reworking limerock base.
Payment will be made under:
Item No. 210- 1Reworking Limerock Base - per square yard.
Item No. 210- 2Limerock, New Material - per cubic yard.
212
SECTION 230
LIMEROCK STABILIZED BASE
230-1 Description.
Construct a base course composed of roadbed soil stabilized with limerock.
230-2 Materials.
Meet the limerock material requirements as specified in Section 911.
230-3 Equipment.
230-3.1 For Mixing: For mixing in the roadway, provide a heavy-duty rotary tiller or
other equipment approved by the Engineer as equally effective for this work.
230-3.2 For Compaction: Select the equipment for compacting the stabilized material,
except that for the final finish use a steel-wheeled roller.
230-4 Preparation of Roadbed.
Complete the area to be stabilized to the lines shown in the Plans and to a grade parallel
to the finished elevation of the stabilized base, before adding the stabilizing material. Ensure that
the elevation of the roadbed is such that the base will conform to the typical cross-section upon
completing the work. Dispose of any surplus excavated materials resulting from this work, as
specified in 120-5.
230-5 Incorporation of Stabilizing Material and Mixing-In.
230-5.1 Spreading and Mixing: Place the limerock on the areas to be stabilized, and
spread it uniformly to the loose depth shown in the Plans or ordered by the Engineer. Then,
thoroughly mix the limerock with the soil. Perform mixing as soon as practicable but not later
than one week after placing the limerock on the road. Do not spread more limerock in advance of
the mixing operations than can be mixed-in with the soil within one week.
230-5.2 Further Mixing Operations: Repeat the mixing operations as often as may be
necessary to distribute the limerock uniformly throughout the soil, as determined by the
Engineer. Further manipulate the material to uniformly distribute the limerock throughout the
width and depth of the base course.
230-5.3 Plant Mixing: The Contractor may mix the soil, limerock, and water using the
central plant-mix method in lieu of mixing in place, provided he obtains a uniform mixture with
the proper amount of water.
230-5.4 Shaping Surface: After mixing, shape the surface so it conforms to the grade
and typical cross-section shown in the Plans after compacting.
230-5.5 Depth of Mixing Stabilizing Material: Ensure that the depth of mixing of the
stabilizing material is in accordance with the following table:
Required Mixing Depth (inches)
Minimum
Maximum
5 1/2
7 1/2
7 1/4
9 3/4
9
12
Specified Base Thickness (inches)
6
8
10
213
In the event that the measured depth of mixing is less than the minimum specified
above, remix the base course, as directed by the Engineer, until the stabilizing material is
distributed to the required depth throughout the base course.
Where the measured depth of mixing exceeds the maximum limits specified in the
table, add 1 inch, loose measure, of stabilizing material for each 1 inch of mixing depth in excess
of the allowable depth (but in no case less than 1 inch of material, for any excess depth), and mix
the added material in the top 6 inches of the base as specified in 230-5.1 and 230-5.2, at no
expense to the Department. The Department will not include the volume of stabilizing material,
which is added to compensate for excess mixing depth, in the pay quantity, and will not allow
any additional compensation for the extra mixing required.
230-6 Compacting and Finishing Base.
Meet the requirements of 200-6.
230-7 Testing Surface.
Test the surface in accordance with the requirements of 200-7.
230-8 Priming and Maintaining.
Meet the requirements of 200-8.
230-9 Method of Measurement.
230-9.1 General: The quantities to be paid for will be the plan quantity, in square yards,
completed and accepted.
230-9.2 Quantity of Limerock: The quantity to be paid for will be as specified in 2108.2.
230-10 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including furnishing, hauling, placing, spreading, mixing, compacting, prime coat application as
specified in 300-7 and finishing all limerock stabilizing material; any necessary excavating
below the finished grade of the base to provide for placing the stabilizing material; and disposing
of all surplus excavation resulting from this work.
Where extra limerock material is placed at locations of culverts, etc., as detailed in the
Plans, the volume of such material, determined as provided above, will be included in the
quantity of limerock material to be paid for, but no adjustment will be made in the area of base to
be paid for.
Payment will be made under:
Item No. 230- 1Limerock Stabilized Base - per square yard.
Item No. 230- 2Limerock Material - per cubic yard.
214
SECTION 234
SUPERPAVE ASPHALT BASE
234-1 Description.
Construct a Superpave Asphalt Concrete base course as defined in these Specifications.
Base course mixes are designated as B-12.5. The Contractor may use a Type SP-12.5 mixture,
(Traffic Level B or C) in lieu of a Type B-12.5.
234-2 Materials.
234-2.1 General: Use materials that conform to the requirements of Division III.
Specific references are as follows:
Superpave PG Asphalt Binder or
Recycling Agent ............................................... 916-1, 916-2
Coarse Aggregate, Stone, Slag or
Crushed Gravel .................................................. Section 901
Fine Aggregate ................................................... Section 902
234-2.2 Reclaimed Asphalt Pavement (RAP): RAP may be used as a component
material of the asphalt mixture provided the requirements of 334-2.3 are met.
234-3 General Composition of Mixture.
234-3.1 General: Compose the asphalt mixture using a combination of aggregate
(coarse, fine or mixtures thereof), mineral filler if required, and asphalt binder material. Size,
grade and combine the aggregate fractions to meet the grading and physical properties of the mix
design. Aggregates from various sources may be combined.
234-3.2 Mix Design: Unless otherwise specified, design the mix such that all
requirements for a Type SP-12.5, Traffic Level B or C mixture as specified in Section 334 are
met.
234-3.2.1 Gradation Classification: Use a fine mix as defined in 334-3.2.2.1.
234-3.2.2 Aggregate Consensus Properties: Meet the aggregate consensus
properties at design as specified in 334-3.2.3. Meet the criteria specified for a depth of top of
pavement layer from surface of greater than 4 inches.
234-3.2.3 Mix Design Revisions: Meet the requirements of 334-3.3.
234-4 Contractors Process Control.
Meet the requirements of 320-2, 330-2 and 334-4.
234-5 Acceptance of the Mixture.
The mixture will be accepted in accordance with the requirements of 334-5. Use the
permissible variations from longitudinal and transverse grades as specified in 200-7.
234-6 Plant, Methods and Equipment.
Meet requirements of Section 320, with the following modifications:
234-6.1 Paving Equipment: A motor grader may be used to spread the first course of
multiple course bases when the subgrade will not support the use of a mechanical spreader. The
Engineer will not require mechanical spreading and finishing equipment for the construction of
base widening strips less than 6 feet in width.
234-6.2 Compaction Equipment: In areas where standard rollers cannot be
accommodated, vibratory rollers supplemented with trucks, motor graders, or other compaction
equipment approved by the Engineer may be used.
215
234-7 Construction Requirements.
234-7.1 General: Meet the General Construction Requirements of Section 330, with the
following modifications:
234-7.1.1 Temperature Limitations: Spread the mixture only when the air
temperature is at least 40F. Do not place the material on frozen subgrade.
234-7.1.2 Tack Coat: Unless otherwise authorized by the Engineer, apply a tack
coat between successive layers of base material.
234-7.1.3 Thickness of Layers: Construct each course in layers not to exceed
3 inches compacted thickness.
234-8 Thickness Requirements.
234-8.1 General: The total thickness of the Type B asphalt layers will be the plan
thickness as shown in the Contract Documents. Before paving, propose a thickness for each
individual layer meeting the requirements of this specification, which when combined with other
layers (as applicable) will equal the plan thickness. For construction purposes, the plan thickness
and individual layer thickness will be converted to spread rate based on the maximum specific
gravity of the asphalt mix being used, as well as the minimum density level, as shown in the
following equation:
Spread rate (lbs. per square yard) = t x G mm x 43.3
Where: t = Thickness (in.) (Plan thickness or individual layer thickness)
G mm = Maximum specific gravity from the verified mix design
The weight of the mixture shall be determined as provided in 320-3.2. For target
purposes only, spread rate calculations should be rounded to the nearest whole number.
234-8.2 Spread Rate Tolerance: Control the average spread rate on a daily basis to
within plus or minus 5% of the target spread rate for the individual layer(s) established by the
Engineer. When the average daily spread rate is outside this tolerance from the target, adjust the
spread rate to the required value established by the Engineer. The Engineer will periodically
verify the spread rate at the job site during the paving operation.
234-8.3 Allowable Deficiencies: The Engineer will allow a maximum deficiency from
the specified spread rate for the total thickness as follows:
1. For pavement of a specified thickness of 2-1/2 inches or more: 50 lbs. per
square yard.
2. For pavement of a specified thickness of less than 2-1/2 inches: 25 lbs. per
square yard.
234-8.4 Pavement Exceeding Allowable Deficiency in Spread Rate: Where the
deficiency in spread rate for the total thickness is: (1) in excess of 50 lbs. per square yard for
pavements with a specified thickness of 2-1/2 inches or more, or (2) in excess of 25 lbs. per
square yard for pavements with a specified thickness of less than 2-1/2 inches, the Engineer may
require removal and replacement at no cost or may require a correction as specified in 234-8.5.
The Engineer may require the Contractor to core the pavement for thickness in order to
determine the area of pavement with deficient thickness.
As an exception to the above, the Contractor may leave pavement outside the
main roadway in place without compensation when the Engineer allows, even though the
deficiency exceeds the tolerance as specified above.
The Department will not compensate the Contractor for any pavement removed or
for the work of removing such pavement.
234-8.5 Correcting Deficiency by Adding New Surface Material: In the event the total
thickness as determined by the spread rate is excessively deficient as defined above and if
approved by the Engineer for each particular location, correct the deficient thickness by adding
216
new surface material and compacting it using a rolling pattern as approved by the Engineer. The
Engineer will determine the area to be corrected and the thickness of new material added.
Perform all overlaying and compacting at no expense to the Department.
234-9 Method of Measurement.
The quantity to be paid for will be the plan quantity. The pay area will be adjusted based
upon the following formula:
Pay Area = Surface Area (Project Average Spread Rate/Specified Spread rate for
the Total Thickness).
Where: The project average spread rate is calculated by totaling the arithmetic
mean of the average daily spread rate values for each layer, and the specified spread rate for the
total thickness is based upon the plan thickness converted to spread rate as defined in 234-8.1.
The pay area shall not exceed 105% of the designed surface area.
Prepare a Certification of Quantities, using the Departments current approved form, for
the certified Superpave Asphalt Base pay item. Submit this certification to the Engineer no later
than Twelve Oclock noon Monday after the estimate cut-off or as directed by the Engineer,
based on the quantity of asphalt produced and accepted on the Contract. The certification must
include the Contract Number, FPID Number, Certification Number, Certification Date, period
represented by Certification, and the tons produced for each asphalt pay item.
234-10 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including the applicable requirements of Sections 320, 330 and 334. The bid price for the asphalt
mix will include the cost of the liquid asphalt binder or the asphalt recycling agent and the tack
coat application as directed in 300-8. For the calculation of unit price adjustments of bituminous
material specified in 9-2.1.1, the average asphalt binder content of the base mixes to be used in
these calculations is set at 6.25%.
Payment will be made under:
Item No. 285- 7Optional Base - per square yard.
217
SECTION 283
RECLAIMED ASPHALT PAVEMENT BASE
283-1 Description.
Construct a base course composed of reclaimed asphalt pavement (RAP) material. Use
RAP material as a base course only on non-limited access paved shoulders, shared use paths, or
other non-traffic bearing applications.
283-2 Materials.
Obtain the RAP material by either milling or crushing an existing asphalt pavement. Use
material so that at least 97% (by weight) pass a 3-1/2 inch sieve and is graded uniformly down to
dust.
When the RAP material is from a Department project and the composition of existing
pavement is known, the Engineer may approve material on the basis of the composition. When
the composition of obtained RAP is not known, the following procedure will be used for
approval:
(1) Conduct a minimum of six extraction gradation analyses of the RAP material.
Take samples at random locations in the stockpile. The average asphalt cement content of the six
stockpile samples must be 4% or greater with no individual result below 3-1/2%.
(2) Request the Engineer to make a visual inspection of the stockpile of RAP
material. Based on this visual inspection of the stockpiled material and the results of the
Contractors extraction gradation analyses, the Engineer will determine the suitability of the
materials.
(3) The Engineer may require crushing of stockpiled material to meet the
gradation criterion. Perform all crushing before the material is placed.
283-3 Spreading RAP Material.
283-3.1 Method of Spreading: Spread the RAP with a blade or device which strikes off
the material uniformly to laying thickness and produces an even distribution of the RAP. The
Contractor may also place the RAP material directly from the milling machine into the trench by
a conveyor. When placing the RAP material by conveyor directly from the milling machine,
obtain the Engineers approval of the milling process.
283-3.2 Number of Courses: When the specified compacted thickness of the base is
greater than 6 inches, construct the base in two courses. Place the first course to a thickness of
approximately one half the total thickness of the finished base, or sufficient additional thickness
to bear the weight of construction equipment without disturbing the subgrade.
Except as might be permitted by the Engineer for special cases, conduct all RAP
base construction operations for shoulders before placing the final pavement on the adjacent
traveled roadway.
283-4 Compacting and Finishing Base.
283-4.1 General: Meet the requirements of 200-6.1:
283-4.1.1 Single-Course Base: Construct as specified in 200-6.1.1.
283-4.1.2 Multiple-Course Base: Construct as specified in 200-6.1.2.
283-4.2 Moisture Content: Meet the requirements of 200-6.2.
218
283-4.3 Density Requirements: Compact the material to a density of not less than
95% of maximum density as determined by FM 1-T 180. Where the width of the base
construction is not sufficient to permit use of standard base compaction equipment, perform
compaction using vibratory compactors, trench rollers, or other special equipment which will
provide the density requirements specified herein.
283-4.4 Density Tests: Meet the requirements of 200-7 with the exception of 200-7.2.1.
Within the entire limits of the width and depth of the base, obtain a minimum density in any
LOT of 95% of the maximum density as determined by FM 1-T 180.
283-4.5 Thickness Requirements: Meets the thickness requirements of 285-6.
283-5 Testing Surface.
Test the surface in accordance with the requirements of 200--.4.
283-6 Priming and Maintaining.
283-6.1 Priming: Apply the prime coat only when the base meets the specified density
requirements and the moisture content in the top half of the base is within 2% of optimum. At the
time of priming, ensure that the base is firm, unyielding, and in such condition that no undue
distortion will occur. The Engineer will not allow priming if the surface is dry, dusty, or
sloughing.
283-6.2 Maintaining: Meet the requirements of 200-8.2.
219
SECTION 285
OPTIONAL BASE COURSE
285-1 Description.
Construct a base course composed of one of the optional materials shown on the typical
cross-sections.
285-2 Materials.
Meet the material requirements as specified in the Section covering the particular type of
base to be constructed.
Graded Aggregate .............................................. Section 204
Asphalt ............................................................... Section 234
Limerock ............................................................ Section 911
Shell Base .......................................................... Section 913
Shell-Rock .......................................................Section 913A
Cemented Coquina ............................................. Section 915
285-3 Selection of Base Option.
The Plans will include typical cross-sections indicating the various types of base
construction (material and thickness) allowable.
Select one base option as allowed for each typical cross-section shown in the Plans. Only
one base option is permitted for each typical cross-section.
Notify the Engineer in writing of the base option selected for each typical cross-section at
least 45 calendar days prior to beginning placement of base material.
285-4 Construction Requirements.
Construct the base in accordance with the Section covering the particular type of base to
be constructed.
Limerock ............................................................ Section 200
Shell Base .......................................................... Section 200
Shell Rock .......................................................... Section 200
Cemented Coquina ............................................. Section 200
Graded Aggregate .............................................. Section 204
Asphalt ............................................................... Section 234
285-5 Variation in Earthwork Quantities.
The Plans will identify the optional materials used by the Department for determining the
earthwork quantities (Roadway Excavation, Borrow Excavation, Subsoil Excavation, Subsoil
Earthwork, or Embankment). The Department will not revise the quantities, for those items
having final pay based on plan quantity, to reflect any volumetric change caused by the
Contractors selection of a different optional material.
285-6 Thickness Requirements.
285-6.1 Measurements: For non-asphalt bases, meet the requirements of 200-7.3.1.2.
For subbases, meet the thickness requirements of 290-4.
220
The Engineer will determine the thickness of asphalt base courses in accordance
with 234-8.1.
285-6.2 Correction of Deficient Areas: For non-asphalt bases, correct all areas of the
completed base having a deficiency in thickness in excess of 1/2 inch by scarifying and adding
additional base material. As an exception, if authorized by the Engineer, such areas may be left
in place without correction and with no payment.
For asphalt bases, correct all areas of deficient thickness in accordance with 2348.
285-7 Calculation of Average Thickness of Base.
For bases that are not mixed in place, the Engineer will determine the average thickness
from the measurements specified in 285-6.1, calculated as follows;
(a) When the measured thickness is more than 1/2 inch greater than the design
thickness shown on the typical cross-section in the Plans, it will be considered as the design
thickness plus 1/2 inch.
(b) Average thickness will be calculated per typical cross-section for the entire
job as a unit.
(c) Any areas of base left in place with no payment will not be included in the
calculations.
(d) Where it is not possible through borings to distinguish the base materials from
the underlying materials, the thickness of the base used in the measurement will be the design
thickness.
(e) For Superpave asphalt base course, the average spread rate of each course
shall be constructed in compliance with 234-8.
285-8 Method of Measurement.
The quantity to be paid for will be the plan quantity area in square yards, omitting any
areas where under-thickness is in excess of the allowable tolerance as specified in 285-6. The
pay area will be the surface area, determined as provided above, adjusted in accordance with the
following formula:
Pay Area = Surface Area (
Calculated Average Thickness per 285 - 7
)
Plan Thickness
The pay area shall not exceed 105% of the surface area.
There will be no adjustment of the pay area on the basis of thickness for base courses
constructed utilizing mixed-in-place operations.
For Superpave asphalt base course, the quantity to be paid for will be the plan quantity.
285-9 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including tack coat between base layers, prime coat, cover material for prime coat, bituminous
material used in bituminous plant mix, and cement used in soil-cement.
Where the Plans include a typical cross-section which requires the construction of an
asphalt base only, price adjustments for bituminous material provided for in 9-2.1.2 will apply to
that typical cross-section. For typical cross-sections which permit the use of asphalt or other
221
materials for construction of an optional base, price adjustments for bituminous material
provided for in 9-2.1.2 will not apply.
Payment will be made under:
Item No. 285- 7Optional Base - per square yard.
222
SECTION 286
TURNOUT CONSTRUCTION
286-1 Description.
Construct turnouts or extend existing turnouts on resurfacing and widening-resurfacing
projects.
The Department does not include placing of asphalt concrete surface course over turnouts
in this Section.
286-2 Materials.
For base material for turnouts, use any material currently specified by the Department for
base or surface construction, except do not use hot bituminous mixtures intended for use as
open-graded friction course. Proportion bituminous mixtures in accordance with a job-mix
formula approved by the Department.
In general, the Engineer will accept the material on the basis of visual inspection, with no
testing required.
286-3 Excavation.
Excavate the area over which turnout construction is to be accomplished to the
dimensions shown in the Plans or the Design Standards. If the surface of the underlying soil is
disturbed during the excavation operation, compact it to the approximate density of the
surrounding undisturbed soil.
If an existing paved turnout lies within the specified limits for turnout construction, leave
the existing base and surface in place, as directed by the Engineer.
286-4 Spreading, Compacting, and Finishing Base.
Uniformly spread base material over the prepared area to a depth which will, upon
completion of compaction and finishing, result in turnout base conforming with the specified
lines and elevations. Then, strike off the base material to a plane paralleling the finished surface,
and compact it in a manner similar to that used in the construction of roadway base. The
Engineer will not require any specific density.
Finish the surface to the specified grade and cross-section.
286-5 Method of Measurement.
The quantity to be paid for will be the plan quantity area, in square yards, except, when
turnout construction is specified to be paid for by weight of mixture, the weight will be measured
as specified in 320-2.
286-6 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including excavating; compacting excavated areas; furnishing material; placing, compacting, and
finishing of base; and incidental work.
The cost of any bituminous material used in hot bituminous mix, or for prime coat or tack
coat between base layers, will not be paid for separately.
Payment will be made under:
Item No. 286- 1Turnout Construction - per square yard.
223
Item No. 286- 2-
Turnout Construction (Asphalt) - per ton.
224
SECTION 287
ASPHALT TREATED PERMEABLE BASE
287-1 Description.
Construct Asphalt Treated Permeable Base (ATPB) and Outlet Pipe for use under
concrete pavement, in accordance with the details shown in the Plans and the Design Standards,
Index No. 287. Meet the plant and equipment requirements of Section 320 and the general
construction requirements of Section 330, except as noted below.
287-2 Materials.
Meet the following requirements:
Coarse Aggregate, Stone, Slag, or Crushed Gravel
Grade No. 57 or 67................................. Section 901
Superpave PG Asphalt Binder (PG 67-22) (1) ............ 916-1
Hydrated Lime (2)......................... AASHTO M-303 Type 1
Polyvinyl-Chloride Pipe (3) ............................... Section 948
Polyethylene Pipe (3) ......................................... Section 948
Geotextile Fabric................................................ Section 985
(1) Use PG 67-22 in the ATPB containing 0.75% heat-stable anti-strip additive
(by weight of asphalt) from an approved source. Introduce and mix the anti-strip additive at the
terminal.
(2) For mixtures containing granite, add hydrated lime at a dosage rate of 1.0% by
weight of the total dry aggregate in lieu of adding 0.75% anti-strip additive. Provide certified test
results for each shipment of hydrated lime indicating compliance with the specifications. In
addition, meet the requirements of 337-9.2 and 337-9.3.
(3) Use either Polyvinyl-Chloride Pipe or Polyethylene Pipe, unless otherwise
specified in the Contract Documents.
287-3 Composition of Mixture.
287-3.1 General: Use ATPB composed of a combination of coarse aggregate and asphalt
cement. Use a mix design verified by the Engineer.
287-3.2 Mix Design: Submit a proposed mix design along with representative samples of
all component materials to the Engineer, at least two weeks before the scheduled start of
production. Establish the design asphalt content within the range of 2.0 - 4.0%, by weight of total
mixture. During the mix design process, the Engineer may adjust the asphalt content within the
2.0 - 4.0% range. The Engineer may increase or decrease the specified asphalt content during
production of the mix after testing and visual inspection. Ensure that a minimum of 95% of the
aggregate is coated. There will be no separate payment for the bituminous material in the mix.
Establish the mix temperature within the range of 230F to 250F, or as approved by the
Engineer.
287-4 Control of Quality.
Provide the necessary control of the ATPB and construction in accordance with the
applicable provisions of 320-2 and 330-2.
225
287-5 Acceptance of the Mixture at the Plant.
The ATPB mixture will be accepted at the plant with respect to 334-5.1 with the
following exceptions:
1. The mixture will be accepted with respect to gradation (P -1/2 if #57 stone is
used and P -3/8 if #67 stone is used) and asphalt binder content (P b ) only.
2. Testing in accordance with AASHTO TP4-00 and FM 1 T-209 (and
conditioning of the mix prior to testing) will not be required as part of 334-5.1.1.1.
3. The standard LOT size will be, 2,000 tons, with each LOT subdivided into four
equal sublots of 500 tons each.
4. Initial production requirements of 334-5.1.3 do not apply.
5. The Between-Laboratory Precision Values described in Table 334-6 are
modified to include (P -1/2 and P -3/8 ) with a maximum difference per FM 1 T-030 (Figure 2).
6. Table 334-5 (Master Production Range) is replaced by Table 287-1.
Table 287-1
ATPB Master Production Range
Characteristic
Asphalt Binder Content (%)
Passing 1/2 inch Sieve (%) if using
#57 stone
Passing 3/8 inch Sieve (%) if using
#67 stone
Tolerance (1)
Target 0.60
Target 12.00
Target 12.00
(1) Tolerances for sample size of n = 1 from the verified mix design
287-5.1 Individual Test Tolerances for ATPB Production: In the event that an
individual Quality Control test result of a sublot for gradation (P -1/2 if #57 stone is used and P -3/8
if #67 stone is used), or asphalt binder content does not meet the requirements of Table 287-1,
take steps to correct the situation and actions taken shall be reported to the Engineer.
In the event that two consecutive individual Quality Control test results for
gradation (P -1/2 if #57 stone is used and P -3/8 if #67 stone is used) or asphalt binder content do
not meet the requirements of Table 287-1, the LOT will be automatically terminated and
production of the mixture stopped until the problem is adequately resolved (to the satisfaction of
the Engineer), unless it can be demonstrated to the satisfaction of the Engineer that the problem
can immediately be (or already has been) resolved. Evaluate any material represented by the
failing test result in accordance with 334-5.1.9.
287-6 Acceptance of the Mixture at the Roadway.
Acceptance of the Contractors methods of placement and compaction will be based upon
the completion of a 500 foot test section, (initially and at other times as determined by the
Engineer), acceptable to the Engineer, prior to further placement. In the event that the
placement/compaction method deviates from the approved method, cease placement of the mix
until the problem is adequately resolved to the satisfaction of the Engineer.
226
287-7 Temperature and Storage Limitations.
Place the ATPB material when the atmospheric temperature is above 50F and rising. Do
not use ATPB material that was mixed more than two hours prior to placement.
287-8 Construction Requirements.
287-8.1 Placement: Ensure that the structural course on which ATPB is to be placed
conforms to the compaction and elevation tolerances specified in the Contract Documents and is
free of loose or extraneous material. Fill any area of the structural course which is lower than the
grade established by the Plans with structural course material, at no additional cost to the
Department.
Place and compact ATPB in one lift, with a compacted thickness of 4 plus or
minus 0.5 inches (except the trench which includes the subdrainage pipe), in accordance with
these Specifications, lines, grades, dimensions and notes as shown in the Plans.
Place and compact ATPB material around the subdrainage pipe for the full width
of the trench, in layers not exceeding 8 inches (loose measure). Do not displace or damage the
subdrainage pipe or filter fabric.
Remove and replace all ATPB material which is greater than 1/2 inch below the
grade shown in the Plans or, in the opinion of the Engineer, is damaged or contaminated, at no
additional cost to the Department.
287-8.2 Compaction: Compact the ATPB by one of the following methods:
1. A steel-wheeled, tandem roller which will produce an operating weight of not
more than 140 PLI of drum width.
2. A steel-wheeled tandem roller weighing from 8 to 12 tons.
Compact the ATPB material (in the static mode only) as approved by the
Engineer. Begin compaction as soon as the surface temperature has cooled to 190F, or as
approved by the Engineer and complete compaction before the surface temperature has cooled to
100F. If necessary, cool the ATPB material with water.
287-8.3 Surface Requirements: Ensure that the finished surface of the ATPB does not
vary more than plus or minus1/2 inch from the grade shown in the Plans.
The Engineer may approve removal of high spots to within specified tolerance by
a method which does not produce contaminating fines. Remove and replace ATPB material that
is outside the established tolerance, at no additional cost to the Department. Neither grinding nor
milling will be permitted.
287-9 Subdrainage Pipe and Geotextile Material.
Place the subdrainage pipe and geotextile material (filter fabric) in accordance with the
Plans and Design Standards, Index No. 287.
287-10 Outlet Pipe.
Install outlet fittings and pipes concurrent with subdrainage pipe to provide positive
gravity drainage and eliminate soil intrusion. The Engineer will restrict installation of additional
sections of ATPB, until appropriate outlets are installed.
Ensure that all fittings and materials are designed and installed to eliminate soil intrusion
into the system.
227
Connect the open end of the outlet pipe into either an existing drainage structure, existing
ditch pavement or terminate with a concrete apron.
Do not block the drainage system at any time. Ensure that at the time of inspection and
project acceptance, all outlet pipes and concrete aprons are clear of earth material, vegetation,
and other debris.
287-11 Compensation.
Meet the requirements of 334-8 with the following exceptions:
1. Pay factors will be calculated for asphalt binder content and the percentages
passing the 1/2 inch and the 3/8 inch sieves only.
2. Table 287-2 replaces Table 334-6.
3. Table 287-3 replaces Table 334-7.
4. The Composite Pay Factor in 334-8.3 is replaced with the following:
CPF = [(0.25 x PF 1/2 inch or 3/8 inch) + (0.75 x PF AC)]
Note: Use the PF for the 1/2 inch sieve if #57 stone is used in the mixture
or use the PF for the 3/8 inch sieve if #67 stone is used in the mixture.
Pay Factor
1.00
0.90
0.80
1.00
0.90
0.80
1.00
0.90
0.80
Table 287-2
Small Quantity Pay Table for ATPB
1-Test Deviation
2-Test Average Deviation
Asphalt Binder Content (%)
0.00-0.50
0.00-0.35
0.51-0.60
0.36-0.42
>0.60
>0.42
1/2 inch Sieve (%) if using #57 stone
0.00-11.00
0.00-7.78
11.01-12.00
7.79-8.49
>12.00
>8.49
3/8 inch Sieve (%) if using #67 stone
0.00- 11.00
0.00- 7.78
11.01-12.00
7.79-8.49
>12.00
>8.49
Table 287-3
Specification Limits for ATPB
Quality Characteristic
Specification Limits
Asphalt Binder Content (%)
Target 0.45
Passing 1/2 inch sieve (%) if using
Target 10.00
#57 stone
Passing 3/8 inch sieve (%) if using
Target 10.00
#67 stone
228
287-12 Low Quality Material.
Meet the requirements of 334-5.1.9. For ATPB, use the Master Production Range defined
in Table 287-1 in lieu of Table 334-5.
287-13 Method of Measurement.
287-13.1 Asphalt Treated Permeable Base: The quantity of ATPB to be paid for will
be the plan quantity, in cubic yards, completed and accepted, subject to 9-3.2. No allowance will
be made for ATPB placed outside plan dimensions, unless otherwise ordered by the Engineer.
287-13.2 Outlet Pipe: The quantity of outlet pipe to be paid for will be the length, in
feet, measured in place along the centerline and gradient of the pipe, completed and accepted.
287-14 Basis of Payment.
287-14.1 Asphalt Permeable Base: Price and payment will be full compensation for
work specified in this Section, including furnishing all labor, materials (including the ATPB
material, geotextile, and subdrainage pipe), tools, equipment, and incidentals, necessary to
complete the work.
287-14.2 Outlet Pipe: Price and payment will be full compensation for work specified in
this Section, including removal of existing shoulder pavement, trench excavation, pipe and
fittings, standard aprons, galvanized hardware cloth (rodent screens), grouting around and
stubbing into existing or proposed drainage structures or ditch pavement; restoration of ditch
pavement, sod and other areas disturbed by the Contractor, backfill in place, disposal of excess
materials and incidentals, necessary to complete the work.
287-14.3 Payment Items: Payment will be made under:
Item No. 287- 1Asphalt Treated Permeable Base - per cubic yard.
Item No. 446- 71-1 Edgedrain Outlet Pipe - per foot.
229
SECTION 288
CEMENT TREATED PERMEABLE BASE
288-1 Description.
288-1.1 General: Construct Cement Treated Permeable Base and Outlet Pipe as shown
in the Plans and Design Standards, Index No. 287. Use any one of the types of pipe listed in 2882, unless a particular type is specifically required by the Contract Documents. Use only
perforated pipe, and do not use open joints.
288-1.2 Concrete Plant and Cement Concrete pavement: Meet the requirements of
Section 346 for plant and equipment, and Section 350 for general construction requirements.
Work will be accepted in accordance with the applicable provisions in
Section 350.
288-2 Materials.
Meet the following requirements:
Coarse Aggregate ............................................... Section 901
Portland Cement................................................. Section 921
Water .................................................................. Section 923
Polyvinyl-Chloride Pipe .................................... Section 948
Polyethylene Pipe .............................................. Section 948
Geotextile Fabric................................................ Section 985
For Cement Treated Permeable Base, the concrete requirements of Section 346
are modified as follows:
Use Type I or II portland cement (no fly ash or other pozzolans permitted).
Composition:
Grade of coarse aggregate (stone) ..................... # 57 or # 67
Maximum Water/Cement ratio* .....................................0.40
Minimum cement factor** ......................................... 9 lb/ft3
Maximum Slump Range ............................... Not Applicable
Fine Aggregate .............................................................. None
Admixtures .................................................................... None
*The Engineer will approve the Water/Cement ratio.
**2 lbs/ft3
Do not use materials which contain hardened lumps, crusts, or frozen matter, or are
contaminated with dissimilar material.
288-3 Control of Quality.
288-3.1 General: Meet the provisions of this Section and Chapter 9.2 of the Materials
Manual - Concrete Production Facilities Guidelines, which may be view at the following URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/files/section92.pdf .
288-3.2 Concrete Design Mix: Submit the proposed design mix prior to production, on
the Concrete Mix Design form, for the Engineers approval. Use only Cement Treated
Permeable Base design mixes having prior approval of the Engineer.
Furnish sufficient material of each component when requested by the Engineer,
for verification of the proposed mix design by the State Materials Office. Verify the unit weight
230
requirements as determined in accordance with FM 5-530. Also, provide one of the following
with the design mix submittal:
(1) Evidence from three sets of production data, either from Department
acceptance tests or independently verifiable commercial mixes, that Cement Treated Permeable
Base produced in accordance with the proposed design mix meets the requirements of this
Section.
(2) Test data from a single trial batch of a 1 yd3 minimum is required,
which demonstrates that the Cement Treated Permeable Base produced using the proposed mix,
designated ingredients, and designated water-cement ratio meets the requirements of this
Section.
288-3.3 Batch Adjustment - Materials: Meet the theoretical yield requirements of the
approved mix design. Inform the Engineer of any adjustments to the approved mix design. Note
any batch adjustments and record the actual quantities incorporated into the mix, on the concrete
Delivery Ticket/Certification form.
288-3.4 Delivery Certification: Furnish to the Engineer a complete Delivery
Ticket/Certification form with each batch of Cement Treated Permeable Base prior to unloading
at the site.
288-4 Acceptance of Placement.
Acceptance of the Contractors method of placement and compaction will be based upon
the completion of a 500 foot test section, acceptable to the Engineer, prior to further placement.
For the purpose of acceptance and partial payment, each days production will be divided
into LOTs as specified in Section 346 and in accordance with the applicable requirements of
Sections 5, 6, and 9.
288-5 Temperature Requirements.
Place Cement Treated Permeable Base only when the atmospheric temperature is above
40F and rising.
288-6 Construction Requirements.
288-6.1 Placement: Ensure that the structural course on which Cement Treated
Permeable Base is to be placed conforms to the compaction and elevation tolerances specified in
the Plans and is free of loose or extraneous material. Fill any area of the structural course which
is lower than the grade established by the Plans with structural course material, at no additional
cost to the Department.
Place and compact Cement Treated Permeable Base in one course (except the
trench which includes the subdrainage pipe), in accordance with these Specifications, lines,
grades, dimensions and notes as shown in the Plans. Placement may be accomplished by either
the fixed-form or the slip-form method.
Place and compact Cement Treated Permeable Base material around the
subdrainage pipe for the full width of the trench, in layers not exceeding 8 inches (loose
measure). Do not displace or damage the subdrainage pipe or filter fabric.
Remove and replace all Cement Treated Permeable Base material which is greater
than 1/2 inch below the grade shown in the Plans or is not covered with the next layer of material
231
within five calendar days after initial placement or in the opinion of the Engineer is damaged or
contaminated, at no additional cost to the Department.
288-6.2 Compaction: Compact the Cement Treated Permeable Base by one of the
following methods.
1. One complete coverages with a steel-wheeled, two-axle tandem roller weighing
between 4 and 10 tons in static mode.
2. By vibratory plates or screeds.
There will be no density requirements for Cement Treated Permeable Base.
288-6.3 Curing: Sprinkle the Cement Treated Permeable Base surface with a fine spray
of water every two hours for a period of eight hours or cover with polyethylene sheets for three
or four calendar days.
Begin the curing process the morning after placement of the base.
288-6.4 Surface Requirements: Ensure that the finished surface of the Cement Treated
Permeable Base does not vary more than 1/2 inch from the grade shown in the Plans.
The Engineer may approve removal of high spots to within the specified tolerance
by a method which does not produce contaminating fines. Remove and replace Cement Treated
Permeable Base material that is above tolerance, at no additional cost to the Department. Neither
grinding nor milling will be permitted.
288-7 Sampling and Testing.
The Engineer will take random samples of the Cement Treated Permeable Base at the
point of placement in accordance with FM 5-530 to determine the unit weight. Cement Treated
Permeable Base not within 3 lbs/ft3of the unit weight of the approved mix design will be
rejected.
Remove and replace all rejected Cement Treated Permeable Base at no cost to the
Department.
288-8 Subdrainage Pipe and Geotextile Material.
Place the subdrainage pipe and geotextile material (filter fabric) in accordance with the
Plans and Design Standards, Index No 287.
288-9 Outlet Pipe.
Install outlet fittings and pipes concurrent with subdrainage pipe to provide positive
gravity drainage and eliminate soil intrusion. The Engineer will restrict installation of additional
sections of Cement Treated Permeable Base, until appropriate outlets are installed.
Ensure that all fittings and materials are designed and installed to eliminate soil intrusion
into the system.
Connect the open end of the outlet pipe into either an existing drainage structure, existing
ditch pavement or terminate with a concrete apron.
Do not block the drainage system at any time. Ensure that at the time of inspection and
project acceptance, all outlet pipes and concrete aprons are clear of earth material, vegetation,
and other debris.
232
288-10 Method of Measurement.
288-10.1 Cement Treated Permeable Base: The quantity of cement treated permeable
base to be paid for will be the plan quantity, in cubic yards, completed and accepted, subject to
9-3.2.
288-10.2 Outlet Pipe: The quantity of outlet pipe to be paid for will be the length, in
feet, completed and accepted, measured in place along the centerline and gradient of the outlet
pipe.
288-11 Basis of Payment.
288-11.1 Cement Treated Permeable Base: Price and payment will be full
compensation for work specified in this Section, including furnishing all labor, materials
(including the cement treated permeable base material, geotextile, and subdrainage pipe), tools,
equipment, and incidentals, necessary to complete the work.
288-11.2 Outlet Pipe: Price and payment will be full compensation for work specified in
this Section, including removal of existing shoulder pavement, trench excavation, pipe and
fittings, standard aprons, galvanized hardware cloth (rodent screens), grouting around and
stubbing into existing or proposed inlets and drainage structures or paved ditches; restoration of
ditch pavement and other areas disturbed by the Contractor, backfill in place, and disposal of
excess materials and incidentals, necessary to complete the work.
Payment will be made under:
Item No. 288- 1Cement Treated Permeable Base - per cubic yard.
Item No. 446- 71-1- Edgedrain Outlet Pipe - per foot.
233
SECTION 290
GRANULAR SUBBASE
290-1 Description.
Construct a granular subbase as a component of an optional base.
290-2 Materials.
Select one of the materials listed below and conform to the following requirements:
Graded Aggregate ........................................................ 204-2
Limerock ............................................................ Section 911
Bank Run Shell .................................................. Section 913
Shell Rock ........................................................Section 913A
Cemented Coquina ............................................. Section 915
290-3 Construction Methods.
For the subbase material selected, construct the subbase in conformance with the
following:
Limerock ............................................................ Section 200
Bank Run Shell .................................................. Section 200
Shell Rock .......................................................... Section 200
Cemented Coquina ............................................. Section 200
Graded Aggregate .............................................. Section 204
Straightedge and hard-planing provisions will not apply. Compact the subbase to a
minimum of 98% of the maximum density as determined under AASHTO FM 1 T-180,
Method D. Priming is not required.
When Granular Subbase is substituted for Subgrade on shoulders, achieve a minimum of
95% density of the maximum density as determined under AASHTO FM 1 T-180, Method D.
290-4 Thickness Requirements.
290-4.1 General: Do not substitute granular subbase materials in excess of the tolerance
specified for the asphalt portion of the optional base.
290-4.2 Measurements: When the Department is ready to measure the finished subbase,
provide the coring equipment and the operator and include this in the unit price for optional base.
The Engineer will select the coring locations and make the acceptance measurements. Thickness
measurements will be taken through 3 inch diameter holes. For subbase areas greater than
1,000 yd2, the minimum frequency of measurement will be one per 200 feet of roadway. For
smaller subbase areas, the minimum frequency of measurement will be one per 500 yd2 of
subbase.
290-4.3 Maximum Allowable Thickness: The maximum allowable thickness of the
subbase is 4 1/4 inches. Remove and replace areas of subbase exceeding the maximum allowable
thickness.
290-4.4 Minimum Allowable Thickness: The minimum allowable thickness of the
subbase is 3 1/2 inches. Remove and replace areas not meeting the minimum allowable
thickness. If authorized by the Engineer, additional asphalt may be substituted to achieve the full
combined optional base thickness.
234
BITUMINOUS TREATMENTS, SURFACE COURSES AND CONCRETE
PAVEMENT
SECTION 300
PRIME AND TACK COATS
300-1 Description.
Apply bituminous prime coats on previously prepared bases, and apply bituminous tack
coats on previously prepared bases and on existing pavement surfaces.
300-2 Materials.
300-2.1 Prime Coat: For prime coat, use Cut-back Asphalt Grade RC-70 or RC-250
meeting the requirements of 916-2; Emulsified Asphalt Grades SS-1 or CSS-1, SS-1H, or CSS1H diluted in equal proportion with water; Emulsified Asphalt Grade AE-60, AE-90, AE-150, or
AE-200 diluted at the ratio of six parts emulsified asphalt to four parts water; Special MSEmulsion diluted at the ratio of six parts emulsified asphalt to four parts water; Asphalt
Emulsion Prime (AEP), Emulsion Prime (RS Type), EPR-1 Prime, or NTSS-1hm meeting the
requirements of 916-3, or other types and grades of bituminous material which may be specified
in the Contract Documents.
Where the above materials for use as a prime coat are to be diluted, certify that
the dilution was done in accordance with this Section for each load of material used.
The Contractor may select any of the specified bituminous materials unless the
Contract Documents indicate the use of a specific material. The Engineer may allow types and
grades of bituminous material other than those specified above if the Contractor can show that
the alternate material will properly perform the function of prime coat material.
300-2.2 Cover Material for Prime Coat: Uniformly cover the primed base by a light
application of cover material. However, if using EPR-1 prime material, the Engineer may waive
the cover material requirement if the primed base is not exposed to general traffic and
construction traffic does not mar the prime coat so as to expose the base. The Contractor may use
either sand or screenings for the cover material. For the sand, meet the requirements as specified
in 902-2 or 902-6, and for the screenings, meet the requirements as specified in 902-5. If
exposing the primed base course to general traffic, apply a cover material that has been coated
with 2 to 4% asphalt cement. Apply the asphalt coated material at approximately 10 lb/yd2. Roll
the entire surface of asphalt coated prime material with a traffic roller as required to produce a
reasonably dense mat.
300-2.3 Tack Coat: Unless the Contract Documents call for a specific type or grade of
tack coat, use PG 52-28 meeting the requirements of 916-1, heated to a temperature of
250 to 300F or undiluted Emulsified Asphalt Grades RS-1h, RS-2, CRS-1h, or NTSS-1hm
meeting the requirements of 916-3. Heat RS-1h, RS-2, CRS-1h, and NTSS-1hm to a temperature
of 150 to 180F. The Contractor may use RS-1h modified to include up to 3% naphtha to
improve handling of the material during the winter months of December, January and February
or at any other time, as approved by the Engineer.
For night paving, use PG 52-28 tack coat. The Engineer may approve RS-1h,
RS-2, CRS-1h, or NTSS-1hm for night paving if the Contractor demonstrates, at the time of use,
that the emulsion will break and not affect the progress of the paving operation.
235
300-3 Equipment.
300-3.1 Pressure Distributor: Provide a pressure distributor that is equipped with
pneumatic tires having a sufficient width of rubber in contact with the road surface to avoid
breaking the bond or forming a rut in the surface. Ensure that the distance between the centers of
openings of the outside nozzles of the spray bar is equal to the width of the application required,
within an allowable variation of 2 inches. Ensure that the outside nozzle at each end of the spray
bar has an area of opening not less than 25% or more than 75% in excess of the other nozzles.
Ensure that all other nozzles have uniform openings. When the application covers less than the
full width, the Contractor may allow the normal opening of the end nozzle at the junction line to
remain the same as those of the interior nozzles.
300-3.2 Sampling Device: Equip all pressure distributors and transport tanks with an
approved spigot-type sampling device.
300-3.3 Temperature Sensing Device: Equip all pressure distributors and transport
tanks with an approved dial type thermometer.
Use a thermometer with a temperature range from 50 to 500F with maximum
25F increments with a minimum dial diameter of 2 inches.
Locate the thermometer near the midpoint in length and within the middle third of
the height of the tank, or as specified by the manufacturer (if in a safe and easily accessible
location). Enclose the thermometer in a well with a protective window or by other means as
necessary to keep the instrument clean and in the proper working condition.
300-4 Contractors Quality Control.
Provide the necessary quality control of the prime and tack coats and application in
accordance with the Contract requirements. Provide in the Quality Control Plan, procedures for
monitoring and controlling of rate of application. If the rate of application varies by more than
5% from the rate set by the Engineer or varies beyond the range established in 300-7or 300-8,
immediately make all corrections necessary to bring the spread rate into the acceptable range.
The Engineer may take additional measurements at any time. The Engineer will randomly check
the Contractors measurement to verify the spread rate.
300-5 Cleaning Base and Protection of Adjacent Work.
Before applying any bituminous material, remove all loose material, dust, dirt, caked clay
and other foreign material which might prevent proper bond with the existing surface for the full
width of the application. Take particular care in cleaning the outer edges of the strip to be
treated, to ensure that the prime or tack coat will adhere.
When applying the prime or tack coat adjacent to curb and gutter, valley gutter, or any
other concrete surfaces, cover such concrete surfaces, except where they are to be covered with a
bituminous wearing course, with heavy paper or otherwise protect them as approved by the
Engineer, while applying the prime or tack coat. Remove any bituminous material deposited on
such concrete surfaces.
300-6 Weather Limitations.
Do not apply prime and tack coats when the air temperature in the shade and away from
artificial heat is less than 40F at the location where the application is to be made or when
weather conditions or the surface conditions are otherwise unfavorable.
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300-7 Application of Prime Coat.
300-7.1 General: Clean the surface to be primed and ensure that the moisture content of
the base does not exceed the optimum moisture. Ensure that the temperature of the prime
material is between 100 and 150F. The Engineer will designate the actual temperature to ensure
uniform distribution. Apply the material with a pressure distributor. Determine the application
amount based on the character of the surface. Use an amount sufficient to coat the surface
thoroughly and uniformly with no excess.
300-7.2 Rate of Application:
300-7.2.1 Limerock, Limerock Stabilized, and Local Rock Bases: For these
bases, use a rate of application that is not less than 0.10 gal/yd2, unless a lower rate is directed by
the Engineer. Determine the application rate at the beginning of each days production, and as
needed to control the operation, a minimum of twice per day.
300-7.2.2 Sand-Clay, Shell and Shell Stabilized Bases: For these bases, use a
rate of application that is not less than 0.15 gal/yd2, unless a lower rate is directed by the
Engineer. Determine the application rate at the beginning of each days production, and as
needed to control the operation, a minimum of twice per day.
300-7.3 Sprinkling: If so required by the Engineer, lightly sprinkle the base with water
and roll it with a traffic roller in advance of the application of the prime coat.
300-7.4 Partial Width of Application: If traffic conditions warrant, the Engineer may
require that the application be made on only 1/2 the width of the base at one time, in which case
use positive means to secure the correct amount of bituminous material at the joint.
300-8 Application of Tack Coat.
300-8.1 General: Where the Engineer requires a tack coat prior to laying a bituminous
surface, apply the tack coat as specified herein below.
300-8.2 Where Required: Place a tack coat on all asphalt layers prior to constructing the
next course. In general, the Engineer will not require a tack coat on primed bases except in areas
that have become excessively dirty and cannot be cleaned, or in areas where the prime has cured
to the extent that it has lost all bonding effect.
300-8.3 Method of Application: Apply the tack coat with a pressure distributor except
that on small jobs, if approved by the Engineer, apply it by other mechanical devices or by hand
methods. Heat the bituminous material to a suitable temperature as designated by the Engineer,
and apply it in a thin, uniform layer.
300-8.4 Rate of Application: Use a rate of application as defined in Table 300-1.
Control the rate of application to be within plus or minus 0.01 gallon per square yard of the
target application rate. The target application rate may be adjusted by the Engineer to meet
specific field conditions. Determine and record the rate of application a minimum of twice per
day, once at the beginning of each days production and again as needed to control the operation.
When using RA-550, multiply the target rate of application by 0.6.
Table 300-1
Tack Coat Application Rates
Asphalt Mixture Type
Underlying Pavement Surface
Base Course, Structural Course,
Dense Graded Friction Course
Newly Constructed Asphalt Layers
Milled Surface or Oxidized and
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Target Tack Rate
(gal/yd2)
0.03 minimum
0.06
Open Graded Friction Course
Cracked Pavement
Concrete Pavement
Newly Constructed Asphalt Layers
Milled Surface
0.08
0.05
0.07
300-8.5 Curing and Time of Application: The Engineer will designate the curing
period for the tack coat. Apply the tack coat sufficiently in advance of the laying of the
bituminous mix to permit drying, but do not apply the tack coat so far in advance that it might
lose its adhesiveness as a result of being covered with dust or other foreign material.
300-8.6 Protection: Keep the tack coat surface free from traffic until the subsequent
layer of bituminous hot mix has been laid.
300-9 Method of Measurement.
300-9.1 General: The quantity specified will be the volume, in gallons of bituminous
material actually applied and accepted. This spread rate will be determined from measurements
made by the Contractor and verified by the Engineer based on tank calibrations, as specified in
300-9.2. Where it is specified that prime coat or tack coat material is to be diluted with water, the
amount specified for the spread rate will be the volume after dilution.
300-9.2 Calibration of Tanks: Ensure that all distributors used for applying tack or
prime coats are calibrated prior to use by a reliable and recognized firm engaged in calibrating
tanks. Provide a certification of calibration and the calibration chart to the Engineer prior to use.
In lieu of a volumetrically calibrated distributor, use a distributor that is equipped with a
calibrated meter and is approved by the Engineer.
300-9.3 Temperature Correction: Measure the volume and increase or decrease the
volume actually measured to a corrected volume at a temperature of 60F.
Make the correction for temperature by applying the applicable conversion factor
(K), as shown below.
For petroleum oils having a specific gravity (60F/60F) above 0.966,
K = 0.00035 per degree.
For petroleum oils having a specific gravity (60F/60F) of between 0.850 and
0.966, K = 0.00040 per degree.
For emulsified asphalt, K = 0.00025 per degree.
When volume-correction tables based on the above conversion factors are not
available, use the following formula in computing the corrections for volumetric change:
1
V=
V
K (T - 60) + 1
Where:
V= Volume of the bituminous material at 60F (pay volume).
V1= Volume of bituminous material as measured.
K= Correction factor (Coefficient of Expansion).
T= Temperature (in F), of the bituminous material when measured.
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300-10 Basis of Payment.
There is no direct payment for the work specified in this Section, it is incidental to, and is
to be included in the other items of related work.
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SECTION 320
HOT MIX ASPHALT PLANT METHODS AND EQUIPMENT
320-1 General.
This Section specifies the basic equipment and operational requirements for hot mix
asphalt (including warm mix asphalt) production facilities used in the construction of asphalt
pavements and bases. Establish and maintain a quality control system that provides assurance
that all materials and products submitted for acceptance meet Contract requirements.
320-2 Quality Control (QC) Requirements.
320-2.1 Minimum Producer QC Requirements: Perform as a minimum the following
activities:
1. Stockpiles:
a. Assure materials are placed in the correct stockpile;
b. Assure good stockpiling techniques;
c. Inspect stockpiles for separation, contamination, segregation, and other
similar items;
d. Properly identify and label each stockpile.
2. Incoming Aggregate:
a. Obtain gradations and bulk specific gravity (G sb ) values from aggregate
supplier for reference;
b. Determine the gradation of all component materials and routinely
compare gradations and G sb values to mix design.
3. Cold Bins:
a. Calibrate the cold gate/feeder belt for each material;
b. Determine cold gate/feeder belt settings;
c. Observe operation of cold feeder for uniformity;
d. Verify accuracy of all settings;
e. Verify that the correct components are being used, and that all modifiers
or additives or both are being incorporated into the mix.
4. Batch Plants:
a. Determine percent used and weight to be pulled from each bin to assure
compliance with the mix design;
b. Check mixing time;
c. Check operations of weigh bucket and scales.
5. Drum Mixer Plants:
a. Determine aggregate moisture content;
b. Calibrate the weigh bridge on the charging conveyor.
6. Control Charts: Maintain QC data and charts (updated daily) for all QC
Sampling and Testing and make available upon demand. Provide the following charts:
a. All components used to determine the composite pay factor (No. 8
sieve, No. 200 sieve, asphalt binder content, air voids, and density) by LOT;
b. Gradation of incoming aggregate;
c. Gradation, asphalt binder content and maximum specific gravity (G mm )
of RAP;
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d. Any other test result or material characteristic (as determined by the
Contractor) necessary for process control.
The above listed minimum activities are to be considered normal activities
necessary to control the production of hot mix asphalt at an acceptable quality level. Depending
on the type of process or materials, some of the activities listed may not be necessary and in
other cases, additional activities may be required. The frequency of these activities will also vary
with the process and the materials. When the process varies from the defined process average
and variability targets, the frequency of these activities will be increased until the proper
conditions have been restored.
320-2.2 Minimum Process Control Testing Requirements: Perform, as a minimum,
the following activities at the testing frequencies provided in Table 320-1. QC tests used in the
acceptance decision may be used to fulfill these requirements.
Material
Aggregate
Asphalt Mix
Asphalt Mix
Asphalt Mix
Asphalt Mix
Asphalt Mix
RAP
RAP
RAP
Table 320-1
Asphalt Plant - Materials Testing Frequencies
Property
Minimum Testing Frequency
Once per 1,000 tons of incoming
Gradation
aggregate
If daily production > 100 tons, once per
Asphalt Binder Content
day; If daily production > 1,000 tons,
twice per day. *
If daily production > 100 tons, once per
Bulk Specific Gravity (G mb )
day; If daily production > 1,000 tons,
twice per day. *
If daily production > 100 tons, once per
Gradation
day; If daily production > 1,000 tons,
twice per day. *
If daily production > 100 tons, once per
Maximum Specific Gravity (G mm )
day; If daily production > 1,000 tons,
twice per day. *
Each of first 5 loads, then once every
Temperature
5 loads thereafter, per day per mix
design.
Asphalt Binder Content
Once per 1,000 tons RAP
Gradation
Once per 1,000 tons RAP
Maximum Specific Gravity (G mm )
Once per 5,000 tons RAP
*If less than 100 tons of mix is produced on each of successive days of production, resulting in a cumulative quantity of greater
than 100 tons, then perform the indicated test.
320-2.3 Personnel Qualifications: Provide QC Technicians in accordance with
Section 105.
320-2.4 Hot Mix Asphalt Testing Laboratory Requirements: Furnish a fully equipped
asphalt laboratory at the production site. The laboratory must be qualified under the
Departments Laboratory Qualification Program, as described in Section 105. In addition, the
laboratory shall meet the following requirements:
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1. Area - The effective working area of the laboratory shall be a minimum of
180 square feet, with a layout of which will facilitate multiple tests being run simultaneously by
two technicians. This area does not include the space for desks, chairs and file cabinets. Any
variations shall be approved by the Engineer.
2. Lighting - The lighting in the lab must be adequate to illuminate all areas of the
work.
3. Temperature Control - Equip the lab with heating and air conditioning units
that provide a satisfactory working environment.
4. Ventilation - Equip the lab with exhaust fans that will remove all hazardous
fumes from within the laboratory in accordance with OSHA requirements.
5. Equipment and Supplies - Furnish the lab with the necessary sampling and
testing equipment and supplies for performing contractor QC and Department Verification
Sampling and Testing. A detailed list of equipment and supplies required for each test is included
in the appropriate FDOT, AASHTO, or ASTM Test Method. In the event testing equipment goes
out of service during production, the Contractor may elect to use replacement equipment at
another laboratory qualified, as described in Section 105, for up to 72 hours upon notification of
the Engineer.
6. Personal Computer - Provide a personal computer capable of running a
Microsoft ExcelTM spreadsheet program, along with a printer.
7. Communication - Provide a telephone and fax machine (with a private line) for
the use of the testing facilitys QC personnel. In addition, provide an internet connection capable
of uploading data to the Departments database and for e-mail communications.
320-3 Requirements for All Plants.
320-3.1 General: Design, manufacture, coordinate, and operate the asphalt plant in a
manner that will consistently produce a mixture within the required tolerances and temperatures
specified.
320-3.2 Electronic Weigh Systems: Equip the asphalt plant with an electronic weigh
system that: 1) has an automatic printout, 2) is certified every six months by an approved
certified scale technician, and 3) meets monthly comparison checks with certified truck scales as
specified in 320-3.2.4. Weigh all plant produced hot mix asphalt on the electronic weigh system,
regardless of the method of measurement for payment.
Include, as a minimum, the following information on the printed delivery ticket:
(a) Sequential load number
(b) Project number
(c) Date
(d) Name and location of plant
(e) Mix design number
(f) Place for hand-recording mix temperature
(g) Truck number
(h) Gross, tare, and net tonnage per truck (as applicable)
(i) Daily total tonnage of mix for the mix design
Print the delivery ticket with an original and at least one copy. Furnish the
original to the Engineer at the plant and one copy to the Engineer at the paving site.
Utilize any one of the following three electronic weigh systems.
320-3.2.1 Electronic Weigh System on the Truck Scales: Provide an electronic
weigh system on all truck scales, which is equipped with an automatic recordation system that is
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approved by the Engineer. Use scales of the type that directly indicate the total weight of the
loaded truck. Use scales meeting the requirements for accuracy, condition, etc., of the Bureau of
Weights and Measures of the Florida Department of Agriculture, and re-certify such fact every
six months, either by the Bureau of Weights and Measures or by a registered scale technician.
320-3.2.2 Electronic Weigh System on Hoppers Beneath a Surge or Storage
Bin: Provide an electronic weigh system on the hopper (hopper scales or load cells) beneath the
surge or storage bin, which is equipped with an automatic recordation system approved by the
Engineer.
320-3.2.3 Automatic Batch Plants with Printout: For batch plants, provide an
approved automatic printer system which will print the individual or cumulative weights of
aggregate and liquid asphalt delivered to the pugmill and the total net weight of the asphalt mix
measured by hopper scales or load cell type scales. Use the automatic printer system only in
conjunction with automatic batching and mixing control systems that have been approved by the
Engineer.
320-3.2.4 Monthly Electronic Weigh System Comparison Checks: Check the
accuracy of the electronic weighing system at the commencement of production and thereafter at
least every 30 days during production by one of the following two methods and maintain a
record of the weights in the Scale Check Worksheet.
320-3.2.4.1. Electronic Weigh System on Truck Scales:
(a) The Engineer will randomly select a loaded truck of asphalt
mix, a loaded aggregate haul truck, or another vehicle type approved by the Engineer and record
the truck number and gross weight from the Contractors delivery ticket.
(b) Weigh the selected truck on a certified truck scale, which is not
owned by the Contractor and record the gross weight for the comparison check. If another
certified truck scale is not available, the Engineer may permit another set of certified truck scales
owned by the Contractor to be used. The Engineer may elect to witness the scale check.
(c) The gross weight of the loaded truck as shown on the
Contractors delivery ticket will be compared to the gross weight of the loaded truck from the
other certified truck scale. The maximum permissible deviation is 8 pounds per ton of load,
based on the certified truck scale weight.
(d) If the distance from the asphalt plant to the nearest certified
truck scale is enough for fuel consumption to affect the accuracy of the comparison checks, a
fuel adjustment may be calculated by using the truck odometer readings for the distance
measurement, and 6.1 miles per gallon for the fuel consumption rate, and 115 ounces per gallon
for fuel weight.
(e) During production, when an additional certified truck scale is
not available for comparison checks, the Engineer may permit the Contractor to weigh the truck
on his certified scales used during production and then weigh it on another certified truck scale,
as soon the other scale is available for the comparison checks.
In addition to the periodic checks as specified above, check the
scales at any time the accuracy of the scales becomes questionable. When such inaccuracy does
not appear to be sufficient to seriously affect the weighing operations, the Engineer will allow a
period of two calendar days for the Contractor to conduct the required scale check. However, in
the event the indicated inaccuracy is sufficient to seriously affect the mixture, the Engineer may
require immediate shut-down until the accuracy of the scales has been checked and necessary
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corrections have been made. Include the cost of all scale checks in the bid price for asphalt
concrete, at no additional cost to the Department.
320-3.2.4.2. Electronic Weigh System on Hoppers Beneath a Surge or
Storage Bin and Automatic Batch Plants with Printout:
(a) The Engineer will randomly select a loaded truck of asphalt
mix and record the truck number, and the net weight of the asphalt mix from the Contractors
delivery ticket.
(b) Weigh the selected truck on a certified truck scale, which is not
owned by the Contractor and record the gross weight for the comparison check. If another
certified truck scale is not available, the Engineer may permit another set of certified truck scales
owned by the Contractor to be used. The Engineer may elect to witness the scale check.
(c) Deliver the asphalt mix to the project, then weigh the selected
empty truck on the same certified truck scales. Record the tare weight of the truck.
(d) Compare the net weight of the asphalt mix from the delivery
ticket to the calculated net weight of the asphalt mix as determined by the certified truck scale
weights. The maximum permissible deviation is 8 pounds per ton of load, based on the certified
truck scale weight.
(e) Use the fuel adjustment as specified in 320-3.2.4.1(d), when the
distance from the asphalt plant to the nearest certified truck scale is enough for fuel consumption
to affect the accuracy of the comparison checks.
(f) During production, when an additional certified truck scale is
not available for comparison checks, the Engineer may permit the Contractor to load a truck with
aggregate from the pugmill, surge or storage bin, and follow the above procedures to conduct the
comparison checks as soon as certified truck scale is available.
If the check shows a greater difference than the tolerance specified
above, then recheck on a second set of certified scales. If the check and recheck indicate that the
printed weight is out of tolerance, have a certified scale technician check the electronic weigh
system and certify the accuracy of the printer. While the system is out of tolerance and before its
adjustment, the Engineer may allow the Contractor to continue production only if provisions are
made to use a set of certified truck scales to determine the truck weights.
320-3.3 Asphalt Binder: Meet the following requirements:
320-3.3.1 Transportation: Deliver the asphalt binder to the asphalt plant at a
temperature not to exceed 370F, and equip the transport tanks with sampling and temperature
sensing devices meeting the requirements of 300-3.2.
320-3.3.2 Storage: Equip asphalt binder storage tanks to heat the liquid asphalt
binder to the temperatures required for the various mixtures. Heat the material in such a manner
that no flame comes in contact with the binder. Heat or insulate all pipe lines and fittings. Use a
circulating system of adequate size to ensure proper and continuous circulation during the entire
operating period. Locate a thermometer, reading from 200 to 400F, either in the storage tank or
in the asphalt binder feed line. Maintain the asphalt binder in storage within a range of 230 to
370F in advance of mixing operations. Locate a sampling device on the discharge piping exiting
the storage tank or at a location as approved by the Engineer.
320-3.4 Aggregate: Meet the following requirements:
320-3.4.1 Stockpiles: Place each aggregate component in an individual stockpile,
and separate each from the adjacent stockpiles, either by space or by a system of bulkheads.
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Prevent the intermingling of different materials in stockpiles at all times. Identify each stockpile,
including RAP, as shown on the mix design.
Form and maintain stockpiles in a manner that will prevent segregation. If
a stockpile is determined to be segregated, discontinue the use of the material on the project until
the appropriate actions have been taken to correct the problem.
320-3.4.2 Blending of Aggregates: Stockpile all aggregates prior to blending or
placing in the cold feed bins. If mineral filler or hydrated lime is required in the mix, feed or
weigh it in separately from the other aggregates.
320-3.4.2.1 Cold Feed Bin: Provide a separate cold feed bin for each
component of the fine and coarse aggregate required by the mix design. Equip the cold feed bins
with accurate mechanical means for feeding the aggregate uniformly into the dryer in the
proportions required for the finished mix to maintain uniform production and temperature. When
using RAP as a component material, prevent any oversized RAP from being incorporated into
the completed mixture by the use of: a grizzly or grid over the RAP bin; in-line roller or impact
crusher; screen; or other suitable means. If oversized RAP material appears in the completed
recycled mix, take the appropriate corrective action immediately. If the appropriate corrective
actions are not immediately taken, stop plant operations.
Use separate bin compartments in the cold aggregate feeder that
are constructed to prevent any spilling or leakage of aggregate from one cold feed bin to another.
Ensure that each cold feed bin compartment has the capacity and design to permit a uniform flow
of aggregates. Mount all cold feed bin compartments over a feeder of uniform speed, which will
deliver the specified proportions of the separate aggregates to the drier at all times. If necessary,
equip the cold feed bins with vibrators to ensure a uniform flow of the aggregates at all times.
320-3.4.2.2 Gates and Feeder Belts: Provide each cold feed bin
compartment with a gate and feeder belt, both of which are adjustable to assure the aggregate is
proportioned to meet the requirements of the mix design.
320-3.4.3 Screening Unit: Remove any oversized pieces of aggregate by the use
of a scalping screen. Do not return this oversized material to the stockpile for reuse unless it has
been crushed and reprocessed into sizes that will pass the scalping screen. Ensure that the
quantity of aggregates being discharged onto the screens does not exceed the capacity of the
screens to actually separate the aggregates into the required sizes.
320-3.5 Dryer: Provide a dryer of satisfactory design for heating and drying the
aggregate. Use a dryer capable of heating the aggregate to within the specified temperature range
for any mix, and equip the dryer with an electric pyrometer placed at the discharge chute to
automatically register the temperature of the heated aggregates.
320-3.6 Asphalt Binder Control Unit: Provide a satisfactory means, either by weighing,
metering, or volumetric measuring, to obtain the proper amount of asphalt binder material in the
mix, within the tolerance specified for the mix design.
320-3.7 Contractors Responsibilities: Acceptance of any automatic delivery ticket
printout, electronic weight delivery ticket, other evidence of weight of the materials or approval
of any particular type of material or production method will not constitute agreement by the
Department that such matters are in accordance with the Contract Documents and it shall be the
Contractors responsibility to ensure that the materials delivered to the project are in accordance
with the Contract Documents.
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320-4 Additional Requirements for Batch Plants.
320-4.1 Heating and Drying: Heat and dry the aggregate before screening. Control the
temperature of the aggregate so the temperature of the completed mixture at the plant falls within
the permissible range allowed by this Section.
320-4.2 Gradation Unit: Provide plant screens capable of separating the fine and coarse
aggregates and of further separating the coarse aggregate into specific sizes. In addition, equip
the gradation unit with a scalping screen to restrict the maximum size of the aggregates. In the
event that the plant is equipped with cold feed bins that are capable of adequately controlling the
gradation of the mixture, the use of plant screens is optional.
320-4.3 Hot Bins: Provide storage bins of sufficient capacity to supply the mixer when it
is operating at full capacity. Provide hot bins with divided compartments to ensure separate and
adequate storage of the appropriate fractions of the aggregate. Equip each compartment with an
overflow chute of suitable size and location to prevent any backing up of material into other bins.
320-4.4 Weigh Box or Hopper: Equip the batch plant with a means for accurately
weighing each bin size of aggregate and the mineral filler into the weigh box or hopper.
320-4.5 Pugmills: Utilize a pugmill capable of mixing the aggregate and the asphalt
binder.
320-5 Additional Requirements for Drum Mixer Plants.
320-5.1 Weight Measurements of Aggregate: Equip the plant with a weigh-in-motion
scale capable of measuring the quantity of aggregate (and RAP) entering the dryer.
320-5.2 Synchronization of Aggregate Feed and Asphalt Binder Feed: Couple the
asphalt binder feed control with the total aggregate weight device, including the RAP feed, in
such a manner as to automatically vary the asphalt binder feed rate as necessary to maintain the
required proportions.
320-5.3 Hot Storage or Surge Bins: Equip the plant with either a surge bin or storage
silo that is capable of storing an adequate amount of material to assure a uniform and consistent
product.
320-6 Preparation of the Mixture.
320-6.1 Mixing: After the aggregate is dried and properly proportioned, mix the
aggregate, along with any other components, with the asphalt binder to produce a thoroughly and
uniformly coated mixture.
320-6.2 Storage: If necessary, store the asphalt mixture in a surge bin or hot storage silo
for a maximum of 72 hours. For FC-5 mixtures, store the asphalt mixture in a surge bin or hot
storage silo for a maximum of one hour.
320-6.3 Mix Temperature: Produce the mixture with a temperature within the master
range as defined in Table 320-2.
320-6.3.1 Test Requirements: Determine the temperature of the completed
mixture using a quick-reading thermometer through a hole in the side of the loaded truck
immediately after loading. Locate a 1/4 inch hole on both sides of the truck body within the
middle third of the length of the body, and at a distance from 6 to 10 inches above the surface
supporting the mixture. If a truck body already has a hole located in the general vicinity of the
specified location, use this hole. At the Engineers discretion, the Contractor may take the
temperature of the load over the top of the truck in lieu of using the hole in the side of the truck.
320-6.3.2 Test Frequency: The normal frequency for taking asphalt mix
temperatures will be for each day, for each design mix on the first five loads and one out of every
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five loads thereafter. Take the temperature of the asphalt mix at the plant and at the roadway
before the mix is placed at the normal frequency. Record the temperature on the front of the
respective delivery ticket. The Engineer shall review the plant and roadway temperature readings
and may take additional temperature measurements at any time.
If any single load at the plant or at the roadway is within the master range
shown in Table 320-2 but does not meet the criteria shown in Table 320-3 (for single
measurements or the average of five consecutive measurements), the temperature of every load
will be monitored until the temperature falls within the specified tolerance range in Table 320-3;
at this time the normal frequency may be resumed.
320-6.3.3 Rejection Criteria: Reject any load or portion of a load of asphalt mix
at the plant or at the roadway with a temperature outside of its respective master range shown in
Table 320-2. Notify the Engineer of the rejection immediately.
Table 320-2
Mix Temperature Master Range Tolerance
Location
Acceptable Temperature Tolerance
Plant
Mixing Temperature 30 F
Roadway
Compaction Temperature 30F
Table 320-3
Mix Temperature Tolerance From Verified Mix Design
Any Single Measurement
25F
Average of Any Five Consecutive
15F
Measurements
320-7 Transportation of the Mixture.
Transport the mix in trucks of tight construction, which prevents the loss of material and
the excessive loss of heat and previously cleaned of all foreign material. After cleaning, thinly
coat the inside surface of the truck bodies with soapy water or an asphalt release agent as needed
to prevent the mixture from adhering to the beds. Do not allow excess liquid to pond in the truck
body. Do not use a release agent that will contaminate, degrade, or alter the characteristics of the
asphalt mix or is hazardous or detrimental to the environment. Petroleum derivatives (such as
diesel fuel), solvents, and any product that dissolves asphalt are prohibited. Provide each truck
with a tarpaulin or other waterproof cover mounted in such a manner that it can cover the entire
load when required. When in place, overlap the waterproof cover on all sides so that it can be
tied down. Cover each load during cool and cloudy weather and at any time it appears rain is
likely during transit with a tarpaulin or waterproof cover.
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SECTION 327
MILLING OF EXISTING ASPHALT PAVEMENT
327-1 Description.
Remove existing asphalt concrete pavement by milling to improve the rideability and
cross slope of the finished pavement, to lower the finished grade adjacent to existing curb prior
to resurfacing, or to completely remove existing pavement.
When milling to improve rideability, the Plans will specify an average depth of cut.
Take ownership of milled material.
327-2 Equipment.
Provide a milling machine capable of maintaining a depth of cut and cross slope that will
achieve the results specified in the Contract Documents. Use a machine with a minimum overall
length (out to out measurement excluding the conveyor) of 18 feet and a minimum cutting width
of 6 feet.
Equip the milling machine with a built-in automatic grade control system that can control
the transverse slope and the longitudinal profile to produce the specified results.
To start the project, the Engineer will approve any commercially manufactured milling
machine that meets the above requirements. If it becomes evident after starting milling that the
milling machine cannot consistently produce the specified results, the Engineer will reject the
milling machine for further use.
The Contractor may use a smaller milling machine when milling to lower the grade
adjacent to existing curb or other areas where it is impractical to use the above described
equipment.
Equip the milling machine with means to effectively limit the amount of dust escaping
during the removal operation.
For complete pavement removal, the Engineer may approve the use of alternate removal
and crushing equipment in lieu of the equipment specified above.
327-3 Construction.
327-3.1 General: Remove the existing raised reflective pavement markers prior to
milling. Include the cost of removing existing pavement markers in the price for milling.
When milling to improve rideability or cross slope, remove the existing pavement
to the average depth specified in the Plans, in a manner that will restore the pavement surface to
a uniform cross-section and longitudinal profile. The Engineer may require the use of a stringline
to ensure maintaining the proper alignment.
Establish the longitudinal profile of the milled surface in accordance with the
milling plans. Ensure that the final cross slope of the milled surface parallels the surface cross
slope shown in the Plans or as directed by the Engineer. Establish the cross slope of the milled
surface by a second sensing device near the outside edge of the cut or by an automatic cross
slope control mechanism. The Plans may waive the requirement of automatic grade or cross
slope controls where the situation warrants such action.
Operate the milling machine to minimize the amount of dust being emitted. The
Engineer may require prewetting of the pavement.
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Provide positive drainage of the milled surface and the adjacent pavement.
Perform this operation on the same day as milling. Repave all milled surfaces no later than the
day after the surface was milled unless otherwise stated in the Plans.
If traffic is to be maintained on the milled surface prior to the placement of the
new asphalt concrete, provide suitable transitions between areas of varying thickness to create a
smooth longitudinal riding surface. Produce a pattern of striations that will provide an acceptable
riding surface. The Engineer will control the traveling speed of the milling machine to produce a
texture that will provide an acceptable riding surface.
Prior to opening an area which has been milled to traffic, sweep the pavement
with a power broom or other approved equipment to remove, to the greatest extent practicable,
fine material which will create dust under traffic. Sweep in a manner that will minimize the
potential for creation of a traffic hazard and to minimize air pollution.
Sweep the milled surface with a power broom prior to placing asphalt concrete.
In urban and other sensitive areas, use a street sweeper or other equipment
capable of removing excess milled materials and controlling dust. Obtain the Engineers
approval of such equipment, contingent upon its demonstrated ability to do the work.
Perform the sweeping operation immediately after the milling operations or as
directed by the Engineer.
327-3.2 Quality Control Requirements: Furnish an electronic level with a length of
4 feet and an accuracy of plus or minus 0.1 degree approved by the Engineer for the control of
cross slope. Make this electronic level available at the jobsite at all times during milling
operations. Calibrate and compare electronic levels in accordance with 330-9.3.1 at a minimum
frequency of once per day before any milling operation.
Multiple cuts may be made to achieve the required pavement configuration or
depth of cut. Measure the cross slope of the milled surface by placing the level at the center
location of a lane and perpendicular to the roadway centerline. Record all the measurements to
the nearest 0.1% on an approved form and submit to the Engineer for documentation.
1. Tangent Sections: Measure the cross slope per lane at a minimum
frequency of one measurement every 100 feet. Calculate the absolute deviation of cross slope at
each measurement and then average the absolute deviation of ten consecutive cross slope
measurements. The absolute deviation is the positive value of a deviation. When the average
absolute deviation cross slope is consistently within the acceptance tolerance as shown in
Table 327-1 and upon approval by the Engineer, the frequency of the cross slope measurements
can be reduced to one measurement every 200 feet during milling operations.
2. Superelevated Sections: Measure the cross slope every 100 feet per lane
within the length of full superelevation. Calculate the absolute deviation of each measurement
and then average the absolute deviation of ten consecutive cross slope measurements. For every
transition section, measure the cross slope at control points identified in the Plans or, if not
shown in the Plans, at a control point at a location of 0.0% cross slope. For curves where the
length of the fully superelevated section is less than 250 feet, measure the cross slope at the
beginning point, midpoint and ending point of the fully superelevated section, calculate the
absolute deviation and average. When the number of measurements is less than ten and the
length of full superelevation is greater than 250 feet, average the absolute deviation of all
measurements.
If the average absolute deviation of the cross slope measurements falls outside the
acceptance tolerance shown in Table 327-1, stop the milling operations and make adjustments
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until the problem is resolved to the satisfaction of the Engineer. If an individual cross slope
deviation falls outside the acceptance tolerance as shown in Table 327-1, make corrections only
in the deficient area to the satisfaction of the Engineer at no cost to the Department. For
pavement with multiple cuts, the deficient areas not caused by the final cut may be left in place
upon approval of the Engineer. All milling corrections shall be completed before placement of
the asphalt course unless stated otherwise in the Plans or as determined by the Engineer.
The limits of deficient areas requiring correction may be verified and adjusted
with more accurate measurement methods, including survey instruments, upon approval by the
Engineer at no cost to the Department. Should the Contractor wish to have any corrections
waived, submit a request to the Engineer for approval. The Engineer may waive the corrections
at no reduction in payment if an engineering determination indicates that the deficiencies are
sufficiently separated so as not to significantly affect the final cross slope or project grade.
For intersections, tapers, crossovers, transitions at the beginning and end of the
project, bridge approaches and similar areas, adjust the cross slope to match the actual site
conditions, or as directed by the Engineer.
TABLE 327-1
Cross Slope Milling Acceptance Tolerance
Individual Absolute
Roadway Feature
Average Absolute Deviation
Deviation
Tangent section
0.4%
0.2%
(including turn lanes)
Superelevated curve
0.4%
0.2%
Shoulder
0.5%
0.5%
In the event that the distance between tow edges of deficient areas is less than
100 feet, the correction work shall include the area between the deficient sections.
327-3.3 Verification: The Engineer will verify the Contractors cross slope
measurements by randomly taking a minimum of ten cross slope measurements per lane per mile
in tangent sections, control points in transition sections, and a minimum of three cross slope
measurements on fully superelevated sections. The Engineer will measure the cross slope of the
milled surface by placing the level at the center location of a lane and perpendicular to the
roadway centerline. If the average absolute deviation or an individual cross slope deviation falls
outside the acceptance tolerance as shown in Table 327-1, immediately make a comparison
check at the QC test locations to verify the QC measurements in the questionable section. If the
comparisons are beyond the acceptable comparison tolerance in accordance with 327-3.2, stop
the milling operation until the problem is resolved to the satisfaction of the Engineer. Correct
any cross slope not meeting the individual deviation acceptance tolerance at no cost to the
Department. The Engineer reserves the right to check the cross slope of the milled surface at any
time by taking cross slope measurements at any location.
327-4 Milled Surface.
Provide a milled surface with a reasonably uniform texture, within 1/4 inch of a true
profile grade, and with no deviation in excess of 1/4 inch from a straightedge applied to the
pavement perpendicular to the centerline. Ensure that the variation of the longitudinal joint
between multiple cut areas does not exceed 1/4 inch. The Engineer may accept areas varying
250
from a true surface in excess of the above stated tolerance without correction if the Engineer
determines that they were caused by a pre-existing condition which could not have reasonably
been corrected by the milling operations. Correct any unsuitable texture or profile, as determined
by the Engineer, at no additional expense to the Department.
The Engineer may require remilling of any area where a surface lamination causes a nonuniform texture to occur.
327-5 Method of Measurement.
The quantity to be paid for will be the plan quantity area, in square yards, over which
milling is completed and accepted.
327-6 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including hauling off and stockpiling or otherwise disposing of the milled material.
Payment will be made under:
Item No. 327- 70Milling Existing Asphalt Pavement - per square yard.
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SECTION 330
HOT MIX ASPHALT GENERAL CONSTRUCTION REQUIREMENTS
330-1 Description.
This Section specifies the basic equipment and construction requirements for hot mix
asphalt (including warm mix asphalt) pavements and bases. Establish and maintain a quality
control system that provides assurance that all materials, products and completed construction
submitted for acceptance meet Contract requirements.
330-2 Quality Control (QC) Requirements.
330-2.1 Minimum QC Requirements: In addition to the requirements set forth in
Section 105, describe in the Quality Control Plan (QCP) how the following attributes will be
monitored: pavement density, mix temperature, pavement smoothness, pavement cross-slope,
mix spread rate, and pavement texture, including methods for monitoring pavement segregation
and the corrective actions that will be taken to resolve any identified problems. Perform as a
minimum, the following activities necessary to maintain process control and meet Specification
requirements:
1. Pavement Density: Monitor the pavement temperature with an infrared
temperature device so that compaction is completed before the surface temperature of the
pavement drops to the extent that effective compaction may not be achieved or the rollers begin
to damage the pavement. Monitor the roadway density with either 6 inch diameter roadway
cores, a nuclear density gauge, or other density measuring device, at a minimum frequency of
once per 1,500 feet of pavement.
2. Mix Temperature: Determine the mix temperature at the roadway for the first
five loads and one out of every five loads thereafter.
3. Mix Spread Rate: Monitor the mix spread rate at the beginning of each days
production, and as needed to control the operations, at a minimum of once per 200 tons placed.
When determining the spread rate, use, at a minimum, an average of five truckloads of mix.
4. Pavement Texture: Monitor the pavement texture to minimize pavement
segregation. Use density gauges, infrared temperature measurement devices, or roadway cores at
the beginning of each days production, and as necessary, both at truck exchanges and during
normal paving operations.
5. Reporting: Ensure the accuracy of the Quality Control Roadway Reports on the
Departments approved form to reflect the actual surface area of the finished work and be in
compliance with the requirements of the Contract Documents.
330-2.2 Personnel Qualifications: Provide QC Technicians in accordance with
Section 105.
330-3 Limitations of Operations.
330-3.1 Weather Limitations: Do not transport asphalt mix from the plant to the
roadway unless all weather conditions are suitable for the paving operations.
330-3.2 Limitations of Paving Operations:
330-3.2.1 General: Place the mixture only when the surface upon which it is to
be placed has been previously prepared, is intact, firm, dry, clean, and the tack or prime coat,
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with acceptable spread rate, is properly broken or cured. Do not place friction course until the
adjacent shoulder area has been dressed and grassed.
330-3.2.2 Ambient Air Temperature: Place the mixture only when the air
temperature in the shade and away from artificial heat meets requirements of Table 330-1. The
minimum ambient temperature requirement may be reduced by 5F when using warm mix
technology, if mutually agreed to by both the Engineer and the Contractor. For FC-5 mixtures,
meet the requirements of 337-7.
Table 330-1
Ambient Air Temperature Requirements for Paving
Layer Thickness or Asphalt Binder Type
Minimum Temperature (F)
1 inch
50
Any mixture > 1 inch containing a PG asphalt binder having a high
45
temperature designation 76C or ARB-5
Any mixture > 1 inch containing a PG asphalt binder having a high
40
temperature designation < 76C
330-3.2.3 Rain and Surface Conditions: Immediately cease transportation of
asphalt mixtures from the plant when rain begins at the roadway. Do not place asphalt mixtures
while rain is falling, or when there is water on the surface to be covered. Once the rain has
stopped and standing water has been removed from the tacked surface to the satisfaction of the
Engineer and the temperature of the mixture caught in transit still meets the requirements as
specified in 320-6.3, the Contractor may then place the mixture caught in transit.
330-3.2.4 Wind: Do not place the mixture when the wind is blowing to such an
extent that proper and adequate compaction cannot be maintained or when sand, dust, etc., are
being deposited on the surface being paved to the extent that the bond between layers will be
diminished.
330-4 Surface Preparation.
330-4.1 Cleaning: Prior to placing the mixture, clean the surface of the base or
underlying pavement of all loose and deleterious material by the use of power brooms or
blowers, supplemented by hand brooming where necessary.
330-4.1.1 Application over Asphalt Rubber Membrane Interlayer (ARMI):
Where an asphalt mix is to be placed over a newly constructed ARMI, do not sweep or otherwise
disturb the cover material prior to placing the asphalt mix, unless directed by the Engineer.
330-4.2 Tacking: Apply a tack coat on all existing pavement surfaces that are to be
overlaid with an asphalt mix as specified in Section 300 and between successive layers of all
asphalt mixes. Apply a tack coat on freshly primed bases only when so directed by the Engineer.
330-5 Paving Equipment.
330-5.1 General Requirements: Use equipment that is mechanically sound and capable
of consistently meeting the requirements of these Specifications.
330-5.2 Asphalt Paver:
330-5.2.1 General: Provide an asphalt paver that is self-propelled, can be steered,
and is equipped with a receiving and distribution hopper and a mechanical screed. Use a
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mechanical screed capable of adjustment to regulate the depth of material spread and to produce
the desired cross-section.
330-5.2.2 Automatic Screed Control: For all asphalt courses placed with an
asphalt paver, equip the paver with automatic longitudinal screed controls of either the skid type,
traveling stringline type, or non-contact averaging ski type with a minimum length of 25 feet. On
the final layer of asphalt base, overbuild, and structural courses, and for friction courses, use the
joint matcher in lieu of the skid, traveling stringline, or non-contact averaging ski on all passes
after the initial pass. Equip the asphalt paver with electronic cross slope controls.
330-5.2.3 Screed Width: Provide an asphalt paver having a screed width greater
than 8 feet when required to pave full width lanes. Do not use extendable screed strike-off
devices that do not provide preliminary compaction of the mat in place of fixed screed
extensions. Use a strike-off device only on irregular areas that would normally be done by hand
and on shoulders 5 feet or less in width. When using the strike-off device on shoulders in lieu of
an adjustable screed extension, demonstrate the ability to obtain an acceptable texture, density,
and thickness.
When using an extendable screed device to extend the screeds width on
the full width lane or shoulder by 24 inches or greater, the Engineer will require an auger
extension, paddle, or kicker device unless written documentation from the manufacturer is
provided that these are not necessary.
330-5.3 Rollers:
330-5.3.1 Steel-Wheeled Rollers: Provide compaction equipment capable of
meeting the density requirements described in these Specifications. In the event that density
testing is not required, and the standard rolling pattern is used, provide a tandem steel-wheeled
roller weighing 5 to 15 tons for breakdown rolling. For finish rolling, use a separate roller with a
weight of 5 to 15 tons. Variations from these requirements shall be approved by the Engineer.
330-5.3.2 Traffic Rollers: Provide compaction equipment capable of meeting the
density requirements described in the Specifications. In the event that density testing is not
required, and the standard rolling pattern is used, provide a self-propelled, pneumatic-tired traffic
roller equipped with at least seven smooth-tread, low pressure tires, equipped with pads or
scrapers on each tire. Maintain the tire pressure between 50 and 55 psi or as specified by the
manufacturer. Use rollers with a minimum weight of 6 tons. Do not use wobble-wheeled rollers.
Variations from these requirements shall be approved by the Engineer.
330-5.3.3 Prevention of Adhesion: Do not allow the mixture to adhere to the
wheels of any rollers. Do not use fuel oil or other petroleum distillates to prevent adhesion. Do
not use any method which results in water being sprinkled directly onto the mixture.
330-5.4 Coring Equipment: Furnish a suitable saw or drill for obtaining the required
density cores.
330-5.5 Hand Tools: Provide the necessary hand tools such as rakes, shovels, and other
similar tools, and a suitable means for keeping them clean.
330-6 Placing Mixture.
330-6.1 Requirements Applicable to All Pavement Types:
330-6.1.1 Alignment of Edges: Place all asphalt mixtures by the stringline
method to obtain an accurate, uniform alignment of the pavement edge. As an exception,
pavement edges adjacent to curb and gutter or other true edges do not require a stringline.
Control the unsupported pavement edge to ensure that it will not deviate more than plus or
minus1.5 inches from the stringline.
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330-6.1.2 Paving Width: If necessary due to the traffic requirements, place the
mixture in strips in such a manner as to provide for the passage of traffic. As an option, where
the road is closed to traffic, place the mixture to the full width with machines traveling in
echelon.
330-6.1.3 Mix Temperature: Maintain the temperature of the mix at the time of
paving within the master range as defined in 320-6.3. The minimum frequency for taking mix
temperatures on the roadway will be as indicated in 320-6.3. Any load or portion of a load of
asphalt mix on the roadway with a temperature outside of the master range shall be rejected for
use on the project. Immediately notify the Engineer of the rejection.
330-6.1.4 Speed of Paver: Establish the forward speed of the asphalt paver based
on the rate of delivery of the mix to the roadway but not faster than the optimum speed needed to
adequately compact the pavement.
330-6.1.5 Thickness and Spread Rate of Layers: Construct each layer as
defined in the following table:
Table 330-2
Thickness and Target Spread Rate Requirements
Mix Type
Specification Section and Article
Type SP
334-1
Type FC
337-8
Type B
234-8
ATPB
287-8
330-6.1.5.1 Thickness Control: Ensure the spread rate is within 5% of the
target spread rate. When determining the spread rate, use, at a minimum, an average of five
truckloads of mix. When the average spread rate is beyond plus or minus 5% of the target spread
rate, monitor the thickness of the pavement layer closely and adjust the construction operations.
If the Contractor fails to maintain an average spread rate within
plus or minus 5% of the target spread rate for two consecutive days, the Engineer may elect to
stop the construction operation at any time until the issue is resolved.
330-6.1.5.2 Maximum Spread Rate Tolerances: When the average
spread rate for the total structural or friction course pavement thickness measured in accordance
with 330-6.1.5.1 exceeds the maximum spread rate tolerances shown in Table 330-3, address the
unacceptable pavement in accordance with 330-9.5.
Course
Structural
Structural
Friction (dense)
Friction (open)
Table 330-3
Maximum Spread Rate Tolerances
Design Thickness
2.5 inches
< 2.5 inches
-
Spread Rate Tolerance
50 lbs per sy
25 lbs per sy
25 lbs per sy
15 lbs per sy
As an exception, the Engineer may allow the Contractor to leave
areas in place if it is determined by the Engineer that the deficiency is not a significant detriment
255
to the pavement quality. A reduction to the pay item quantity will be made in accordance with
330-9.5.2.
330-6.1.6 Correcting Defects: Before starting any rolling, check the surface;
correct any irregularities; remove all drippings, sand accumulations from the screed, and fat
spots from any source; and replace them with satisfactory material. Do not skin patch. When
correcting a depression while the mixture is hot, scarify the surface and add fresh mixture.
330-6.1.7 Hand Work: In limited areas where the use of the paver is impossible
or impracticable, the Contractor may place and finish the mixture by hand.
330-7 Compacting Mixture.
330-7.1 General Requirements: When density testing for acceptance is required, select
equipment, sequence, and coverage (number of times the roller passes over a given area of
pavement) of rolling to meet the specified density requirement. Regardless of the rolling
procedure used, complete the final rolling before the surface temperature of the pavement drops
to the extent that effective compaction may not be achieved or the rollers begin to damage the
pavement.
330-7.2 Standard Rolling Procedure: When density testing for acceptance is not
required, propose an alternative rolling pattern to be approved by the Engineer or use the
following standard rolling procedure:
1. Breakdown rolling: Provide two static coverages with a tandem steel-wheeled
roller, following as close behind the paver as possible without pick-up, undue displacement, or
blistering of the material.
2. Intermediate rolling: Provide five static coverages with a pneumatic-tired roller,
following as close behind the breakdown rolling operation as the mix will permit.
3. Finish rolling: Provide one static coverage with a tandem steel-wheeled roller,
after completing the breakdown rolling and intermediate rolling, but before the surface pavement
temperature drops to the extent that effective compaction may not be achieved or the rollers
begin to damage the pavement.
330-7.3 Rolling Procedures: Utilize procedures that will uniformly compact the
pavement layer to the desired density level, while meeting the appropriate smoothness
requirements, without damaging the pavement surface, crushing aggregate or leaving excessive
roller marks, roller heads, or ripples. While rolling is in progress, monitor the surface
continuously, and adjust the compaction operations to comply with the surface requirements.
330-7.4 Compaction of Areas Inaccessible to Rollers: Use hand tamps or other
satisfactory means to compact areas which are inaccessible to a roller, such as areas adjacent to
curbs, gutters, bridges, manholes, etc.
330-7.5 Correcting Defects: Do not allow the compaction equipment to deposit
contaminants onto the pavement surface. Remove and replace any areas damaged by such
deposits as directed by the Engineer. Correct any depressions that develop before completing the
rolling by loosening the mixture and adding new mixture to bring the depressions to a true
surface. Should any depression remain after obtaining the final compaction, remove the full
depth of the mixture, and replace it with sufficient new mixture to form a true and even surface.
Correct all defects prior to laying the subsequent course.
330-7.6 Use of Traffic Roller: Use a traffic roller on the first overbuild course. Use a
traffic roller or vibratory roller (unless restricted by the Contract Documents) on the first
structural layer placed on an ARMI.
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330-7.7 Compaction at Bridge Structures: Compact asphalt mixtures placed over
bridge decks and approach slabs using static compaction only. Utilize the standard rolling
procedure described in 330-7.2 or an alternative procedure approved by the Engineer.
330-8 Joints.
330-8.1 General: When laying fresh mixture against the exposed edges of joints, place it
in close contact with the exposed edge to produce an even, well-compacted joint after rolling.
330-8.2 Transverse Joints: Place the mixture as continuously as possible to minimize
transverse joints. When constructing permanent transverse joints, meet the surface requirements
as defined in 330-9. Construct temporary transverse joints in such a manner to allow traffic to
pass over it. When resuming the paving operation, construct a transverse joint by cutting back on
the previously placed pavement at a location where the straightedge requirements are met. At the
project limits, tie into the adjoining pavement layers as shown in the Plans.
330-8.3 Longitudinal Joints: Place each layer of pavement so that all longitudinal
construction joints are offset 6 to 12 inches laterally between successive layers. Plan offsets in
advance so that longitudinal joints of the friction course are not in wheel path areas. The
longitudinal joints for friction course layers should be within 6 inches of the lane edge or at the
center of the lane. The Engineer may waive this requirement where offsetting is not feasible due
to the sequence of construction.
330-8.4 Placing Asphalt Next to Concrete Pavement: When placing asphalt next to
concrete pavement, construct the joint as shown in the Plans.
330-9 Surface Requirements.
330-9.1 General: Construct a smooth pavement with good surface texture and the proper
cross-slope.
330-9.2 Texture of the Finished Surface of Paving Layers: Produce a finished surface
of uniform texture and compaction with no pulled, torn, raveled, crushed or loosened portions
and free of segregation, bleeding, flushing, sand streaks, sand spots, or ripples. Address any
pavement not meeting the requirements of this specification in accordance with 330-9.5.
For dense graded structural and friction course mixtures, in areas not defined to be
a density testing exception per 334-5.1.2, obtain for the Engineer three 6 inch diameter roadway
cores at locations visually identified by the Engineer to be segregated. The Engineer will
determine the density of each core in accordance with FM 1-T 166 and calculate the percent Gmm
of the segregated area using the average Gmb of the roadway cores and the QC sublot Gmm for the
questionable material. If the average percent Gmm is less than 90.0, address the segregated area in
accordance with 330-9.5.
Do not use asphalt concrete mixtures containing aggregates that cause a different
color appearance in the final wearing surface unless the section is greater than or equal to one
mile in length and across the full width of the pavement, including shoulders and turn lanes.
Exceptions to these requirements will be permitted if approved by the Engineer.
330-9.3 Cross Slope: Construct a pavement surface with cross slopes in compliance with
the requirements of the Contract Documents. Furnish an electronic level with a length of 4 feet
and an accuracy of 0.1 degree, approved by the Engineer for the control of cross slope. Make this
electronic level available at the jobsite at all times during paving operations.
330-9.3.1 QC Requirements: Calibrate the electronic levels a minimum of once
per day before paving operations begin, in accordance with manufacturers instructions.
Compare the QC level with the Verification level before paving operations
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begin, and at any time as directed by the Engineer. If the comparison between the QC and
Verification levels is within the comparison tolerance of plus or minus 0.2%, the QC level is
considered to compare favorably and can be used for measurement and acceptance of cross
slopes. If the levels do not compare favorably, perform a second comparison using another
calibrated electronic level (FDOT or Contractor) for resolution. If this resolution level compares
favorably with the QC level, the QC level is considered to be verified. If the second level does
not compare favorably with the QC level, discontinue the use of the QC electronic level and
obtain another approved electronic level that meets the requirements of this specification.
Regardless of the comparison analysis outcome, the Contractor assumes all risk associated with
placing the pavement at the correct cross slope.
Measure the cross slope of the compacted pavement surface by placing the
level at the center location of a lane and perpendicular to the roadway centerline. Record all
measurements to the nearest 0.1% on the Cross Slope Measurement Data Form and submit to the
Engineer for documentation.
1. Tangent Sections: Measure the cross slope at a minimum
frequency of one measurement every 100 feet per lane. Calculate the absolute deviation of each
cross slope measurement and then average the absolute deviations of ten consecutive cross slope
measurements. (The absolute deviation is the positive value of a deviation) When the average
absolute deviation cross slope is consistently within the acceptance tolerance as shown in Table
330-4 and upon the approval of the Engineer, the frequency of cross slope measurements can be
reduced to one measurement every 200 feet during paving operations.
2. Superelevated Sections: Measure the cross slope every 100 feet
per lane within the length of the full superelevation. Calculate the absolute deviation of each
measurement and then average the absolute deviations of ten consecutive cross slope
measurements. For the transition sections, measure the cross slope at control points identified in
the Plans, or if not shown in the Plans, at a control point at the location of 0.0% cross slope and
calculate the absolute deviation. For curves where the length of full superelevation is less than
250 feet, measure the cross slope at the beginning point, midpoint and ending point of the fully
superelevated sections, calculate the absolute deviation, and average. When the number of
measurements is less than ten and the length of full superelevation is greater than 250 feet,
average the absolute deviation of all measurements.
If the average absolute deviation of the cross slope measurements falls
outside the acceptance tolerance, as shown in Table 330-4, stop the paving operation and make
adjustments until the problem is resolved to the satisfaction of the Engineer. If an individual
cross slope deviation falls outside the acceptance tolerance as shown in Table 330-4, make
corrections at no cost to the Department in accordance with 330-9.5 to address the deficient area
of the structural course. Complete all corrections before placement of the final pavement surface
layer, unless stated otherwise in the Plans, or as determined by the Engineer. For pavement with
multiple layers, the deficient areas for the structural course may be left in place, upon the
approval of the Engineer. For friction course layers, make corrections in accordance with 3309.5.
The limits of deficient areas requiring correction may be verified and
adjusted with more accurate measurement methods, including survey instruments, upon approval
by the Engineer at no cost to the Department.
Should the Contractor wish to have any corrections waived, submit a
request to the Engineer for approval. The Engineer may waive the corrections at no reduction in
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payment if the deficiencies are sufficiently separated so as not to affect the overall traffic safety,
surface drainage and ride quality characteristics of the pavement and the corrective action would
unnecessarily mar the appearance of the finished pavement.
For intersections, tapers, crossovers, transitions at the beginning and end
of the project, bridge approaches and similar areas, adjust the cross slope to match the actual site
conditions, or as directed by the Engineer.
Table 330-4
Cross Slope Acceptance Tolerance
Roadway Feature
Tangent section
(including turn lanes)
Superelevated curve
Shoulder
Individual Absolute Deviation
Average Absolute Deviation
0.4%
0.2%
0.4%
0.5%
0.2%
0.5%
In the event that the distance between two edges of deficient areas is less
than 100 feet, the correction work shall include the area between the deficient sections.
330-9.3.2 Verification: The Engineer will verify the Contractors cross slope
measurements by randomly taking a minimum of ten cross slope measurements per lane per mile
in tangent sections, control points in transition sections, and a minimum of three cross slope
measurements on fully superelevated sections over a days production. The Engineer will
measure the cross slope of the compacted pavement surface by placing the level at the center
location of a lane and perpendicular to the roadway centerline. If the average absolute deviation
or an individual cross slope deviation falls outside of the acceptance tolerance as shown in Table
330-4, immediately make a comparison check at the QC test locations to verify the QC
measurements in the section. If the comparisons are beyond the acceptable comparison tolerance
in accordance with 330-9.3.1, stop the paving operations until the issue is resolved to the
satisfaction of the Engineer. Correct any cross slope not meeting the individual deviation
acceptance tolerance in accordance with 330-9.5 at no cost to the Department. The Engineer
reserves the right to check the pavement cross slope at any time by taking cross slope
measurements at any location.
330-9.4 Pavement Smoothness: Construct a smooth pavement meeting the requirements
of this Specification.
330-9.4.1 General: Furnish a 15 foot manual and a 15 foot rolling straightedge
meeting the requirements of FM 5-509. Obtain a smooth surface on all pavement courses placed,
and then straightedge all layers as required by this Specification.
330-9.4.2 Test Method: Perform all straightedge testing in accordance with
FM 5-509 in the outside wheel path of each lane. The Engineer may require additional testing at
other locations within the lane.
330-9.4.3 Traffic Control: Provide traffic control in accordance with Section 102
and the Design Standards Index Nos. 607 or 619 during all testing. When traffic control cannot
be provided in accordance with Index Nos. 607 or 619, submit an alternative Traffic Control
Plan as specified in 102-4. Include the cost of this traffic control in the Contract bid prices for the
asphalt items.
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330-9.4.4 Process Control Testing: Assume full responsibility for controlling all
paving operations and processes such that the requirements of these Specifications are met at all
times.
330-9.4.5 QC Testing:
330-9.4.5.1 General: Straightedge the final Type SP structural layer and
friction course layer in accordance with 330-9.4.2, with the exception that if the method of
acceptance is by laser profiler, then straightedging of the friction course layer is not required.
Test all pavement lanes and ramps where the width is constant and document all deficiencies in
excess of 3/16 inch on a form approved by the Engineer.
330-9.4.5.2 Straightedge Exceptions: Straightedge testing will not be
required in the following areas: shoulders, intersections, tapers, crossovers, sidewalks, shared use
paths, parking lots and similar areas, or in the following areas when they are less than 250 feet in
length: turn lanes, acceleration/deceleration lanes and side streets. The limits of the intersection
will be from stop bar to stop bar for both the mainline and side streets.
As an exception, in the event the Engineer identifies a surface
irregularity in the above areas that is determined to be objectionable, straightedge and address all
deficiencies in excess of 3/8 inch in accordance with 330-9.5.
The Engineer may waive straightedge requirements for transverse
joints at the beginning and end of the project, at the beginning and end of bridge structures, at
manholes, and at utility structures if the deficiencies are caused by factors beyond the control of
the Contractor, as determined by the Engineer. In addition, the Engineer may also waive the
straightedging requirements on ramps and superelevated sections where the geometrical
orientation of the pavement results in an inaccurate measurement with the rolling straightedge.
330-9.4.5.3 Intermediate Layers and Temporary Pavement: When the
design speed is 55 mph or greater and the intermediate Type SP layer or temporary pavement is
to be opened to traffic, if the Engineer identifies a surface irregularity that is determined to be
objectionable, straightedge and address all deficiencies in excess of 3/8 inch within 72 hours of
placement in accordance with 330-9.5.
330-9.4.5.4 Final Type SP Structural Layer: Straightedge the final
Type SP structural layer in accordance with 330-9.4.2, either behind the final roller of the paving
train or as a separate operation. Notify the Engineer of the location and time of straightedge
testing a minimum of 48 hours before beginning testing. The Engineer will verify the
straightedge testing by observing the QC straight edging operations. Address all deficiencies in
excess of 3/16 inch in accordance with 330-9.5.
When the final structural course is to be opened to traffic and the
design speed is 55 mph or greater, if any defect is 3/8 inch or greater, the Engineer may require
deficiencies to be corrected within 72 hours after opening to traffic.
330-9.4.5.5 Friction Course Layer: Where required per 330-9.4.5.1,
straightedge the friction course layer in accordance with 330-9.4.2, either behind the final roller
of the paving train or as a separate operation upon completion of all paving operations. Notify
the Engineer of the location and time of straightedge testing a minimum of 48 hours before
beginning testing. The Engineer will verify the straightedge testing by observing the QC
straightedging operations. Address all deficiencies in excess of 3/16 inch in accordance with
330-9.5.
330-9.4.6 Acceptance:
330-9.4.6.1 Straightedge Acceptance: For areas of roadways where the
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design speed is less than 55 miles per hour, acceptance for pavement smoothness of the friction
course will be based on verified QC measurements using the straightedge as required by 3309.4.5. The Engineer will verify the straightedge testing by observing the QC straightedging
operations.
330-9.4.6.2 Laser Acceptance: For areas of high speed roadways where
the design speed is equal to or greater than 55 miles per hour, acceptance testing for pavement
smoothness of the friction course (for mainline traffic lanes only) will be based on the Laser
Profiler. Ramps, acceleration and deceleration lanes, and other areas not suitable for testing with
the Laser Profiler will be tested and accepted with the straightedge in accordance with 3309.4.5.5 and 330-9.4.6.1.
The pavement smoothness of each lane will be determined by a
Laser Profiler furnished and operated by the Department in accordance with FM 5-549 and a
report issued with the Ride Number (RN) reported to one decimal place. If corrections are made,
as required following Laser Acceptance, the pavement will not be retested for smoothness using
the Laser Profiler.
For this testing, the pavement will be divided into 0.1 mile
segments. Partial segments equal to or greater than 0.01 mile will be considered as a 0.1 mile
segment. The pavement will be accepted as follows:
1) For segments with a RN greater than or equal to 4.0, the
pavement will be accepted at full pay.
2) For segments with a RN less than 4.0, the Engineer will
further evaluate the data in 0.01 mile intervals for both wheel paths.
If the RN is 3.5 or above for all 0.01 mile intervals
in both wheel paths, the segment will be accepted at full payment.
If the RN is less than 3.5 for one or more 0.01 mile
intervals, the segment will be tested with the rolling straightedge in both wheel paths in
accordance with FM 5-509. If approved by the Engineer, this straightedging may be completed
(in both wheel paths) as part of the QC straightedging operations described in 330-9.4.5.5, prior
to testing with the laser profiler. Notify the Engineer of the location and time of straightedge
testing a minimum of 48 hours before beginning testing. The Engineer will verify the
straightedge testing by observing the QC straightedging operations. Address all deficiencies in
excess of 3/16 inch in accordance with 330-9.5.
Test and accept areas at the beginning and ending of the project,
bridge approaches and departures, and areas where the segment is less than 0.01 mile, with the
straightedge in accordance with 330-9.4.5.5 and 330-9.4.6.1.
330-9.5 Unacceptable Pavement:
330-9.5.1 Corrections: Address all areas of unacceptable pavement at no cost to
the Department. Retest all corrected areas and assure the requirements of these Specifications are
met.
330-9.5.1.1 Structural Layers: Correct all deficiencies, as defined in
these Specifications, in the Type SP structural layers by removing and replacing the full depth of
the layer, extending a minimum of 50 feet on both sides (where possible) of the defective area
for the full width of the paving lane.
As an option, for high straightedge deficiencies only, mill the
pavement surface the full lane width to a depth and length that is adequate to remove the
deficiency. This option only applies if the structural layer is not the final surface layer.
261
330-9.5.1.2 Friction Course: Correct deficiencies in the friction course or
final surface layer by removing and replacing the full depth of the layer, extending a minimum of
50 feet on both sides (where possible) of the defective area for the full width of the paving lane.
As an exception, the Engineer may allow the Contractor to leave these areas in place if it is
determined by the Engineer that the deficiency is not a significant detriment to the pavement
quality. A reduction to the pay item quantity will be made in accordance with 330-9.5.2.
330-9.5.2 Reduction in Pay Item Quantity: When the Engineer elects to waive
corrections, the Department will reduce the pay quantity for the pay item in question by the
amount of material that the Contractor would have removed and replaced had the correction been
made. When the pay quantity is in tons, the Department will base the reduction on the volume of
material that the Contractor would have removed (the length by the lane width by layer
thickness) multiplied by the maximum specific gravity of the mix as determined through the
following equation:
Quantity (tons) = L x W x t x Gmm x 0.0024
Where: L = Lane length (ft.)
W = Lane width (ft.)
t = Layer thickness (in.)
Gmm = Maximum specific gravity from verified mix design
For FC-5 open-graded friction course, the Department will base the reduction on
the area that the Contractor would have removed (the length by lane width) multiplied by a
spread rate of 80 lb/yd2 as determined through the following equation:
Quantity (tons) = L x W x 0.0044
Where: L = Lane length (ft.)
W = Lane width (ft.)
330-10 Protection of Finished Surface.
Keep sections of newly compacted asphalt concrete, which are to be covered by
additional courses, clean until the successive course is laid.
Do not dump embankment or base material directly on the pavement. Dress shoulders
before placing the friction course on adjacent pavement.
Equip blade graders operating adjacent to the pavement during shoulder construction
with a 2 inch by 8 inch or larger board, or other attachment providing essentially the same
results, attached to their blades in such manner that it extends below the blade edge in order to
protect the pavement surface from damage by the grader blade.
To prevent rutting or other distortion, protect sections of newly finished dense-graded
friction course and the last structural layer prior to the friction course from traffic until the
surface temperature has cooled below 160F.
The Contractor may use artificial methods to cool the pavement to expedite paving
operations. The Department may direct the Contractor to use artificial cooling methods when
maintenance of traffic requires opening the pavement to traffic at the earliest possible time.
262
SECTION 334
SUPERPAVE ASPHALT CONCRETE
334-1 Description.
334-1.1 General: Construct a Superpave Asphalt Concrete pavement with the type of
mixture specified in the Contract, or when offered as alternates, as selected. Superpave mixes are
identified as Type SP-9.5, Type SP-12.5 or Type SP-19.0.
Meet the requirements of Section 320 for plant and equipment. Meet the general
construction requirements of Section 330, except as modified herein, including the provision for
Quality Control (QC) Plans and Quality Control (QC) Systems as specified in Section 105.
334-1.2 Traffic Levels: The requirements for Type SP Asphalt Concrete mixtures are
based on the design traffic level of the project, expressed in 18,000 pound Equivalent Single
Axle Loads (ESALs). The five traffic levels are as shown in Table 334-1.
Traffic Level
A
B
C
D
E
Table 334-1
Superpave Traffic Levels
Traffic Level (1x106 ESALs)
<0.3
0.3 to <3
3 to <10
10 to <30
30
The traffic levels for the project are as specified in the Contract. A Type SP mix
one traffic level higher than the traffic level specified in the Contract may be substituted, at no
cost to the Department (i.e. Traffic Level B may be substituted for Traffic Level A, etc.).
334-1.3 Gradation Classification: The Superpave mixes are classified as either coarse
or fine, depending on the overall gradation of the mixture. Coarse and fine mixes are defined in
334-3.2.2.
The equivalent AASHTO nominal maximum aggregate size Superpave mixes are
as follows:
Type SP-9.5............................................................... 9.5 mm
Type SP-12.5........................................................... 12.5 mm
Type SP-19.0........................................................... 19.0 mm
334-1.4 Thickness: The total thickness of the Type SP asphalt layers will be the plan
thickness as shown in the Contract Documents. Before paving, propose a thickness for each
individual layer meeting the requirements of this specification, which when combined with other
layers (as applicable) will equal the plan thickness. For construction purposes, the plan thickness
and individual layer thickness will be converted to spread rate based on the maximum specific
gravity of the asphalt mix being used, as well as the minimum density level, as shown in the
following equation:
Spread rate (lbs/yd2) = t x Gmm x 43.3
Where: t = Thickness (in.) (plan thickness or individual layer thickness)
Gmm = Maximum specific gravity from the verified mix design
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The weight of the mixture shall be determined as provided in 320-3.2. For target
purposes only, spread rate calculations should be rounded to the nearest whole number.
Note: Plan quantities are based on a Gmm of 2.540, corresponding to a spread rate
2
of 110 lbs/yd -in. Pay quantities will be based on the actual maximum specific gravity of the mix
being used.
334-1.4.1 Layer Thicknesses - Fine Mixes: The allowable layer thicknesses for
fine Type SP Asphalt Concrete mixtures are as follows:
Type SP-9.5................................................. 1 to 1-1/2 inches
Type SP-12.5......................................... 1 1/2 to 2-1/2 inches
Type SP-19.0..................................................... 2 to 3 inches
In addition to the minimum and maximum thickness requirements, the
following restrictions are placed on fine mixes when used as a structural course:
Type SP-9.5 - Limited to the top two structural layers, two layers
maximum.
Type SP-9.5 May not be used on Traffic Level D and E
applications.
Type SP-19.0 - May not be used in the final (top) structural layer.
334-1.4.2 Layer Thicknesses - Coarse Mixes: The allowable layer thicknesses
for coarse Type SP Asphalt Concrete mixtures are as follows:
Type SP-9.5................................................. 1-1/2 to 2 inches
Type SP-12.5..................................................... 2 to 3 inches
Type SP-19.0............................................... 3 to 3-1/2 inches
In addition to the minimum and maximum thickness requirements, the
following restrictions are placed on coarse mixes when used as a structural course:
Type SP-19.0 - May not be used in the final (top) structural layer.
334-1.4.3 Additional Requirements: The following requirements also apply to
coarse and fine Type SP Asphalt Concrete mixtures:
1. A minimum 1-1/2 inch initial lift is required over an Asphalt Rubber
Membrane Interlayer (ARMI).
2. When construction includes the paving of adjacent shoulders (less than
or equal to 5 feet wide), the layer thickness for the upper pavement layer and shoulder must be
the same and paved in a single pass, unless called for differently in the Contract Documents.
3. All overbuild layers must be fine Type SP Asphalt Concrete designed at
the traffic level as stated in the Contract Documents. Use the minimum and maximum layer
thicknesses as specified above unless called for differently in the Contract Documents. On
variable thickness overbuild layers, the minimum and maximum allowable thicknesses will be as
specified below, unless called for differently in the Contract Documents.
Type SP-9.5.................................................... 3/8 to 2 inches
Type SP-12.5.................................................. 1/2 to 3 inches
Type SP-19.0........................................ 1-1/2 to 3-1/2 inches
334-2 Materials.
334-2.1 General Requirements: Meet the material requirements specified in
Division III. Specific references are as follows:
Superpave PG Asphalt Binder ..................................... 916-1
Coarse Aggregate ................................................Section 901
Fine Aggregate ....................................................Section 902
264
334-2.2 Superpave Asphalt Binder: Unless specified otherwise in the Contract, use a
PG 67-22 asphalt binder. In addition, meet the requirements of 334-2.3.
334-2.3 Reclaimed Asphalt Pavement (RAP) Material:
334-2.3.1 General requirements: RAP may be used as a component of the
asphalt mixture subject to the following requirements:
1. When using a PG 76-22 Asphalt Binder, limit the amount of RAP
material used in the mix to a maximum of 20% by weight of total aggregate. As an exception,
amounts greater than 20% RAP by weight of total aggregate can be used if no more than 20% by
weight of the total asphalt binder comes from the RAP material.
2. Assume full responsibility for the design, production and construction
of asphalt mixes which incorporate RAP as a component material.
3. Use RAP from a Department approved stockpile or RAP that has a
Department furnished Pavement Composition Data Sheet.
4. Provide stockpiled RAP material that is reasonably consistent in
characteristics and contains no aggregate particles which are soft or conglomerates of fines.
5. Provide RAP material having a minimum average asphalt binder
content of 4.0% by weight of RAP. As an exception, when using fractionated RAP, the minimum
average asphalt binder content for the coarse portion of the RAP shall be 2.5% by weight of the
coarse portion of the RAP. The coarse portion of the RAP shall be the portion of the RAP
retained on the No. 4 sieve. The Engineer may sample the stockpiles to verify that this
requirement is met.
334-2.3.2 Material Characterization for Mix Design: Assume responsibility for
establishing the asphalt binder content, gradation, and bulk specific gravity (Gsb) of the RAP
material based on a representative sampling of the material by roadway cores or stockpile
samples. For roadway core samples, assume responsibility for the degradation that will occur
during the milling operation.
334-2.3.3 RAP Stockpile Approval: Prior to the incorporation of RAP into the
asphalt mixture, stockpile the RAP material and obtain approval for the stockpile by one of the
following methods:
1. Continuous stockpile: When RAP is obtained from one or multiple
sources and is either processed, blended, or fractionated, and stockpiled in a continuous manner,
assure an adequate number of test results are obtained for stockpile approval. Test the RAP
material for gradation and asphalt content at a minimum frequency of one sample per 1000 tons
with a minimum of six test results. Test the RAP material for Gmm (for Gsb determination) at a
minimum frequency of one sample per 5000 tons with a minimum of two test results. Based on
visual inspection and a review of the test data, the Engineer will determine the suitability of the
stockpiled material. In addition, address in the QC Plan the details and specifics of the
processing, sampling, testing and actions to be taken.
2. Non-continuous single stockpile: When an individual stockpile is being
constructed, obtain representative samples at random locations and test the RAP material for
gradation and asphalt content at a minimum frequency of one sample per 1000 tons with a
minimum of six test results. Test the RAP material for Gmm (for Gsb determination) at a minimum
frequency of one sample per 5000 tons with a minimum of two test results. Based on visual
inspection and a review of the test data, the Engineer will determine the suitability of the
stockpiled material. Once the RAP stockpile has been approved, do not add additional material
without prior approval of the Engineer.
265
Determine the asphalt binder content and gradation of the RAP material in
accordance with FM 5-563 and FM 1-T 030, respectively. Establish the Gsb of the RAP material
by using one of the following methods:
a. Calculate the Gsb value based upon the effective specific gravity
(Gse) of the RAP material, determined on the basis of the asphalt binder content and maximum
specific gravity (Gmm) of the RAP material. The Engineer will approve the estimated asphalt
binder absorption value used in the calculation.
b. Measure the Gsb of the RAP aggregate, in accordance with
FM 1-T 084 and FM 1-T 085. Obtain the aggregate by using a solvent extraction method.
334-2.3.4 Pavement Composition: When the Contract includes milling of the
existing asphalt pavement, the Pavement Coring Report may be available on the Departments
website.
334-2.3.5 Asphalt Binder for Mixes with RAP: Select the appropriate asphalt
binder grade based on Table 334-2. Obtain a sample of the mixture for the Engineer within the
first 1,000 tons of production and at a continuing frequency of one sample per 4,000 tons of mix.
The Engineer reserves the right to change the asphalt binder type and grade at design based on
the characteristics of the RAP asphalt binder, and reserves the right to make changes during
production.
Table 334-2
Asphalt Binder Grade for Mixes Containing RAP
Percent RAP
Asphalt Binder Grade
0 - 15
PG 67-22
16 - 30
PG 58-22
>30
PG 52-28
334-2.4 Recycled Crushed Glass: Recycled crushed glass may be used as a component
of the asphalt mixture subject to the following requirements:
1. Consider the recycled crushed glass a local material and meet all requirements
specified in 902-6.
2. Limit the amount of recycled crushed glass to a maximum of 15% by weight of
total aggregate.
3. Use an asphalt binder that contains a minimum of 0.5% anti-stripping agent by
weight of binder. The antistrip additive shall be one of the products listed on the Qualified
Products List (QPL). The antistrip additive shall be introduced into the asphalt binder by the
supplier during loading.
4. Do not use recycled crushed glass in friction course mixtures or in structural
course mixtures which are to be used as the final wearing surface.
334-3 General Composition of Mixture.
334-3.1 General: Compose the asphalt mixture using a combination of aggregate
(coarse, fine or mixtures thereof), mineral filler, if required, and asphalt binder material. Size,
grade and combine the aggregate fractions to meet the grading and physical properties of the mix
design. Aggregates from various sources may be combined.
334-3.2 Mix Design:
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334-3.2.1 General: Design the asphalt mixture in accordance with
AASHTO R35-09, except as noted herein. Prior to the production of any asphalt mixture, submit
the proposed mix design with supporting test data indicating compliance with all mix design
criteria to the Engineer. For Traffic Level B through E mix designs, include representative
samples of all component materials, including asphalt binder. Allow the State Materials Engineer
a maximum of four weeks to either conditionally verify or reject the mix as designed.
Do not use more than three mix designs per nominal maximum aggregate
size per traffic level per binder grade per year, where the year starts at the Notice to Proceed.
Exceeding this limitation will result in a maximum Composite Pay Factor of 1.00 as defined in
334-8.2 for all designs used beyond this limit.
Warm mix technologies (additives, foaming techniques, etc.) listed on the
Departments website may be used in the production of the mix. The URL for obtaining this
information, if available, is:
http://www.dot.state.fl.us/Specificationsoffice/implemented/URLinSpecs/files/WarmMixAsphalt
.pdf .
The Engineer will consider any marked variations from original test data
for a mix design or any evidence of inadequate field performance of a mix design as sufficient
evidence that the properties of the mix design have changed, and the Engineer will no longer
allow the use of the mix design.
334-3.2.2 Mixture Gradation Requirements: Combine the coarse and fine
aggregate in proportions that will produce an asphalt mixture meeting all of the requirements
defined in this specification and conform to the gradation requirements at design as defined in
AASHTO M323-07, Table 3. Aggregates from various sources may be combined.
334-3.2.2.1 Mixture Gradation Classification: Plot the combined
mixture gradation on an FHWA 0.45 Power Gradation Chart. Include the Control Points from
AASHTO M323-07, Table-3, as well as the Primary Control Sieve (PCS) Control Point from
AASHTO M323-07, Table 4. Coarse mixes are defined as having a combined aggregate
gradation that passes below the primary control sieve control point and below the maximum
density line for all sieve sizes smaller than the primary control sieve. Fine mixes are defined as
having a gradation that passes above the primary control sieve control point and above the
maximum density line for all sieve sizes smaller than the primary control sieve and larger than
the No. 100 sieve. Use a fine mix for Traffic Levels A through C; use either a coarse mix or fine
mix for Traffic Levels D and E.
334-3.2.3 Aggregate Consensus Properties: For Traffic Level C through E
mixtures, meet the following consensus properties at design for the aggregate blend.
Aggregate consensus properties do not apply to Traffic Level A and B mixtures.
334-3.2.3.1 Coarse Aggregate Angularity: When tested in accordance
with ASTM D 5821, meet the percentage of fractured faces requirements specified in
AASHTO M 323-07, Table 5.
334-3.2.3.2 Fine Aggregate Angularity: When tested in accordance with
AASHTO T 304-11, Method A, meet the uncompacted void content of fine aggregate specified
in AASHTO M 323-07, Table 5.
334-3.2.3.3 Flat and Elongated Particles: When tested in accordance
with ASTM D 4791, (with the exception that the material passing the 3/8 inch sieve and retained
on the No. 4 sieve shall be included), meet the requirements specified in AASHTO M 323-07,
267
Table 5. Measure the aggregate using the ratio of 5:1, comparing the length (longest dimension)
to the thickness (shortest dimension) of the aggregate particles.
334-3.2.3.4 Sand Equivalent: When tested in accordance with
AASHTO T 176-08, meet the sand equivalent requirements specified in AASHTO M 323-07,
Table 5.
334-3.2.4 Gyratory Compaction: Compact the design mixture in accordance
with AASHTO T 312-11, with the following exception: use the number of gyrations at Ndesign as
defined in Table 334-3. Measure the inside diameter of gyratory molds in accordance with
AASHTO T 312-11.
Table 334-3
Gyratory Compaction Requirements
Traffic Level
Ndesign Number of Gyrations
A
50
B
65
C
75
D
100
E
100
334-3.2.5 Design Criteria: Meet the requirements for nominal maximum
aggregate size as defined in AASHTO M 323-07, as well as for relative density, VMA, VFA,
and dust-to-binder ratio as specified in AASHTO M 323-07, Table 6. Use a dust-to-binder ratio
of 0.8 to 1.6 for coarse mixes. Ninitial and Nmaximum requirements are not applicable.
334-3.2.6 Moisture Susceptibility:
1. For Traffic Level A and B mixtures, use a liquid anti-strip additive, at a
rate of 0.5% by weight of the asphalt binder. The anti-strip additive must be listed on the QPL.
Other rates of anti-strip additive may be used upon approval of the Engineer.
2. For Traffic Level C through E mixtures, test 4 inch specimens in
accordance with FM 1-T 283. Provide a mixture having a retained tensile strength ratio of at
least 0.80 and a minimum tensile strength (unconditioned) of 100 psi. If necessary, add a liquid
anti-stripping agent and/or hydrated lime (meeting the requirements of Section 337) in order to
meet these criteria. The anti-strip additive must be listed on the QPL.
334-3.2.7 Additional Information: In addition to the requirements listed above,
provide the following information with each proposed mix design submitted for verification:
1. The design traffic level and the design number of gyrations (Ndesign).
2. The source and description of the materials to be used.
3. The Department source number and the Department product code of the
aggregate components furnished from a Department approved source.
4. The gradation and proportions of the raw materials as intended to be
combined in the paving mixture. The gradation of the component materials shall be
representative of the material at the time of use. Compensate for any change in aggregate
gradation caused by handling and processing as necessary.
5. A single percentage of the combined mineral aggregate passing each
specified sieve. Degradation of the aggregate due to processing (particularly material passing the
No. 200 sieve) should be accounted for and identified.
268
6. The bulk specific gravity (Gsb) value for each individual aggregate and
RAP component, as identified in the Departments aggregate control program.
7. A single percentage of asphalt binder by weight of total mix intended to
be incorporated in the completed mixture, shown to the nearest 0.1%.
8. A target temperature for the mixture at the plant (mixing temperature)
and a target temperature for the mixture at the roadway (compaction temperature) in accordance
with 320-6.3. Do not exceed a target temperature of 330F for PG 76-22 asphalt binders, 320F
for ARB-12 asphalt binders, and 315F for ARB-5 and unmodified asphalt binders.
9. Provide the physical properties achieved at four different asphalt binder
contents. One of which must be at the optimum asphalt content, and must conform to all
specified physical requirements.
10. The name of the CTQP Qualified Mix Designer.
11. The ignition oven calibration factor.
12. The warm mix technology, if used.
334-3.3 Mix Design Revisions: During production, the Contractor may request a target
value revision to a mix design, subject to meeting the following requirements: (1) the target
change falls within the limits defined in Table 334-4, (2) appropriate data exists demonstrating
that the mix complies with production air voids specification criteria, and (3) the mixture
gradation meets the basic gradation requirements defined in 334-3.2.2.
(1)
Table 334-4
Limits for Potential Adjustments to Mix Design Target Values
Characteristic
Limit from Original Mix Design
No. 8 sieve and Coarser
5.0%
No. 16 sieve
4.0%
No. 30 sieve
4.0%
No. 50 sieve
3.0%
No. 100 sieve
3.0%
No. 200 sieve
1.0%
Asphalt Binder Content (1)
0.3%
Each Component of Aggregate Blend (2)
5.0 %
Reductions to the asphalt binder content will not be permitted if the VMA during production is lower than 1.0% below the
design criteria.
(2)
Revisions to FC-5 mixtures to be determined by the Engineer.
Submit all requests for revisions to mix designs, along with supporting
documentation, to the Engineer. In order to expedite the revision process, the request for revision
or discussions on the possibility of a revision may be made verbally, but must be followed up by
a written request. The verified mix design will remain in effect until the Engineer authorizes a
change. In no case will the effective date of the revision be established earlier than the date of the
first communication between the Contractor and the Engineer regarding the revision.
A new design mix will be required if aggregate sources change, or for any
substitution of an aggregate product with a different aggregate code, unless approved by the
Engineer.
269
334-4 Contractor Process Control.
Assume full responsibility for controlling all operations and processes such that the
requirements of these Specifications are met at all times. Perform any tests necessary at the plant
and roadway for process control purposes. Enter all Process Control test data into the
Departments Laboratory Information Management System (LIMS) database. The Engineer will
not use these test results in the acceptance payment decision.
Address in the QC Plan how Process Control failures will be handled. When a Process
Control failure occurs, investigate, at a minimum, the production process, testing equipment
and/or sampling methods to determine the cause of the failure, and make any necessary changes
to assure compliance with these Specifications. Obtain a follow up sample immediately after
corrective actions are taken to assess the adequacy of the corrections. In the event the follow-up
Process Control sample also fails to meet Specification requirements, cease production of the
asphalt mixture until the problem is adequately resolved to the satisfaction of the QC Manager.
334-5 Acceptance of the Mixture.
334-5.1 General: The mixture will be accepted at the plant with respect to gradation (P-8
and P-200), asphalt content (Pb), and volumetrics (volumetrics is defined as air voids at Ndesign).
The mixture will be accepted on the roadway with respect to density of roadway cores.
Acceptance will be on a LOT by LOT basis (for each mix design) based on tests of random
samples obtained within each sublot taken at a frequency of one set of samples per sublot. A
roadway LOT and a plant production LOT shall be the same. Acceptance of the mixture will be
based on Contractor QC test results that have been verified by the Department.
334-5.1.1 Sampling and Testing Requirements: Obtain the samples in
accordance with FM 1-T 168. Obtain samples at the plant of a sufficient quantity to be split into
three smaller samples; one for QC, one for Verification and one for Resolution testing; each
sample at approximately 35 pounds. The split samples for Verification testing and Resolution
testing shall be reduced in size and stored in three boxes each. The approximate size of each box
must be 12 inches x 8 inches x 4 inches. Provide, label and safely store sample boxes in a
manner agreed upon by the Engineer for future testing.
The asphalt content of the mixture will be determined in accordance with
FM 5-563. The gradation of the recovered aggregate will be determined in accordance with
FM 1-T 030. Volumetric testing will be in accordance with AASHTO T 312-11 and FM 1-T 209.
Measure the inside diameter of gyratory molds in accordance with FM 5-585. Prior to testing
volumetric samples, condition the test-sized sample for one hour, plus or minus five minutes, at
the target roadway compaction temperature in a shallow, flat pan, such that the mixture
temperature at the end of the one hour conditioning period is within plus or minus 20F of the
roadway compaction temperature. Test for roadway density in accordance with FM 1-T 166.
334-5.1.2 Acceptance Testing Exceptions: When the total combined quantity of
hot mix asphalt for the project, as indicated in the Plans for Type SP and Type FC mixtures only,
is less than 2000 tons, the Engineer will accept the mix on the basis of visual inspection. The
Engineer may require the Contractor to run process control tests for informational purposes, as
defined in 334-4, or may run independent verification tests to determine the acceptability of the
material.
Density testing for acceptance will not be performed on widening strips or
shoulders with a width of 5 feet or less, open-graded friction courses, variable thickness
overbuild courses, leveling courses, any asphalt layer placed on subgrade (regardless of type),
miscellaneous asphalt pavement, shared use paths, crossovers, or any course with a specified
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thickness less than 1 inch or a specified spread rate that converts to less than 1 inch as described
in 334-1.4. Density testing for acceptance will not be performed on asphalt courses placed on
bridge decks or approach slabs; compact these courses in static mode only per the requirements
of 330-7.7. In addition, density testing for acceptance will not be performed on the following
areas when they are less than 1,000 feet (continuous) in length: turning lanes, acceleration lanes,
deceleration lanes, shoulders, parallel parking lanes or ramps. Do not perform density testing for
acceptance in situations where the areas requiring density testing is less than 50 tons within a
sublot.
Density testing for acceptance will not be performed in intersections. The
limits of the intersection will be from stop bar to stop bar for both the mainline and side streets.
A random core location that occurs within the intersection shall be moved forward or backward
from the intersection at the direction of the Engineer.
Where density testing for acceptance is not required, compact these
courses (with the exception of open-graded friction courses) in accordance with the rolling
procedure (equipment and pattern) as approved by the Engineer or with Standard Rolling
Procedure as specified in 330-7.2. In the event that the rolling procedure deviates from the
procedure approved by the Engineer, or the Standard Rolling Procedure, placement of the mix
shall be stopped.
The density pay factor (as defined in 334-8.2) for areas not requiring
density testing for acceptance will be paid at the same density pay factor as for the areas
requiring density testing within the same LOT. If the entire LOT does not require density testing
for acceptance, the LOT will be paid at a density pay factor of 1.00.
334-5.2 Full LOTs: Each LOT will be defined (as selected by the Contractor prior to the
start of the LOT) as either (1) 2,000 tons, with each LOT subdivided into four equal sublots of
500 tons each, or (2) 4,000 tons, with each LOT subdivided into four equal sublots of 1,000 tons
each. As an exception to this, the initial LOT of all new mix designs shall be defined as
2,000 tons, subdivided into four equal sublots of 500 tons each. Before the beginning of a LOT,
the Engineer will develop a random sampling plan for each sublot and direct the Contractor on
sample points, based on tonnage, for each sublot during construction.
334-5.3 Partial LOTs: A partial LOT is defined as a LOT size that is less than a full
LOT. A partial LOT may occur due to the following:
l. The completion of a given mix type or mix design on a project.
2. Closure of the LOT due to time. LOTs will be closed 30 calendar days after the
start of the LOT. Time periods other than 30 calendar days may be used if agreed to by both the
Engineer and the Contractor.
3. A LOT is terminated per 334-5.4.4.
All partial LOTs will be evaluated based on the number of tests available, and
will not be redefined. If a LOT is closed before the first plant random sample is obtained, then
the LOT will be visually accepted by the Engineer and the LOT pay factor will be 1.00.
334-5.4 QC Sampling and Testing: Obtain all samples randomly as directed by the
Engineer.
Should the Engineer determine that the QC requirements are not being met or that
unsatisfactory results are being obtained, or should any instances of falsification of test data
occur, approval of the Contractors QC Plan will be suspended and production will be stopped.
334-5.4.1 Lost or Missing Verification/Resolution Samples: In the event that
any of the Verification and/or Resolution samples that are in the custody of the Contractor are
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lost, damaged, destroyed, or are otherwise unavailable for testing, the minimum possible pay
factor for each quality characteristic as described in 334-8.2 will be applied to the entire LOT in
question, unless called for otherwise by the Engineer. Specifically, if the LOT in question has
more than two sublots, the pay factor for each quality characteristic will be 0.55. If the LOT has
two or less sublots, the pay factor for each quality characteristic will be 0.80. In either event, the
material in question will also be evaluated in accordance with 334-5.9.5.
If any of the Verification and/or Resolution samples that are in the custody
of the Department are lost, damaged, destroyed or are otherwise unavailable for testing, the
corresponding QC test result will be considered verified, and payment will be based upon the
Contractors data.
334-5.4.2 Plant Sampling and Testing Requirements: Obtain one random
sample of mix per sublot in accordance with 334-5.1.1 as directed by the Engineer. Test the QC
split sample for gradation, asphalt binder content and volumetrics in accordance with 334-5.1.1.
Complete all QC testing within one working day from the time the samples were obtained.
334-5.4.3 Roadway Sampling and Testing Requirements: Obtain five 6 inch
diameter roadway cores within 24 hours of placement at random locations as directed by the
Engineer within each sublot. Test these QC samples for density (Gmb) in accordance with
334-5.1.1. Obtain a minimum of three cores per sublot at random locations as identified by the
Engineer in situations where the sublot/LOT was closed or terminated before the random
numbers were reached or where it is impractical to cut five cores per sublot. Do not obtain cores
any closer than 12 inches from an unsupported edge. The Engineer may adjust randomly
generated core locations for safety purposes or as the Engineer deems necessary. Maintain traffic
during the coring operation; core the roadway, patch the core holes (within three days of coring);
and trim the cores to the proper thickness prior to density testing.
Density for the sublot shall be based on the average value for the cores cut
from the sublot with the target density being the maximum specific gravity (Gmm) of the sublot.
Once the average density of a sublot has been determined, do not retest the samples unless
approved by the Engineer. Ensure proper handling and storage of all cores until the LOT in
question has been accepted.
334-5.4.4 Individual Test Tolerances for QC Testing: Terminate the LOT if
any of the following QC failures occur:
1) An individual test result of a sublot for air voids does not meet the
requirements of Table 334-5,
2) The average sublot density does not meet the requirements of
Table 334-5,
3) Two consecutive test results within the same LOT for gradation or
asphalt binder content do not meet the requirements of Table 334-5,
4) Two core densities for coarse mixes within a sublot are less than
91.00% of Gmm.
When a LOT is terminated due to a QC failure, stop production of the
mixture until the problem is resolved to the satisfaction of the QC Manager and/or Asphalt Plant
Level II technician responsible for the decision to resume production after a QC failure, as
identified in 105-8.6.4. In the event that it can be demonstrated that the problem can immediately
be or already has been resolved, it will not be necessary to stop production. When a LOT is
terminated, make all necessary changes to correct the problem. Do not resume production until
appropriate corrections have been made. Inform the Engineer of the problem and corrections
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made to correct the problem. After resuming production, sample and test the material to verify
that the changes have corrected the problem. Summarize this information and provide it to the
Engineer prior to the end of the work shift when production resumes.
In the event that a QC failure is not addressed as defined above, the
Engineers approval will be required prior to resuming production after any future QC failures.
Address any material represented by a failing test result in accordance
with 334-5.9.5. Any LOT terminated under this subarticle will be limited to a maximum Pay
Factor of 1.00 (as defined in 334-8.2) for each quality characteristic.
In the event that a Gmm test result differs by more than 0.040 from the mix
design Gmm, investigate the causes of the discrepancy and report the findings and proposed
actions to the Engineer.
Table 334-5
Master Production Range
(1)
(2)
Tolerance (1)
Target 0.55
Target 1.50
2.00 - 6.00
2.30 6.00
93.00
90.00
Characteristic
Asphalt Binder Content (%)
Passing No. 200 Sieve (%)
Air Voids (%) Coarse Graded
Air Voids (%) Fine Graded
Density (% Gmm) (2)
Coarse Graded (minimum)
Fine Graded (minimum)
Tolerances for sample size of n = 1 from the verified mix design
Based on an average of 5 randomly located cores
334-5.5 Verification Testing: In order to determine the validity of the Contractors QC
test results prior to their use in the Acceptance decision, the Engineer will run verification tests.
334-5.5.1 Plant Testing: At the completion of each LOT, the Engineer will test a
minimum of one Verification split sample randomly selected from the LOT. Results of the
testing and analysis for the LOT will be made available to the Contractor within one working day
from the time the LOT is completed. Verification samples shall be reheated at the target roadway
compaction temperature for 1-1/2 hours, plus or minus 5 minutes, reduced to the appropriate
testing size, and conditioned and tested as described in 334-5.1.1. In lieu of the 1-1/2 hours
reheating procedure, the mixture may be reheated to within plus or minus 20F of the roadway
compaction temperature using a microwave oven. Stir the mixture as necessary during the
reheating process to maintain temperature uniformity. Subsequently, condition and test the
mixture as described in 334-5.1.1.
The Verification test results will be compared with the QC test results
based on the between-laboratory precision values shown in Table 334-6.
Table 334-6
Between-Laboratory Precision Values
Property
Maximum Difference
Gmm
0.016
Gmb (gyratory compacted samples)
0.022
Gmb (roadway cores fine graded mixture)
0.015
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Table 334-6
Between-Laboratory Precision Values
Property
Maximum Difference
Gmb (roadway cores coarse graded mixture)
0.018
Pb
0.44%
P-200
FM 1-T 030 (Figure 2)
P-8
FM 1-T 030 (Figure 2)
If all of the specified mix characteristics compare favorably, then the LOT
will be accepted, with payment based on the Contractors QC test data for the LOT.
If any of the results do not compare favorably, then the Resolution
samples from the LOT will be sent to the Resolution laboratory for testing, as described in 3345.6.
334-5.5.2 Roadway Testing: At the completion of each LOT, the Engineer will
determine the density (Gmb) of each core (previously tested by Quality Control) as described in
334-5.1.1 from the same sublot as the plant samples. For situations where roadway density is not
required for the random sublot chosen, then another sublot shall be randomly chosen for roadway
density cores only. Results of the testing and analysis for the LOT will be made available to the
Contractor within one working day from the time the LOT is completed.
The individual Verification test results will be compared with individual
QC test results by the Engineer based on the between-laboratory precision values given in
Table 334-6.
If each of the core test results compare favorably, then the LOT will be
accepted with respect to density, with payment based on the Contractors QC test data for the
LOT.
If any of the results do not compare favorably, then the core samples from
the LOT will be sent to the Resolution laboratory for testing as specified in 334-5.6.
334-5.6 Resolution System:
334-5.6.1 Plant Samples: In the event of an unfavorable comparison between the
Contractors QC test results and the Engineers Verification test results on any of the properties
identified in Table 334-6, the Resolution laboratory will test all of the split samples from the
LOT for only the property (or properties) in question. Resolution samples shall be reheated at the
target roadway compaction temperature for 1-1/2 hours, plus or minus 5 minutes, reduced to the
appropriate testing size, and conditioned and tested as described in 334-5.1.1. In lieu of the 11/2 hours reheating procedure, the mixture may be reheated to within plus or minus 20F of the
roadway compaction temperature using a microwave oven. Stir the mixture as necessary during
the reheating process to maintain temperature uniformity. Subsequently, condition and test the
mixture as described in 334-5.1.1.
334-5.6.2 Roadway Samples: In the event of an unfavorable comparison between
the Contractors QC test data and the Engineers Verification test data on the density results, the
Resolution laboratory will test all of the cores from the LOT. Testing will be as described in 3345.1.1. Any damaged roadway cores will not be included in the evaluation; replace damaged cores
with additional cores at the direction of the Engineer.
334-5.6.3 Resolution Determination: The Resolution test results (for the
property or properties in question) will be compared with the QC test results based on the
between-laboratory precision values shown in Table 334-6.
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If the Resolution laboratory results compare favorably with all of the QC
results, then acceptance and payment for the LOT will be based on the QC results, and the
Department will bear the costs associated with Resolution testing. No additional compensation,
either monetary or time, will be made for the impacts of any such testing.
If the Resolution laboratory results do not compare favorably with all of
the QC results, then acceptance and payment for the LOT will be based on the Resolution test
data for the LOT, and the costs of the Resolution testing will be deducted from monthly
estimates. No additional time will be granted for the impacts of any such testing. In addition, in
the event that the application of the Resolution test data results in a failure to meet the
requirements of Table 334-5, address any material represented by the failing test result in
accordance with 334-5.9.5.
In the event of an unfavorable comparison between the Resolution test
results and QC test results, make the necessary adjustments to assure that future comparisons are
favorable.
334-5.7 Independent Verification Testing:
334-5.7.1 Plant: The Contractor shall provide sample boxes and take samples as
directed by the Engineer for Independent Verification testing. Obtain enough material for three
complete sets of tests (two samples for Independent Verification testing by the Engineer and one
sample for testing by the Contractor). If agreed upon by both the Engineer and the Contractor,
only one sample for Independent Verification testing by the Engineer may be obtained.
Independent Verification samples will be reheated at the target roadway compaction temperature
for 1-1/2 hours, plus or minus 5 minutes, reduced to the appropriate testing size, and conditioned
and tested as described in 334-5.1.1. The Contractors split sample, if tested immediately after
sampling, shall be reduced to the appropriate testing size, and conditioned and tested as
described in 334-5.1.1. If the Contractors sample is not tested immediately after sampling, then
the sample shall be reheated at the target roadway compaction temperature for 1-1/2 hours, plus
or minus 5 minutes, reduced to the appropriate testing size, and conditioned and tested as
described in 334-5.1.1. For the Independent Verification and Contractor's samples, in lieu of the
1-1/2 hours reheating procedure, the mixture may be reheated to within plus or minus 20F of the
roadway compaction temperature using a microwave oven. Stir the mixture as necessary during
the reheating process to maintain temperature uniformity. Subsequently, condition and test the
mixture as described in 334-5.1.1. The Contractors test results shall be provided to the Engineer
within one working day from the time the sample was obtained.
If any of the Independent Verification test results do not meet the
requirements of Table 334-5, then a comparison of the Independent Verification test results and
the Contractors test results, if available, will be made. If a comparison of the Independent
Verification test results and the Contractors test results meets the precision values of Table 3346 for the material properties in question, or if the Contractors test results are not available, then
the Independent Verification test results are considered verified and the Contractor shall cease
production of the asphalt mixture until the problem is adequately resolved (to the satisfaction of
the Engineer), unless it can be demonstrated to the satisfaction of the Engineer that the problem
can immediately be (or already has been) resolved. Address any material represented by the
failing test results in accordance with 334-5.9.5.
If a comparison of the Independent Verification test results and the
Contractors test results does not meet the precision values of Table 334-6 for the material
properties in question, then the second Independent Verification sample shall be tested by the
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Engineer for the material properties in question. If a comparison between the first and second
Independent Verification test results does not meet the precision values of Table 334-6 for the
material properties in question, then the first Independent Verification test results are considered
unverified for the material properties in question and no action shall be taken.
If a comparison between the first and second Independent Verification test
results meets the precision values of Table 334-6 for the material properties in question, then the
first Independent Verification sample is considered verified and the Contractor shall cease
production of the asphalt mixture until the problem is adequately resolved (to the satisfaction of
the Engineer), unless it can be demonstrated to the satisfaction of the Engineer that the problem
can immediately be (or already has been) resolved. Address any material represented by the
failing test results in accordance with 334-5.9.5.
The Engineer has the option to use the Independent Verification sample
for comparison testing as specified in 334-6.
334-5.7.2 Roadway: Obtain five 6 inch diameter roadway cores within 24 hours
of placement, as directed by the Engineer, for Independent Verification testing. In situations
where it is impractical to cut five cores per sublot, obtain a minimum of three cores per sublot at
random locations, as identified by the Engineer. These independent cores will be obtained from
the same LOTs and sublots as the Independent Verification Plant samples, or as directed by the
Engineer. The density of these cores will be obtained as described in 334-5.1.1. If the average of
the results for the sublot does not meet the requirements of Table 334-5 for density, cease
production of the asphalt mixture until the problem is adequately resolved (to the satisfaction of
the Engineer), unless it can be demonstrated to the satisfaction of the Engineer that the problem
can immediately be (or already has been) resolved. Address any material represented by the
failing test results in accordance with 334-5.9.5.
334-5.8 Surface Tolerance: The asphalt mixture will be accepted on the roadway with
respect to surface tolerance in accordance with the applicable requirements of 330-9.
334-5.9 Minimum Acceptable Quality Levels:
334-5.9.1 Pay Factors Below 0.90: In the event that an individual pay factor for
any quality characteristic of a LOT falls below 0.90, take steps to correct the situation and report
the actions to the Engineer. In the event that the pay factor for the same quality characteristic for
two consecutive LOTs is below 0.90, cease production of the asphalt mixture until the problem is
adequately resolved (to the satisfaction of the Engineer), unless it can be demonstrated to the
satisfaction of the Engineer that the problem can immediately be (or already has been) resolved.
Actions taken must be approved by the Engineer before production resumes.
334-5.9.2 Composite Pay Factors Less Than 0.90 and Greater Than or Equal
to 0.80: If the composite pay factor for the LOT is less than 0.90 and greater than or equal to
0.80, cease production of the asphalt mixture until the problem is adequately resolved (to the
satisfaction of the Engineer), unless it can be demonstrated to the satisfaction of the Engineer
that the problem can immediately be (or already has been) resolved. Actions taken must be
approved by the Engineer before production resumes.
334-5.9.3 Composite Pay Factors Less Than 0.80 and Greater Than or Equal
to 0.75: If the composite pay factor for the LOT is less than 0.80 and greater than or equal to
0.75, address the defective material in accordance with 334-5.9.5.
334-5.9.4 Composite Pay Factors Less Than 0.75: If the composite pay factor
for the LOT is less than 0.75, remove and replace the defective LOT at no cost to the
Department, or as approved by the Engineer.
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334-5.9.5 Defective Material: Assume responsibility for removing and replacing
all defective material placed on the project, at no cost to the Department.
As an exception to the above and upon approval of the Engineer,
obtain an engineering analysis by an independent laboratory (as approved by the Engineer) to
determine the disposition of the material. The engineering analysis must be signed and sealed by
a Professional Engineer licensed in the State of Florida.
The Engineer may determine that an engineering analysis is not
necessary or may perform an engineering analysis to determine the disposition of the material.
Any material that remains in place will be accepted with a
composite pay factor as determined by 334-8, or as determined by the Engineer.
If the defective material is due to a gradation, asphalt binder
content or density failure, upon approval of the Engineer the Contractor may perform delineation
tests on roadway cores in lieu of an engineering analysis to determine the limits of the defective
material that may require removal and replacement. Prior to any delineation testing, all sampling
locations shall be approved by the Engineer. All delineation sampling and testing shall be
monitored and verified by the Engineer. For materials that are defective due to air voids, an
engineering analysis is required.
When evaluating defective material by engineering analysis or
delineation testing, at a minimum, evaluate all material located between passing QC, Process
Control or Independent Verification test results. Exceptions to this requirement shall be
approved by the Engineer.
334-6 Comparison Testing.
At the start of the project (unless waived by the Engineer) and at other times as
determined necessary by the Engineer, provide split samples for comparison testing with the
Engineer. The purpose of these tests is to verify that the testing equipment is functioning
properly and that the testing procedures are being performed correctly. In the event that the
Engineer determines that there is a problem with the Contractors testing equipment and/or
testing procedures, immediately correct the problem to the Engineers satisfaction. In the event
that the problem is not immediately corrected, cease production of the asphalt mixture until the
problem is adequately resolved to the satisfaction of the Engineer.
If so agreed to by both the Contractor and the Engineer, the split sample used for
comparison testing may also be used for the QC sample. The split sample used for comparison
testing must also meet the requirements for Independent Verification Testing described in
334-5.7.
334-7 Method of Measurement.
For the work specified under this Section (including the pertinent provisions of
Sections 320 and 330), the quantity to be paid for will be the weight of the mixture, in tons. The
pay quantity will be based on the project average spread rate, excluding overbuild, limited to a
maximum of 105% of the spread rate determined in accordance with 334-1.4 or as set by the
Engineer. The project average spread rate is calculated by totaling the arithmetic mean of the
average daily spread rate values for each layer.
The bid price for the asphalt mix will include the cost of the liquid asphalt or the asphalt
recycling agent and the tack coat application as directed in 300-8. There will be no separate
payment or unit price adjustment for the asphalt binder material in the asphalt mix. For the
calculation of unit price adjustments of bituminous material, the average asphalt content will be
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based on the percentage specified in 9-2.1.2. The weight will be determined as provided in
320-3.2 (including the provisions for the automatic recordation system).
Prepare a Certification of Quantities, using the Departments current approved form, for
the certified Superpave asphalt concrete pay item. Submit this certification to the Engineer no
later than Twelve Oclock noon Monday after the estimate cut-off or as directed by the Engineer,
based on the quantity of asphalt produced and accepted on the roadway per Contract. The
certification must include the Contract Number, FPID Number, Certification Number,
Certification Date, period represented by Certification and the tons produced for each asphalt pay
item.
334-8 Basis of Payment.
334-8.1 General: Price and payment will be full compensation for all the work specified
under this Section (including the applicable requirements of Sections 320 and 330).
For materials accepted in accordance with 334-5, based upon the quality of the material, a
pay adjustment will be applied to the bid price of the material as determined on a LOT by LOT
basis. The pay adjustment will be assessed by calculating a Pay Factor for the following
individual quality characteristics: pavement density, air voids, asphalt binder content, and the
percentage passing the No. 200 and No. 8 sieves. The pay adjustment will be computed by
multiplying a Composite Pay Factor for the LOT by the bid price per ton. Perform all
calculations using the latest version of the Departments Asphalt Plant Worksheet.
334-8.2 Pay Factors:
334-8.2.1 Partial LOTs: For Partial LOTs where no random sample is obtained
due to insufficient tonnage, a Composite Pay Factor of 1.00 shall be applied.
334-8.2.2 Two or Less Sublot Test Results: In the event that two or less sublot
test results are available for a LOT, Pay Factors will be determined based on the Small Quantity
Pay Table. The Small Quantity Pay Table and Pay Factor calculations are determined in
accordance with the instructions contained within the Departments Asphalt Plant Worksheet.
334-8.2.3 Three or More Sublot Test Results: When three or more sublot test
results are available for a LOT, the variability-unknown, standard deviation method will be used
to determine the estimated percentage of the LOT that is within the specification limits shown in
Table 334-7. The Percent Within Limits (PWL) is determined in accordance with the instructions
contained within the Departments Asphalt Plant Worksheet.
Table 334-7
Specification Limits
Quality Characteristic
Passing No. 8 sieve (%)
Passing No. 200 sieve (%)
Asphalt Content (%)
Air Voids - Coarse Mixes (%)
Air Voids - Fine Mixes (%)
Density - Coarse Mixes (% of Gmm):
Density - Fine Mixes (% of Gmm):
Specification Limits
Target 3.1
Target 1.0
Target 0.40
4.00 1.40
4.00 1.20
94.50 1.30
93.00 + 2.00, - 1.20 (1)
Note (1): If the Engineer (or Contract Documents) limits compaction to the static mode only, or for all one-inch thick lifts,
compaction shall be in the static mode. No vibratory mode in the vertical direction will be allowed. Other vibratory modes will be
allowed, if approved by the Engineer. In either case, the specification limits will be as follows: 92.00 + 3.00, -1.20%of Gmm. No
additional compensation, cost or time, shall be made.
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334-8.2.3.1 Pay Factors (PF): Pay Factors will be calculated by using the
following equation:
Pay Factor = (55 + 0.5 x PWL) / 100
The PWL is determined in accordance with the instructions
contained within the Departments Asphalt Plant Worksheet.
334-8.3 Composite Pay Factor (CPF): A Composite Pay Factor for the LOT will be
calculated based on the individual Pay Factors (PF) with the following weighting applied: 35%
Density (D), 25% Air Voids (Va), 25% asphalt binder content (Pb), 10% Passing No. 200 (P-200)
and 5% Passing No. 8 (P-8). Calculate the CPF by using the following formula:
CPF = [(0.350 x PF D) + (0.250 x PF Va) + (0.250 x PF Pb) + (0.100 x PF P-200) +
(0.050 x PF P-8)]
Where the Pay Factor (PF) for each quality characteristic is determined in either
334-8.2.2 or 334-8.2.3, depending on the number of sublot tests. Note that the number after each
multiplication will be rounded to the nearest 0.01.
The pay adjustment shall be computed by multiplying the Composite Pay Factor
for the LOT by the bid price per ton.
334-8.4 Payment: Payment will be made under:
Item No. 334- 1Superpave Asphaltic Concrete - per ton.
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SECTION 336
ASPHALT RUBBER BINDER
336-1 Description.
Produce asphalt rubber binder for use in Asphalt Concrete Friction Courses and Asphalt
Rubber Membrane Interlayers.
336-2 Materials.
336-2.1 Superpave PG Asphalt Binder: For the particular grade of asphalt as specified
in Table 336-1, meet the requirements of Section 916.
336-2.2 Ground Tire Rubber: For the type of ground tire rubber, meet the requirements
of Section 919.
336-3 Asphalt Rubber Binder.
Thoroughly mix and react the asphalt binder and ground tire rubber in accordance with
the requirements of Table 336-1. Accomplish blending of the asphalt binder and ground tire
rubber at the project site or asphalt plant, or at the suppliers terminal.
Binder Type
Rubber Type
Table 336-1
Asphalt Rubber Binder
ARB 5
ARB 12
TYPE B
TYPE A (or B)(1)
(or A)(2)
ARB 20
TYPE C
(or B or A)(2)
Minimum Ground Tire Rubber
(by weight of asphalt binder)
Binder Grade
Temperature Range
5%
12%
20%
PG 67-22
300 - 335F
Minimum Reaction Time
10 minutes
Unit Weight @ 60F(3)
8.6 lbs/gal.
4.0 - 6.0 Poises
@ 300F
PG 67-22
300 - 350F
15 minutes
(Type B)
8.7 lbs/gal.
10.0 - 15.0 Poises
@ 300F
PG 64-22
335 - 375F
30 minutes
(Type C)
8.8 lbs/gal.
15.0 - 20.0 Poises
@ 350F
Viscosity Range(4)
(1) Use of Type B rubber may require an increase in the mix temperature in order to offset higher viscosity values.
(2) Use of finer rubber could result in the reduction of the minimum reaction time.
(3) Conversions to standard 60F are as specified in 300-9.3.
(4) FM 5-548, Viscosity of Asphalt Rubber by Rotational (Dip-N-Read) Viscometer or AASHTO T 316, Viscosity
Determination of Asphalt Binder Using Rotational Viscometer.
NOTE: The Contractor may adjust the minimum reaction time if approved by the Engineer depending upon the temperature, size
of the ground tire rubber and viscosity measurement determined from the asphalt rubber binder material prior to or during
production. Apply the asphalt rubber binder for use in membrane interlayers within a period of six hours, unless some form of
corrective action such as cooling and reheating is approved by the Engineer.
336-4 Equipment.
Use blending equipment that is designed for asphalt rubber binder and capable of
producing a homogeneous mixture of ground tire rubber and asphalt binder meeting the
requirements of Table 336-1. Use a batch type or continuous type blending unit that provides for
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sampling of the blended and reacted asphalt rubber binder material during normal production
and provides for accurate proportioning of the asphalt binder and ground tire rubber either by
weight or volume.
In order to meet specification requirements, keep the asphalt rubber uniformly blended
while in storage. Equip storage tanks with a sampling device.
336-5 Testing of Asphalt Rubber Binder:
336-5.1 Quality Control Requirements: Test the asphalt rubber binder for the viscosity
requirement of Table 336-1 at the following frequencies and situations:
1. One per batch (for batch blending) or two per day (for continuous blending)
during blending at the project site or asphalt plant, or the suppliers terminal.
2. Each load delivered to the project site or asphalt plant when blended at the
suppliers terminal.
3. Beginning of each day from the storage tank when storing the asphalt rubber
binder at the project site or asphalt plant, or the suppliers terminal, obtain the sample for testing
from the discharge piping exiting the storage tank.
Obtain the viscosity testing equipment specified in FM 5-548 and make it
available to the Engineer for verification purposes at the project site or asphalt plant and
suppliers terminal.
336-5.1.1 Action at Project Site or Asphalt Plant: If the asphalt rubber binder
does not meet the minimum viscosity requirement at the project site or asphalt plant, stop use of
the asphalt rubber binder in the Asphalt Concrete Friction Course and Asphalt Rubber
Membrane Interlayer, notify the Engineer, and make the appropriate adjustments as necessary to
meet the requirements of Table 336-1 in order to: (1) correct the viscosity of the blended
material and (2) correct the blending operation. In the event that the corrective actions taken fail
to correct the problem, or the material consistently fails to meet the minimum viscosity
requirement, do not use the asphalt rubber binder in storage, and where applicable, stop all
asphalt rubber blending operations at the project site or asphalt plant and solve the problem.
Do not use asphalt rubber binder with low viscosity in mix and interlayer
construction, or resume blending operations at the project site or asphalt plant until the Engineer
grants approval. The Engineer may require that any mix and interlayer placed with low viscosity
asphalt rubber binder be evaluated in accordance with 334-5.9.5. In the event that the viscosity
of the asphalt rubber binder increases to the extent that plant production or paving operations of
the mix are adversely affected (i.e. density or texture problems occur), stop plant operations and
resolve the problem to the Engineers satisfaction.
336-5.1.2 Action at Suppliers Terminal: If the asphalt rubber binder does not
meet the minimum viscosity requirement at the suppliers terminal, stop shipment and blending
of asphalt rubber binder, and make the appropriate adjustments as necessary to meet the
requirements of Table 336-1 in order to (1) correct the viscosity of the blended material in the
tank, and (2) correct the blending operation. Resume shipment and blending of asphalt rubber
binder when a retest indicates the viscosity meets Specifications. Document actions taken in the
Quality Control records.
336-5.2 Verification Requirements: The Engineer will test the asphalt rubber in
accordance with FM 5-548 or AASHTO T 316 randomly on an as needed basis at the project site
or asphalt plant, or the suppliers terminal to ensure conformance with the minimum viscosity
requirement as specified in Table 336-1.
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336-5.2.1 Action at Project Site or Asphalt Plant: If the asphalt rubber binder
does not meet the viscosity requirements at the project site or asphalt plant, stop use of asphalt
rubber binder. Do not use asphalt rubber binder with a viscosity outside of the specified range in
mix and interlayer construction until corrective actions, as necessary to meet the requirements of
Table 336-1, have been made, verified by passing test results, and the Engineer grants approval.
The Engineer may require that any mix and interlayer placed with an asphalt rubber binder with
a viscosity outside of the specified range be evaluated in accordance with 334-5.9.5. In the event
that the viscosity of the asphalt rubber binder adversely affects plant production or paving
operations, stop plant and paving operations and resolve the problem to the Engineers
satisfaction.
336-5.2.2 Action at Suppliers Terminal: If the asphalt rubber binder does not
meet the viscosity requirements at the suppliers terminal, stop shipment and blending of asphalt
rubber binder until corrective actions are made to meet the requirements of Table 336-1.
336-5.3 Asphalt Rubber Binder Blending Quality Control Records: Maintain
adequate Quality Control records for the Engineers review of all blending activities. The
Quality Control records shall include at a minimum the following information (for each batch of
asphalt rubber binder produced): asphalt rubber binder type, asphalt rubber binder batch
quantity, asphalt binder supplier (including QPL number and LOT), asphalt binder quantity in
gallons, ground tire rubber supplier (including QPL number and LOT), ground tire rubber
quantity in pounds, individual quantities of asphalt rubber binder shipped, financial project
number, shipping date, customer name, delivery location, and viscosity test results.
336-5.3.1 Additional Records for Blending at Project Site or Asphalt Plant:
Monitor the ground tire rubber content in the asphalt rubber binder on a daily basis based on one
of the following methods:
1. Record the weight of the ground tire rubber used and the number of
gallons of asphalt rubber binder produced. Calculate the percentage of rubber used and confirm
that the minimum rubber requirements are met. Use the unit weight per gallon for the various
types of asphalt rubber binder shown in Table 336-1 for the calculations.
2. Record the weight of the ground tire rubber used and the number of
gallons of asphalt binder used. Calculate the percentage of rubber used and confirm that the
minimum rubber requirements are met.
336-6 Use of Excess Asphalt Rubber.
The Contractor may use excess asphalt rubber in other asphalt concrete mixes requiring
the use of a PG 67-22 binder by blending with straight PG 67-22 binder so that the total amount
of ground tire rubber in the binder is less than 2.0%. The Contractor may use excess asphalt
rubber in asphalt concrete mixtures requiring the use of a recycling agent in a recycled mixture
by blending with a recycling agent in such proportions that the total amount of ground tire rubber
in the recycling agent is less than 1.0%.
336-7 Certification Requirements for Blending at Suppliers Terminal:
Where blending the asphalt rubber binder at the suppliers terminal, the supplier shall
furnish certification on the bill of lading for each load delivered to the project site or asphalt
plant that includes: the quantity of asphalt rubber binder, the asphalt rubber binder type, the
customer name, the delivery location, and a statement that the asphalt rubber binder has been
produced in accordance with and meets the requirements of Section 336. In addition, include,
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with the certification, copies of the certifications for the asphalt binder and ground tire rubber, as
specified in 916-1.3.6 and 919-6, respectively.
336-8 Basis of Payment.
Payment for asphalt rubber binder will be included in Sections 337 and 341, as
appropriate.
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SECTION 337
ASPHALT CONCRETE FRICTION COURSES
337-1 Description.
Construct an asphalt concrete friction course pavement with the type of mixture specified
in the Contract, or when offered as alternates, as selected. This Section specifies mixes
designated as FC-5, FC-9.5, and FC-12.5.
Meet the plant and equipment requirements of Section 320, as modified herein. Meet the
general construction requirements of Section 330, as modified herein.
337-2 Materials.
337-2.1 General Requirements: Meet the requirements specified in Division III as
modified herein. The Engineer will base continuing approval of material sources on field
performance. Warm mix technologies (additives, foaming techniques, etc.) listed on the
Departments website may be used in the production of the mix. The URL for obtaining this
information, if available, is:
http://www.dot.state.fl.us/Specificationsoffice/implemented/URLinSpecs/files/WarmMixAsphalt
.pdf .
337-2.2 Asphalt Binder: Meet the requirements of Section 336, and any additional
requirements or modifications specified herein for the various mixtures. When called for in the
Contract Documents, use a PG 76-22 asphalt binder meeting the requirements of 916-1. For
projects with a total quantity of FC-5, FC-9.5, or FC-12.5 less than 500 tons, the Contractor may
elect to substitute a PG 76-22 for the ARB-12 or ARB-5, meeting the requirements of 916-1.
337-2.3 Coarse Aggregate: Meet the requirements of Section 901, and any additional
requirements or modifications specified herein for the various mixtures.
337-2.4 Fine Aggregate: Meet the requirements of Section 902, and any additional
requirements or modifications specified herein for the various mixtures.
337-2.5 Hydrated Lime: Meet the requirements of AASHTO M 303-89 (2010), Type 1.
Provide certified test results for each shipment of hydrated lime indicating
compliance with the specifications.
337-2.6 Liquid Anti-strip Additive: Meet the requirements of 916-4 and be listed on the
Departments Qualified Products List (QPL).
337-2.7 Fiber Stabilizing Additive (Required for FC-5 only): Use either a mineral or
cellulose fiber stabilizing additive. Meet the following requirements:
337-2.7.1 Mineral Fibers: Use mineral fibers (made from virgin basalt, diabase,
or slag) treated with a cationic sizing agent to enhance the disbursement of the fiber, as well as to
increase adhesion of the fiber surface to the bitumen. Meet the following requirements for
physical properties:
1. Size Analysis
Average fiber length: 0.25 inch (maximum)
Average fiber thickness: 0.0002 inch (maximum)
2. Shot Content (ASTM C612)
Percent passing No. 60 Sieve: 90 - 100
Percent passing No. 230 Sieve: 65 - 100
Provide certified test results for each batch of fiber material indicating
compliance with the above tests.
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337-2.7.2 Cellulose Fibers: Use cellulose fibers meeting the following
requirements:
1. Fiber length: 0.25 inch (maximum)
2. Sieve Analysis
a. Alpine Sieve Method
Percent passing No. 100 sieve: 60-80
b. Ro-Tap Sieve Method
Percent passing No. 20 sieve: 80-95
Percent passing No. 40 sieve: 45-85
Percent passing No. 100 sieve: 5-40
3. Ash Content: 18% non-volatiles (plus or minus 5%)
4. pH: 7.5 (plus or minus 1.0)
5. Oil Absorption: 5.0% (plus or minus 1.0) (times fiber weight)
6. Moisture Content: 5.0% by weight (maximum)
Provide certified test results for each batch of fiber material indicating
compliance with the above tests.
337-3 General Composition of Mixes.
337-3.1 General: Use a bituminous mixture composed of aggregate (coarse, fine, or a
mixture thereof), asphalt binder, and in some cases, fibers and/or hydrated lime. Size, uniformly
grade and combine the aggregate fractions in such proportions that the resulting mix meets the
requirements of this Section.
337-3.2 Specific Component Requirements by Mix:
337-3.2.1 FC-5:
337-3.2.1.1 Aggregates: Use an aggregate blend which consists of either
100% crushed granite, 100% crushed Oolitic limestone or 100% other crushed materials (as
approved by the Engineer for friction courses per Rule 14-103.005, Florida Administrative
Code).
Crushed limestone from the Oolitic formation may be used if it
contains a minimum of 12% silica material as determined by FM 5-510 and the Engineer grants
approval of the source prior to its use.
A list of aggregates approved for use in friction course may be
available on the Departments website. The URL for obtaining this information, if available, is:
ftp://ftp.dot.state.fl.us/fdot/smo/website/sources/frictioncourse.pdf .
337-3.2.1.2 Asphalt Binder: Use an ARB-12 asphalt rubber binder. If
called for in the Contract Documents, use a PG 76-22 asphalt binder.
337-3.2.1.3 Hydrated Lime: Add the lime at a dosage rate of 1.0% by
weight of the total dry aggregate to mixes containing granite.
337-3.2.1.4 Liquid Anti-strip Additive: Use a liquid anti-strip additive at
a rate of 0.5% by weight of the asphalt binder for mixtures containing limestone aggregate. Other
rates of anti-strip additive may be used upon approval of the Engineer.
337-3.2.1.5 Fiber Stabilizing Additive: Add either mineral fibers at a
dosage rate of 0.4% by weight of the total mix, or cellulose fibers at a dosage rate of 0.3% by
weight of total mix.
337-3.2.2 FC-9.5 and FC-12.5:
337-3.2.2.1: Aggregates: Use an aggregate blend that consists of crushed
granite, crushed Oolitic limestone, other crushed materials (as approved by the Engineer for
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friction courses per Rule 14-103.005, Florida Administrative Code), or a combination of the
above. Crushed limestone from the Oolitic formation may be used if it contains a minimum of
12% silica material as determined by FM 5-510 and the Engineer grants approval of the source
prior to its use. As an exception, mixes that contain a minimum of 60% crushed granite may
either contain: 1) up to 40% fine aggregate from other sources or 2) a combination of up to 20%
RAP and the remaining fine aggregate from other sources.
A list of aggregates approved for use in friction course may be
available on the Departments website. The URL for obtaining this information, if available, is:
ftp://ftp.dot.state.fl.us/fdot/smo/website/sources/frictioncourse.pdf .
337-3.2.2.2: Asphalt Binder: Use an ARB-5 asphalt rubber binder. If
called for in the Contract Documents, use a PG 76-22 asphalt binder.
337-3.3 Grading Requirements:
337-3.3.1 FC-5: Use a mixture having a gradation at design within the ranges
shown in Table 337-1.
3/4 inch 1/2 inch 3/8 inch
100
85-100 55-75
Table 337-1
FC-5 Gradation Design Range
No. 4
No. 8 No. 16 No. 30
15-25
5-10
---
No. 50 No. 100 No. 200
--2-4
337-3.3.2 FC-9.5: Meet the design gradation requirements for a SP-9.5 Superpave
fine mix as defined in 334-3.2.2.
337-3.3.3 FC-12.5: Meet the design gradation requirements for a SP-12.5
Superpave fine mix as defined in 334-3.2.2.
337-4 Mix Design.
337-4.1 FC-5: The Department will design the FC-5 mixtures. Furnish the materials and
all appropriate information (source, gradation, etc.) as specified in 334-3.2.7. The Department
will have two weeks to design the mix.
The Department will establish the design binder content for FC-5 within the
following ranges based on aggregate type:
Aggregate Type
Crushed Granite
Crushed Limestone (Oolitic)
Binder Content
5.5 - 7.0
6.5 - 8.0
337-4.2 FC-9.5 and FC-12.5: Provide a mix design conforming to the requirements of
334-3.2 unless otherwise designated in the plans. Develop the mix design using an ARB-5 or
PG 76-22 asphalt binder if called for in the Contract Documents.
337-4.3 Revision of Mix Design: For FC-5, FC-9.5 and FC-12.5, meet the requirements
of 334-3.3. For FC-5, all revisions must fall within the gradation limits defined in Table 337-1.
337-5 Contractors Process Control.
Provide the necessary process control of the friction course mix and construction in
accordance with the applicable provisions of 320-2, 330-2 and 334-4.
The Engineer will monitor the spread rate periodically to ensure uniform thickness.
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Provide quality control procedures for daily monitoring and control of spread rate variability. If
the spread rate varies by more than 5% of the spread rate set by the Engineer in accordance with
337-8, immediately make all corrections necessary to bring the spread rate into the acceptable
range.
337-6 Acceptance of the Mixture.
337-6.1 FC-9.5 and FC-12.5: Meet the requirements of 334-5.
337-6.2 FC-5: Meet the requirements of 334-5 with the following exceptions:
1. The mixture will be accepted with respect to gradation (P-3/8, P-4, and P-8), and
asphalt binder content (Pb) only.
2. Testing in accordance with AASHTO T 312-11 and FM 1-T 209 (and
conditioning prior to testing) will not be required as part of 334-5.1.1.
3. The standard LOT size of FC-5 will be 2,000 tons, with each LOT subdivided
into four equal sublots of 500 tons each.
4. The Between-Laboratory Precision Values described in Table 334-6 are
modified to include (P-3/8, P-4, and P-8) with a maximum difference per FM 1-T 030 (Figure 2).
5. Table 334-5 (Master Production Range) is replaced by Table 337-2.
6. The mixture will be accepted on the roadway with respect to surface tolerance
in accordance with 334-5.8. No density testing will be required for these mixtures.
Table 337-2
FC-5 Master Production Range
Characteristic
Tolerance (1)
Asphalt Binder Content (%)
Target 0.60
Passing 3/8 inch Sieve (%)
Target 7.50
Passing No. 4 Sieve (%)
Target 6.00
Passing No. 8 Sieve (%)
Target 3.50
(1) Tolerances for sample size of n = 1 from the verified mix design
337-6.2.1 Individual Test Tolerances for FC-5 Production: Terminate the LOT
if any of the following Quality Control (QC) failures occur:
1) An individual test result of a sublot for asphalt binder content does not
meet the requirements of Table 337-2,
2) Two consecutive test results within the same LOT for gradation on any
of the following sieve sizes (P-3/8, P-4, and P-8) do not meet the requirements of Table 337-2. The
two consecutive failures must be on the same sieve.
When a LOT is terminated due to a QC failure, stop production of the
mixture until the problem is resolved to the satisfaction of the QC Manager(s) and/or Asphalt
Plant Level II technician(s) responsible for the decision to resume production after a quality
control failure, as identified in 105-8.6.4. In the event that it can be demonstrated that the
problem can immediately be or already has been resolved, it will not be necessary to stop
production. When a LOT is terminated, make all necessary changes to correct the problem. Do
not resume production until appropriate corrections have been made. Inform the Engineer of the
problem and corrections made to correct the problem. After resuming production, sample and
test the material to verify that the changes have corrected the problem. Summarize this
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information and provide it to the Engineer prior to the end of the work shift when production
resumes.
In the event that a QC failure is not addressed as defined above, the
Engineers approval will be required prior to resuming production after any future QC failures.
Address any material represented by a failing test result in accordance
with 334-5.9.5. Any LOT terminated under this Subarticle will be limited to a maximum Pay
Factor of 1.00 (as defined in 337-12.3) for each quality characteristic.
337-7 Special Construction Requirements.
337-7.1 Hot Storage of FC-5 Mixtures: When using surge or storage bins in the normal
production of FC-5, do not leave the mixture in the surge or storage bin for more than one hour.
337-7.2 Longitudinal Grade Controls for Open-Graded Friction Courses: On FC-5,
use either longitudinal grade control (skid, ski or traveling stringline) or a joint matcher.
337-7.3 Temperature Requirements for FC-5:
337-7.3.1 Air Temperature at Laydown: Spread the mixture only when the air
temperature (the temperature in the shade away from artificial heat) is at or above 65F. As an
exception, place the mixture at temperatures no lower than 60F, only when approved by the
Engineer based on the Contractors demonstrated ability to achieve a satisfactory surface texture
and appearance of the finished surface. The minimum ambient temperature may be further reduced
to 55F when using warm mix technology, if agreed to by both the Engineer and the Contractor.
337-7.3.2 Temperature of the Mix: Heat and combine the asphalt binder and
aggregate in a manner to produce a mix having a temperature, when discharged from the plant,
meeting the requirements of 320-6.3. Meet all requirements of 330-6.1.3 at the roadway. The
target mixing temperature shall be established at 320F for mixtures utilizing ARB-12 asphalt
binder. For mixtures utilizing PG 76-22 asphalt binder, the target mixing temperature shall be
established by the Contractor. The target mixing temperature may be reduced when using warm mix
technology.
337-7.4 Compaction of FC-5: Provide two, static steel-wheeled rollers, with an effective
compactive weight in the range of 135 to 200 PLI, determined as follows:
PLI
Total Weight of Roller (pounds)
Total Width of Drums (inches)
(Any variation of this equipment requirement must be approved by the Engineer.) Establish an
appropriate rolling pattern for the pavement in order to effectively seat the mixture without
crushing the aggregate. In the event that the roller begins to crush the aggregate, reduce the
number of coverages or the PLI of the rollers. If the rollers continue to crush the aggregate, use a
tandem steel-wheel roller weighing not more than 135 lb/per linear inch (PLI) of drum width.
337-7.5 Temperature Requirements for FC-9.5 and FC-12.5:
337-7.5.1 Air Temperature at Laydown: Meet the requirements of Table 330-1.
337-7.5.2 Temperature of the Mix: Heat and combine the asphalt binder and
aggregate in a manner to produce a mix having a temperature, when discharged from the plant,
meeting the requirements of 320-6.3. Meet all requirements of 330-6.1.3 at the roadway.
337-7.6 Prevention of Adhesion: To minimize adhesion to the drum during the rolling
operations, the Contractor may add a small amount of liquid detergent to the water in the roller.
At intersections and in other areas where the pavement may be subjected to cross-
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traffic before it has cooled, spray the approaches with water to wet the tires of the approaching
vehicles before they cross the pavement.
337-7.7 Transportation Requirements of Friction Course Mixtures: Cover all loads
of friction course mixtures with a tarpaulin, or waterproof cover, meeting requirements of 320-7.
337-7.8 Asphalt Rubber Binder Requirements: Meet the requirements of Section 336
Asphalt Rubber Binder, particularly noting testing and action requirements to be met at the
project site.
337-8 Thickness of Friction Courses.
337-8.1 FC-12.5 and FC-9.5: The thickness of the friction course layer will be the plan
thickness as shown in the Contract Documents. For construction purposes, the plan thickness
will be converted to spread rate as defined in 334-1.4.
Plan quantities are based on a Gmm of 2.540, corresponding to a spread rate of 110
2
lbs/yd -in. Pay quantities will be based on the actual maximum specific gravity of the mix being
used.
337-8.2 FC-5: The total thickness of the FC-5 layer will be the plan thickness as shown
in the Contract Documents. For construction purposes, the plan thickness will be converted to
spread rate based on the combined aggregate bulk specific gravity of the asphalt mix being used
as shown in the following equation:
Spread rate (lbs/yd2) = t x Gsb x 40.5
Where: t = Thickness (in.) (Plan thickness)
Gsb = Combined aggregate bulk specific gravity from the verified
mix design
The weight of the mixture shall be determined as provided in 320-3.2.
Plan quantities are based on a Gsb of 2.635, corresponding to a spread rate of
80 lbs/yd2. Pay quantities will be based on the actual combined aggregate bulk specific gravity
(Gsb) of the mix being used.
337-9 Special Equipment Requirements for FC-5.
337-9.1 Fiber Supply System: Use a separate feed system to accurately proportion the
required quantity of mineral fibers into the mixture in such a manner that uniform distribution is
obtained. Interlock the proportioning device with the aggregate feed or weigh system to maintain
the correct proportions for all rates of production and batch sizes. Control the proportion of fibers
to within plus or minus 10% of the amount of fibers required. Provide flow indicators or sensing
devices for the fiber system, interlocked with plant controls so that the mixture production will
be interrupted if introduction of the fiber fails.
When a batch plant is used, add the fiber to the aggregate in the weigh hopper or
as approved and directed by the Engineer. Increase the batch dry mixing time by 8 to 12 seconds,
or as directed by the Engineer, from the time the aggregate is completely emptied into the
pugmill. Ensure that the fibers are uniformly distributed prior to the addition of asphalt rubber
into the pugmill.
When a drum-mix plant is used, add and uniformly disperse the fiber with the
aggregate prior to the addition of the asphalt rubber. Add the fiber in such a manner that it will
not become entrained in the exhaust system of the drier or plant.
337-9.2 Hydrated Lime Supply System: For FC- mixes containing granite, use a
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separate feed system to accurately proportion the required quantity of hydrated lime into the
mixture in such a manner that uniform coating of the aggregate is obtained prior to the addition
of the asphalt rubber. Add the hydrated lime in such a manner that it will not become entrained
in the exhaust system of the drier or plant. Interlock the proportioning device with the aggregate
feed or weigh system to maintain the correct proportions for all rates of production and batch
sizes and to ensure that all mixture produced is properly treated with hydrated lime. Control the
proportion of hydrated lime to within plus or minus 10% of the amount of hydrated lime
required. Provide and interlock flow indicators or sensing devices for the hydrated lime system
with plant controls so that the mixture production will be interrupted if introduction of the
hydrated lime fails. The addition of the hydrated lime to the aggregate may be accomplished by
Method (A) or (B) as follows:
337-9.2.1 Method (A) - Dry Form: Add hydrated lime in a dry form to the
mixture according to the type of asphalt plant being used.
When a batch plant is used, add the hydrated lime to the aggregate in the
weigh hopper or as approved and directed by the Engineer. Increase the batch dry mixing time
by eight to twelve seconds, or as directed by the Engineer, from the time the aggregate is
completely emptied into the pugmill. Uniformly distribute the hydrated lime prior to the addition
of asphalt rubber into the pugmill.
When a drum-mix plant is used, add and uniformly disperse the hydrated
lime to the aggregate prior to the addition of the asphalt rubber. Add the hydrated lime in such a
manner that it will not become entrained in the exhaust system of the drier or plant.
337-9.2.2 Method (B) - Hydrated Lime/Water Slurry: Add the required
quantity of hydrated lime (based on dry weight) in a hydrated lime/water slurry form to the
aggregate. Provide a solution consisting of hydrated lime and water in concentrations as directed
by the Engineer. Use a plant equipped to blend and maintain the hydrated lime in suspension and
to mix it with the aggregates uniformly in the proportions specified.
337-9.3 Hydrated Lime Pretreatment: For FC-5 mixes containing granite, as an
alternative to 337-9.2, pretreat the aggregate with hydrated lime prior to incorporating the
aggregate into the mixture. Use a feed system to accurately proportion the aggregate and
required quantity of hydrated lime, and mix them in such a manner that uniform coating of the
aggregate is obtained. Control the proportion of hydrated lime to within plus or minus 10% of
the amount required. Aggregate pretreated with hydrated lime in this manner shall be
incorporated into the asphalt mixture within 45 days of pretreatment.
337-9.3.1 Hydrated Lime Pretreatment Methods: Pretreat the aggregate using
one of the following two methods:
Pretreatment Method A - Dry Form: Add the required quantity of hydrated
lime in a dry form to the aggregate. Assure that the aggregate at the time of pretreatment contains
a minimum of 3% moisture over saturated surface dry (SSD) conditions. Utilize equipment to
accurately proportion the aggregate and hydrated lime and mix them in such a manner as to
provide a uniform coating.
Pretreatment Method B - Hydrated Lime/Water Slurry: Add the required
quantity of hydrated lime (based on dry weight) in a hydrated lime/water slurry form to the
aggregate. Provide a solution consisting of hydrated lime and water in a concentration to provide
effective treatment. Use equipment to blend and maintain the hydrated lime in suspension, to
accurately proportion the aggregate and hydrated lime/water slurry, and to mix them to provide a
uniform coating.
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337-9.3.2 Blending QC Records: Maintain adequate QC records for the
Engineers review for all pretreatment activities. Include as a minimum the following
information (for each batch or days run of pretreatment): pretreatment date, aggregate
certification information, certified test results for the hydrated lime, aggregate moisture content
prior to blending, as-blended quantities of aggregate and hydrated lime, project number,
customer name, and shipping date.
337-9.3.3 Certification: In addition to the aggregate certification, provide a
certification with each load of material delivered to the HMA plant, that the material has been
pretreated in conformance with these specifications. Include also the date the material was
pretreated.
337-10 Failing Material.
Meet the requirements of 334-5.9. For FC-5, use the Master Production Range defined in
Table 337-2 in lieu of Table 334-5.
337-11 Method of Measurement.
For the work specified under this Section (including the pertinent provisions of
Sections 320 and 330), the quantity to be paid for will be the weight of the mixture, in tons. The
pay quantity will be based on the project average spread rate, limited to a maximum of 105% of
the spread rate determined in accordance with 337-8 or as set by the Engineer. The project
average spread rate is calculated by totaling the arithmetic mean of the average daily spread rate
values for each layer.
The bid price for the asphalt mix will include the cost of the asphalt binder (asphalt
rubber (or polymer), asphalt cement, ground tire rubber, anti-stripping agent, blending and
handling) and the tack coat application as directed in 300-8, as well as fiber stabilizing additive
and hydrated lime (if required). There will be no separate payment or unit price adjustment for
the asphalt binder material in the asphalt mix. The weight will be determined as provided in 3203.2 (including the provisions for the automatic recordation system).
Prepare a Certification of Quantities, using the Departments current approved form, for
the certified asphalt concrete friction course pay item. Submit this certification to the Engineer
no later than Twelve Oclock noon Monday after the estimate cut-off or as directed by the
Engineer, based on the quantity of asphalt produced and accepted on the roadway per Contract.
The certification must include the Contract Number, FPID Number, Certification Number,
Certification Date, period represented by Certification and the tons produced for each asphalt pay
item.
337-12 Basis of Payment.
337-12.1 General: Price and payment will be full compensation for all the work
specified under this Section (including the applicable requirements of Sections 320 and 330).
Based upon the quality of the material, a pay adjustment will be applied to the bid
price of the material as determined on a LOT by LOT basis. The pay adjustment will be assessed
by calculating a Pay Factor for individual quality characteristics. The pay adjustment will be
computed by multiplying a Composite Pay Factor for the LOT by the bid price per ton. Perform
all calculations with the Departments Asphalt Plant - Pay Factor Worksheets.
337-12.2 FC-9.5 and FC-12.5: Meet the requirements of 334-8.
337-12.3 FC-5: Meet the requirements of 334-8 with the following exceptions:
1. Pay factors will be calculated for asphalt binder content and the percentages
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passing the 3/8 inch, the No. 4, and the No. 8 sieves only.
2. The Small Quantity Pay Table for FC-5 Mixtures replaces the Small Quantity
Pay Table for Dense Graded Mixtures in the Departments Asphalt Plant - Pay Factor
Worksheets.
3. Table 337-3 replaces Table 334-7.
4. The Composite Pay Factor equation in 334-8.3 is replaced with the following:
CPF = [(0.20 x PF 3/8 inch) + (0.30 x PF No. 4) + (0.10 x PF No. 8) +
(0.40 x PF AC)]
Table 337-3
Specification Limits for FC-5
Quality Characteristic
Specification Limits
Asphalt Binder Content (%)
Target 0.45
Passing 3/8 inch sieve (%)
Target 6.00
Passing No. 4 sieve (%)
Target 4.50
Passing No. 8 sieve (%)
Target 2.50
337-12.4 Payment: Payment will be made under:
Item No. 337- 7Asphaltic Concrete Friction Course - per ton.
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SECTION 338
VALUE ADDED ASPHALT PAVEMENT
338-1 Description.
Construct Value Added Asphalt Pavement consisting of Asphalt Concrete Structural
Course and Asphalt Concrete Friction Course, subject to a three year warranty period after final
acceptance of the Contract in accordance with 5-11.
For purposes of this Specification, the Responsible Party, as designated herein, is
responsible for performance of the Value Added Asphalt Pavement including continued
responsibility for performing all remedial work associated with pavement distresses exceeding
threshold values determined in accordance with this Section, and as to which notice was
provided to the Responsible Party.
The work specified in this Section will not be paid for directly, but will be considered as
incidental to other Contract items.
338-2 Materials and Construction Requirements.
Meet the following requirements:
Hot Bituminous Mixtures - Plant, Methods and
Equipment ...........................................................Section 320
Hot Bituminous Mixtures - General Construction
Requirements ......................................................Section 330
Superpave Asphalt Concrete ...............................Section 334
Asphalt Concrete Friction Courses.......................Section 337
338-3 Responsible Party.
Prior to any Value Added Asphalt Pavement being placed on the project, the Contractor
shall designate a Responsible Party to accept responsibility for maintaining the Value Added
Asphalt Pavement, when remedial work is required. When the scope of the asphalt work is only
milling and resurfacing, and there is no construction of the embankment, subgrade or base below
the pavement included in the Contract, the Responsible Party may be either the Contractor or the
Department approved subcontractor performing the Value Added Asphalt Pavement work. When
the construction of the embankment, subgrade or base below the pavement is included in the
Contract, in addition to the construction of the Asphalt Concrete Structural Course and Asphalt
Concrete Friction Course, the Contractor shall be considered as the Responsible Party.
When the Responsible Party is a subcontractor, the subcontractor must be pre-qualified
with the Department in the category of asphalt, and such designation must be made to the
Department by the Contractor. The proposed subcontractor must execute and deliver to the
Department a form, provided by the Department, prior to or concurrent with the Contractors
request to sublet any Value Added Asphalt Pavement work, stipulating that the subcontractor
assumes all responsibility as the Responsible Party for the Value Added Asphalt Pavement
within the three-year warranty period. Failure to timely designate the Responsible Party will
result in the Contractor being the Responsible Party unless otherwise agreed to in writing by the
Department.
Upon final acceptance of the Contract in accordance with 5-11, the Contractors
responsibility for maintenance of all the work or facilities within the project limits of the
Contract will terminate in accordance with 5-11; with the sole exception that the obligations set
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forth in this Section for Value Added Asphalt Pavement will continue thereafter to be the
responsibility of the Responsible Party as otherwise provided in this Section.
338-4 Statewide Disputes Review Board.
The Statewide Disputes Review Board in effect for this Contract will resolve any and all
disputes that may arise involving administration and enforcement of this Specification. The
Responsible Party and the Department acknowledge that use of the Statewide Disputes Review
Board is required, and the determinations of the Statewide Disputes Review Board for disputes
arising out of this Specification will be binding on both the Responsible Party and the
Department, with no right of appeal by either party.
Meet the requirements of 8-3.
338-5 Pavement Evaluation and Remedial Work.
338-5.1 General: The Departments Pavement Condition Survey Program, along with
observations by the Engineer, will be used as the basis for determining the extent and the
magnitude of the pavement distresses occurring on the project. In the event the level of distress
exceeds any of the threshold values defined below, remedial work as described in 338-5.5 by the
Responsible Party will be required.
The Department will monitor the pavement for distresses and may require
remedial action at any time. For evaluation purposes, the project will be subdivided into LOTs of
0.1 mile per lane. When the segment is less than 0.1 mile, the segment will be called a partial
LOT. For purposes of threshold values and remedial work, partial lots and lots will be treated as
lots. The Department may conduct a Pavement Condition Survey of the value added pavement
following the final acceptance of the project, and at intermediate times throughout the warranty
period with findings provided when considered by the Department to be the obligation of the
Responsible Party.
The final survey, if determined by the Engineer to be necessary, will be conducted
before the end of the warranty period with results provided to the Responsible Party for those
conditions exceeding contract threshold values requiring remedial action that the Department
believes to be an obligation of the Responsible Party. The Department will be responsible for all
costs associated with the surveys.
If the survey findings, intermediate or final, are to be disputed by the Responsible
Party, written notification must be provided to the Engineer within 30 calendar days of the date
of receipt of the information from the Department.
During the warranty period, the Responsible Party may monitor the project using
nondestructive methods and may participate with the Department in the Pavement Condition
Surveys upon request. The Responsible Party shall not conduct any coring, milling or other
destructive methods without prior approval by the Engineer.
338-5.2 Category 1 Pavement: For purposes of this Specification, Category 1
Pavement is defined as mainline roadways, access roads and frontage roads with a design speed
of 55 mph and greater.
Threshold values and associated remedial work for Category 1 Value Added
Asphalt Pavement are specified in Table 338-1.
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TABLE 338-1
Category 1 Pavements
Type of Distress
Threshold Values
Remedial Work
Remove and replace the distressed LOT(s)
to the full depth of all layers and to the full
lane width (2)
Remove and replace the friction course layer
(3)
Ride
RN < 3.5
for the full length and the full lane width of
the distressed LOT(s)(4)
Propose the method of correction to the
Settlement/Depression(5)
Depth 1/2 inch
Engineer for approval prior to beginning
remedial work
Cumulative length of Remove and replace the distressed LOT(s)
Cracking (6)
cracking > 30 feet for to the full depth of all layers, and to the full
Cracks > 1/8 inch
lane width (7)
Remove and replace the distressed area(s) to
Raveling and/or
the full distressed depth and the full lane
Delamination affecting the
Any length
width for the full distressed length plus 50
Friction Course (8)
on each end
Rutting (1)
Depth > 0.25 inch
Pot holes and Slippage
Area(s) (8)
Observation by
Engineer
Bleeding (9)
Remove and replace the distressed area(s) to
the full distressed depth and the full lane
width for the full distressed length plus 50
on each end
Loss of surface
Remove and replace the distressed area(s) to
texture due to excess the full distressed depth and the full lane
asphalt, individual width for the full distressed length plus 50
area 10 sf.
on each end
(1) Rutting: Rut depth to be determined by Laser Profiler in accordance with the Flexible Pavement Condition Survey Handbook.
For any LOT that cannot be surveyed by Laser Profiler, the rut depth will be determined manually in accordance with the
Flexible Pavement Condition Survey Handbook, with the exception that the number of readings per LOT will be one every
20 feet. For a partial LOT, a minimum of three measurements not exceeding 20 feet apart will be made. When the average of the
measurements obtained manually exceeds 0.30 inch or if any individual measurement exceeds 0.6 inch, remedial work will be
required.
(2) Remedial Work for Rutting: The Contractor may propose removal and replacement of less than the full depth of all layers by
preparation and submittal of a signed and sealed engineering analysis report, demonstrating the actual extent of the distressed
area(s). Remedial work must be performed in accordance with Table 338-1 unless approved otherwise by the Engineer.
(3) Ride: Ride Number (RN) to be established by Laser Profiler in accordance with FM 5-549.
(4)If the deficient ride is due to underlying asphalt layers; base, subgrade, or embankment which were constructed by the
Responsible Party, propose the method of correction to the Engineer for approval prior to beginning the remedial work.
(5)Settlement/Depression: Depth of the settlement/depression to be determined by a 6 foot manual straightedge.
(6) Cracking: Beginning and ending of 1/8 inch cracking will be determined as the average of three measurements taken at one
foot intervals. The longitudinal construction joint at the lane line will not be considered as a crack.
(7) Remedial Work for Cracking: The Contractor may propose removal and replacement of less than the full depth of all layers
by preparation and submittal of a signed and sealed engineering analysis report, demonstrating the actual extent of the distressed
area(s). Remedial work must be performed in accordance with Table 338-1 unless approved otherwise by the Engineer.
(8) Raveling, Delamination, Pot holes, Slippage: As defined and determined by the Engineer in accordance with the examples
displayed at the following URL: http://www.dot.state.fl.us/SpecificationsOffice/Implemented/URLinSpecs/Pavement.shtm
(9) Bleeding: Bleeding to be defined and determined by the Engineer in accordance with the examples displayed at the following
URL: http://www.dot.state.fl.us/SpecificationsOffice/Implemented/URLinSpecs/Pavement.shtm
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338-5.3 Category 2 Pavement: For purposes of this Specification, Category 2
Pavement is defined as mainline roadways, access roads and frontage roads with a design speed
less than 55 mph; approach transition and merge areas at toll booths; ramps; acceleration and
deceleration lanes (including tapers); turn lanes; parking areas; rest areas; weigh stations; and
agricultural inspection stations.
Threshold values and associated remedial work for Category 2 Value Added
Asphalt Pavement are specified in Table 338-2.
TABLE 338-2
Category 2 Pavements
Type of Distress
Rutting(1)
Cracking
Threshold Values
Remedial Work
Measured by Laser Profiler:
See Table 338-1
See Table 338-1
Manual Measurement: Avg.
Remove and replace 1.5 inch(1a) the
Depth > 0.4 inch
full lane width for the area plus 50 feet
Cumulative length of cracking
> 300 feet for Cracks > 1/8
See Table 338-1
inch
Surface Deterioration (2)
See Table 338-1
See Table 338-1
Settlement/Depression(3)
Depth 1/2 inch
See Table 338-1
(1) Rutting: Rut depth to be determined by Laser Profiler in accordance with the Flexible Pavement Condition Survey Handbook.
For any LOT that cannot be surveyed by the Laser Profiler, the rut depth will be determined manually in accordance with the
Flexible Pavement Condition Survey Handbook, with the exception that the number of readings per LOT will be one every 20
feet. For partial LOT, minimum of three measurements not exceeding 20 feet apart will be checked. When the average of the
measurements obtained manually exceeds 0.40 inch, or if any individual measurement exceeds 0.6 inch, remedial work will be
required..
(1a) If pavement has an open graded friction course, remove and replace 2.0 inches.
(2) Surface Deterioration: As used in Table 338-2, Surface Deterioration includes Raveling and/or Delamination affecting the
Friction Course; Pot holes; Slippage Area(s); and Bleeding; all as defined and footnoted in Table 338-1.
(3)Settlement/Depression: Depth of the settlement/depression to be determined by a 6 foot manual straightedge.
338-5.4 Category 3 Pavement: For purposes of this Specification, Category 3
Pavement is defined as bicycle paths, walking paths, median crossovers, shoulders and other
areas as determined by the Engineer.
Threshold values and associated remedial work for Category 3 Value Added
Asphalt Pavement are specified in Table 338-3.
TABLE 338-3
Category 3 Pavements
Type of Distress
Threshold Values
Remedial Work
Rutting
N/A
N/A
Cracking
Cumulative length
of cracking > 500
feet for Cracks >
1/8 inch
See Table 338-1
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TABLE 338-3
Category 3 Pavements
Type of Distress
Threshold Values
Remedial Work
Surface Deterioration (1)
See Table 338-1
See Table 338-1
Settlement/Depression(2)
Depth 1/2 inch
See Table 338-1
(1) Surface Deterioration: As used in Table 338-3, Surface Deterioration includes Raveling and/or Delamination affecting the
Friction Course; Pot holes; Slippage Area(s); and Bleeding; all as defined and footnoted in Table 338-1. Raveling of FC-5 for
Category 3 Pavements is excluded from this requirement.
(2) Settlement/Depression: Depth of the settlement/depression to be determined by a 6 foot manual straightedge.
338-5.5 Remedial Work: The Responsible Party will perform all necessary remedial
work described within this Section at no cost to the Department. If the pavement distresses
exceed threshold values and it is determined that the cause of the distress is due to the
embankment, subgrade, base or other activities performed by the Contractor, the Responsible
Party will be responsible for performing all remedial work associated with the pavement distress.
Should an impasse develop in any regard as to the need for remedial work or the extent required,
the Statewide Disputes Review Board will render a final decision by majority vote.
Remedial work will not be required if any one of the following conditions is
found to apply:
a. Determination that the pavement thickness design as provided by the
Department is deficient. The Department will make available a copy of the original pavement
thickness design package and design traffic report to the Responsible Party upon request. The
Responsible Party is responsible for performing all remedial work associated with the pavement
distress if the pavement design is provided by the Contractor.
b. Determination that the Accumulated ESALs (Number of 18 Kip
Equivalent Single Axle Loads in the design lane) has increased by 25% or more than the
Accumulated ESALs used by the Department for design purposes for the warranty period for the
pavement design life. In calculating ESALs, the Average Annual Daily Traffic (AADT) will be
obtained from the Departments traffic count data and the T24 (Percent Heavy Trucks during a
24 hour period) will be obtained from the Departments traffic classification survey data.
c. Determination that the deficiency was due to the failure of the existing
underlying layers that were not part of the Contract work.
d. Determination that the deficiency was the responsibility of a third party
or its actions, unless the third party was performing work included in the Contract.
If a measured distress value indicates remedial action is required per Table 338-1,
Table 338-2 and/or Table 338-3, the Responsible Party must begin remedial work within
45 calendar days of notification by the Department or a ruling of the Statewide Disputes Review
Board. The Disputes Review Board will determine the allowable duration for the completion of
the remedial work, but not to exceed 6 months.
In the event remedial action is necessary and forensic information is required to
determine the source of the distress, the Department may core and/or trench the pavement. The
Responsible Party will not be responsible for damages to the pavement as a result of any forensic
activities conducted by the Department.
As applicable to distress criteria for rutting, ride and cracking for Category 1 and
Category 2 pavements, when two LOTs requiring remedial action are not separated by three or
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more LOTs not requiring remedial action, the remedial work shall be required for the total length
of all such contiguous LOTs, including the intermediate LOTs not requiring remedial action.
Additionally, for Category 1 and Category 2 pavements, where such areas of
remedial action are required due to raveling, slippage or bleeding are separated by less than
1,000 feet, the remedial work will be required for the entire area contiguous to the distressed
areas, including intermediate areas otherwise requiring no remedial action.
The Responsible Party has the first option to perform all remedial work that is
determined by the Department to be their responsibility. If, in the opinion of the Engineer, the
problem poses an immediate danger to the traveling public and the Responsible Party cannot
provide temporary mitigation for the defect within 4 hours of written notification and restore the
pavement to its original design condition within 72 hours of written notification, the Engineer
has the authority to have the remedial work performed by other forces. Temporary mitigation
includes the use of traffic control systems such as barricades, drums, or other approved devices
to secure the area including lane closures if necessary, and constructing temporary repairs
making it safe for the roadway user until the defect can be restored to its original design
condition. The Responsible Party is responsible for all incurred costs of the work performed by
other forces should the problem (remedial work) be determined to be the responsibility of the
Responsible Party. Remedial work performed by other forces does not alter any of the
requirements, responsibilities or obligations of the Responsible Party.
The Responsible Party must complete all remedial work to the satisfaction of the
Engineer. Any disputes regarding the adequacy of the remedial work will be resolved by the
Statewide Disputes Review Board. Approval of remedial work does not relieve the Responsible
Party from continuing responsibility under the provisions of this Specification.
Notify the Engineer in writing prior to beginning any remedial work. Meet the
requirements of the Departments Standard Specifications for Road and Bridge Construction and
implemented modifications thereto when performing any remedial work. Perform all signing and
traffic control in accordance with the current edition of the Departments Design Standards for
Design, Construction, Maintenance and Utility Operations on the State Highway System.
Provide Maintenance of Traffic during remedial work at no additional cost to the Department.
Lane closure restrictions listed in the original Contract will apply to remedial work. Written
request(s) to obtain permission for lane closure(s) for either forensic investigation or remedial
work must be made to the Engineer 48 hours in advance of any lane closures. Do not perform
any lane closures until written permission is given by the Engineer.
If remedial work necessitates a corrective action to overlying asphalt layers,
pavement markings, signal loops, adjacent lane(s), roadway shoulders, or other affected Contract
work, perform these corrective actions using similar products at no additional cost to the
Department.
338-6 Responsible Partys Failure to Perform.
Should the Responsible Party fail to timely submit any dispute to the Statewide Disputes
Review Board, fail to satisfactorily perform any remedial work, or fail to compensate the
Department for any remedial work performed by the Department and determined to be the
Responsible Partys responsibility in accordance with this Specification, the Department will
suspend, revoke or deny the Responsible Partys certificate of qualification under the terms of
Section 337.16(d)(2), Florida Statutes, for a minimum of 6 months or until the remedial work has
been satisfactorily performed (or full and complete payment for remedial work performed by
others made to the Department), whichever is longer. Should the Responsible Party choose to
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challenge the Departments notification of intent for suspension, revocation or denial of
qualification and the Departments action is upheld, the Responsible Party will have its
qualification suspended for an additional minimum of 6 months.
The remedial work is not an obligation of the Contractors bond required by
Section 337.18, Florida Statutes.
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SECTION 339
MISCELLANEOUS ASPHALT PAVEMENT
339-1 Description.
Construct asphalt pavement in areas where vehicular traffic does not travel, such as
pavement under guardrail, bicycle paths, median pavement, sidewalks, etc.
Also, chemically treat the underlying soil to prevent plant growth.
339-2 Materials.
For the pavement, use any plant-mixed hot bituminous mixture meeting the requirements
of a mix design verified by the Engineer, except do not use open-graded friction course (FC-5).
For bicycle paths, use a mixture that produces a finished pavement which will not distort or mar
under bicycle or mower wheel loads.
In general, the Engineer will accept the mixture on the basis of visual inspection with no
further testing required.
339-3 Foundation and Soil Treatment.
Shape the soil in areas where pavement is to be constructed, to a surface true to the lines,
grades and typical cross-sections shown in the Plans. Compact the soil to a firm state.
Immediately before placing the pavement, uniformly apply a pre-emergent herbicide in
accordance with the requirements of 7-1.7, to the foundation soil. Ensure that the herbicide
carries an approved label for use under paved surfaces, and that herbicide is applied in
accordance with directions on the label.
Prevent damage to any adjacent vegetation during herbicide application. Replace, at no
expense to the Department, any plants damaged as the result of soil treatment outside designated
areas.
339-4 Placing Mixture.
Uniformly place the hot bituminous mixture by machine or hand methods at the rate of
spread or dimensions indicated in the Plans or as otherwise directed by the Engineer. If posts are
to be constructed within the pavement area, the Contractor may cut holes for installation through
the completed pavement. After completing installation of posts and compaction of the backfill
material, patch the area around each post with fresh hot bituminous mixture.
If directed by the Engineer, place miscellaneous asphalt pavement prior to placement of
the final surface course.
339-5 Compacting Mixture.
Uniformly compact the hot bituminous mixture with lightweight rollers or vibratory
compactors as directed by the Engineer. The Contractor may use hand tamps for compaction in
areas which are inaccessible to other compaction equipment.
The Engineer will not require a specific density.
339-6 Surface Requirements.
Provide a finished surface that is reasonably smooth, of uniform texture, and shaped so as
to drain without ponding of water.
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Upon completion of the pavement, shape the surface of the adjacent earth to match the
pavement edges.
339-7 Method of Measurement.
The quantity to be paid for will be the weight, in tons, determined by an electronic
weighing system as described in 320-3.2. The pay quantity will be based on the average spread
rate of the area shown in the Plans or authorized by the Engineer or dimensions for the project,
limited to a maximum of 105% of the plan thickness quantity. For calculation, a weight of
100 lbs/yd2 per inch thickness of asphalt will be used.
Prepare a Certification of Quantities, using the Departments current approved form, for
the certified miscellaneous asphalt pavement pay item. Submit this certification to the Engineer
no later than Twelve Oclock noon Monday after the estimate cut-off or as directed by the
Engineer, based on the quantity of asphalt produced and accepted on the Contract. The
certification must include the Contract Number, FPID Number, Certification Number,
Certification Date, period represented by Certification and the tons produced for each asphalt
pay item.
339-8 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including shaping and compacting the foundation, soil sterilization treatment, furnishing of the
bituminous material used in the mixture, and shaping of adjacent earth surfaces.
Payment will be made under:
Item No. 339- 1Miscellaneous Asphalt Pavement - per ton.
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SECTION 341
ASPHALT RUBBER MEMBRANE INTERLAYER
341-1 Description.
Construct an asphalt rubber membrane interlayer composed of a separate application of
asphalt rubber binder covered with a single application of aggregate.
341-2 Materials.
341-2.1 Asphalt Rubber Binder: Use ARB-20 meeting the requirements of Section 336.
341-2.2 Cover Material: Use Size No. 6 stone, slag, or gravel meeting the requirements
of Section 901.
341-3 Equipment.
341-3.1 Power Broom: Provide a power broom for cleaning the existing pavement
capable of removing all loose material from the surface.
341-3.2 Spreading Equipment: Provide a self-propelled aggregate spreader that can be
adjusted to accurately apply the cover material at the specified rate and that spreads the material
uniformly.
341-3.3 Rollers: Provide self-propelled, pneumatic-tired traffic type rollers equipped
with at least 7 smooth-tread, low-pressure tires, and capable of carrying a gross load of at least
8 tons. Maintain a minimum tire inflation pressure of 90 psi, or as specified by the manufacturer,
such that in no two tires the air pressure varies more than 5 psi. Load the traffic roller as directed
by the Engineer.
341-3.4 Mixing Equipment: Use mixing equipment for asphalt rubber binder designed
for that purpose and capable of producing and maintaining a homogeneous mixture of rubber and
asphalt cement at the specified temperature.
341-3.5 Pressure Distributor: Use a pressure type distributor to apply asphalt rubber
binder capable of maintaining a homogeneous mixture of rubber and asphalt cement at the
specified temperature and consistently apply the material in a uniform manner.
341-4 Contractors Quality Control.
Provide the necessary quality control of the asphalt rubber binder, and interlayer
construction in accordance with the Contract requirements. Provide in the Quality Control Plan
procedures for monitoring and controlling of rate of application. If the rate of application varies
by more than 5% from the rate set by the Engineer in accordance with 341-6, immediately make
all corrections necessary to bring the spread rate into the acceptable range. The Engineer may
take additional measurements at any time. The Engineer will randomly check the Contractors
measurement to verify the spread rate.
341-5 Preparation of Asphalt Rubber Binder.
Meet the requirements of Section 336 Asphalt Rubber Binder, particularly noting testing
and action requirements to be met at the project site/asphalt plant. Combine the materials as
rapidly as possible for such a time and at such a temperature that the consistency of the binder
approaches that of a semi-fluid material. The Engineer will be the sole judge of when the
material has reached application consistency and will determine if an extender oil or diluent is
needed for that purpose. After reaching the proper consistency, proceed with application
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immediately. Never hold the mixture at temperatures over 350F for more than six hours after
reaching that temperature.
341-6 Construction Procedure.
341-6.1 Preparation of Surface: Prior to application of the asphalt rubber binder, clean
the existing pavement as specified in 300-5.
341-6.2 Application of Asphalt Rubber Binder: Apply the asphalt rubber binder only
under the following conditions:
a. The air temperature is above 50F and rising.
b. The pavement is absolutely dry.
c. The wind conditions are such that cooling of the asphalt rubber binder will not
be so rapid as to prevent good bonding of the aggregate.
Uniformly apply the asphalt rubber binder, at the rate of 0.6 to 0.8 gal/yd2 as
directed by the Engineer. Use an application rate based on the unit weight as shown in Table
336-1. For conversions to standard 60F, refer to 300-9.3. Determine the rate of application after
each application operation.
341-6.3 Application of Cover Material: Immediately after application of the asphalt
rubber binder, uniformly spread the cover material at a rate of 0.26 and 0.33 ft3/yd2. The
Engineer will set the exact rate. Determine the application rate at the beginning of each days
production, and as needed to control the operation, a minimum of twice per day. Maintain an
application rate such that the pavement is covered uniformly with aggregate, and is one
aggregate layer thick. For the cover material, use aggregate that is reasonably free of any
adherent coatings and that does not contain excessive moisture. Immediately after the application
of cover material, check the surface to ensure a uniform distribution of cover material and a
smooth surface.
Do not separate the application of the asphalt rubber binder and the application of
the cover material by more than 300 feet, unless approved by the Engineer.
341-6.4 Rolling: In order to ensure maximum embedment of the aggregate, cover the
entire width of the mat immediately by traffic rollers. For the first coverage, provide a minimum
of three traffic rollers in order to accomplish simultaneous rolling in echelon of the entire width
of the spread.
After initial rolling, immediately correct all portions of the completed surface,
that the Engineer deems are defective (not properly covered by aggregates, fat spots, excessive
free aggregate, etc.).
Following the first coverage, make additional coverages with traffic rollers as
directed by the Engineer.
341-6.5 Traffic Control: For the normal sequence of construction operations, place the
first course of asphalt concrete overlay over the membrane prior to opening to traffic.
341-7 Unacceptable Asphalt Rubber Membrane Interlayer.
If the asphalt rubber membrane interlayer is unacceptable due to incorrect blending,
application rate, or not meeting the requirements of this Section, or damaged prior to placement
of the asphalt concrete layer, remove and replace it as directed by the Engineer at no additional
cost to the Department. Do not apply excessive amounts of asphalt rubber binder.
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341-8 Placement of Asphalt Concrete Overlay.
Ensure that the thickness and temperature of the initial layer of asphalt concrete placed
on top of the asphalt rubber membrane interlayer are such that the overlay bonds to the interlayer
and the underlying layer without voids or excessive binder. Core the asphalt overlay as directed
by the Engineer to evaluate the binder and aggregate spread rates, as well as the effectiveness of
the asphalt concrete overlay in producing a well-bonded interlayer.
341-9 Method of Measurement.
341-9.1 Asphalt Rubber Membrane Interlayer: The quantity to be paid for will be
plan quantity, in square yards, completed and accepted.
341-9.2 Bituminous Material (Asphalt Rubber Binder-Interlayer): The quantity will
be the volume, in gallons, determined as provided in 300-8.
341-9.3 Submittal of Certification of Quantities for Bituminous Material: Prepare a
Certification of Quantities, using the Departments current approved form, for the quantity of
bituminous material placed and accepted. Submit this certification to the Engineer no later than
Twelve Oclock noon Monday after the monthly estimate cutoff date or as directed by the
Engineer. The certification must include the Contract Number, FPID Number, State Project
Number, Certification Number and period represented by the Certification.
341-10 Basis of Payment.
341-10.1 Asphalt Rubber Membrane Interlayer: Price and payment will be full
compensation for all work specified in this Section, including furnishing cover materials,
handling, spreading, rolling, bituminous material, and other incidental work necessary to
complete this item.
341-10.2 Bituminous Material (Asphalt Rubber Binder-Interlayer): Payment will be
included in the price of the asphalt rubber membrane interlayer and will be full compensation for
furnishing asphalt cement, ground tire rubber, blending and handling.
341-10.3 Payment Items: Payment will be made under:
Item No. 341- 70Asphalt Rubber Membrane Interlayer - per square yard.
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SECTION 346
PORTLAND CEMENT CONCRETE
346-1 Description.
Use concrete composed of a mixture of portland cement, aggregate, water, and, where
specified, admixtures, pozzolan and ground granulated blast furnace slag. Deliver the portland
cement concrete to the site of placement in a freshly mixed, unhardened state.
Obtain concrete from a plant that is currently on the list of Producers with Accepted
Quality Control Programs. Producers seeking inclusion on the list shall meet the requirements of
105-3. If the concrete production facilitys QCP is suspended, the Contractor is solely
responsible to obtain the services of another concrete production facility with an accepted QCP
or await the re-acceptance of the affected concrete production facilitys QCP prior to the
placement of any further concrete on the project. There will be no changes in the contract time or
completion dates. Bear all delay costs and other costs associated with the concrete production
facilitys QCP acceptance or re-acceptance.
346-2 Materials.
346-2.1 General: Meet the following requirements:
Coarse Aggregate ..................................................................... Section 901
Fine Aggregate* ....................................................................... Section 902
Portland Cement....................................................................... Section 921
Water ........................................................................................ Section 923
Admixtures** ........................................................................... Section 924
Pozzolans and Slag .................................................................. Section 929
*Use only silica sand except as provided in 902-5.2.3.
**Use products listed on the Departments Qualified Products List (QPL).
Do not use materials containing hard lumps, crusts or frozen matter, or that is
contaminated with dissimilar material.
346-2.2 Types of Cement: Unless a specific type of cement is designated elsewhere, use
Type I, Type P, Type IS, Type II, Type II (MH) or Type III cement in all classes of concrete.
Use Type II (MH) for all mass concrete elements.
Use only the types of cements designated for each environmental condition in
structural concrete. A mix design for a more aggressive environment may be substituted for a
lower aggressive environmental condition.
TABLE 1
BRIDGE SUPERSTRUCTURES
Slightly Aggressive Moderately Aggressive Extremely Aggressive
Component
Environment
Environment
Environment
Precast Superstructure
Type I, Type II,
and Prestressed
Type I or Type III
Type III, Type IP, or
Type II (MH)
Elements
Type IS
Type I, Type II,
Cast In Place
Type I
Type II (MH)
Type IP, or Type IS
BRIDGE SUBSTRUCTURE, DRAINAGE STRUCTURES AND OTHER STRUCTURES
All Elements
Type I or Type III
Type I, Type II,
Type II (MH)
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Component
TABLE 1
BRIDGE SUPERSTRUCTURES
Slightly Aggressive Moderately Aggressive Extremely Aggressive
Environment
Environment
Environment
Type IP, or Type IS
346-2.3 Pozzolans and Slag: Use fly ash or slag materials as a cement replacement, on
an equal weight replacement basis, in all classes of concrete with the following limitations:
(1) Mass Concrete:
a. Fly Ash - Ensure that the quantity of cement replaced with fly ash is
18% to 50% by weight, except where the core temperature is expected to rise above 165F. In
that case, ensure that the percentage of fly ash is 35% to 50% by weight.
b. Slag - Ensure that the quantity of cement replaced with slag is 50% to
70% by weight. Ensure that slag is 50% to 55% of total cementitious content by weight when
used in combination with silica fume, ultrafine fly ash and/or metakaolin.
c. Fly Ash and Slag - Ensure that there is at least 20% fly ash by weight
and 40% portland cement by weight for mixes containing portland cement, fly ash and slag.
(2) Drilled Shaft:
a. Fly Ash - Ensure that the quantity of cement replaced with fly ash is
33% to 37% by weight.
b. Slag - Ensure that the quantity of cement replaced with slag is 58% to
62% by weight.
(3) Precast Concrete - Ensure that the precast concrete has a maximum of 25% fly
ash or a maximum of 70% slag. In extremely aggressive environments, ensure that the precast
concrete has a minimum of 18% fly ash or a minimum of 50% slag.
(4) For all other concrete uses not covered in (1), (2) and (3) above,
a. Fly Ash - Ensure that the quantity of cement replaced with fly ash is
18% to 22% by weight.
b. Slag - Ensure that the quantity of cement replaced with slag is 25% to
70% for slightly and moderately aggressive environments and 50% to 70% by weight when used
in extremely aggressive environments. Ensure that slag is 50% to 55% of total cementitious
content by weight when used in combination with silica fume, ultra fine fly ash and/or
metakaolin.
c. Fly Ash and Slag - Ensure that there is at least 20% fly ash by weight
and 40% portland cement by weight for mixes containing portland cement, fly ash and slag.
d. Class I and Class II concrete, excluding Class II (Bridge Deck), are not
required to meet the minimum fly ash or slag requirements in slightly and moderately aggressive
environments. The fly ash content shall be less than or equal to 25% by weight of cement and the
slag content shall be less than or equal to 70% by weight of cement.
(5) Blended Cements:
a. Type IS - Ensure that the quantity of slag in Type IS is less than or
equal to 70% by weight.
b. Type IP - Ensure that the quantity of the pozzolan in Type IP is less
than or equal to 40% by weight.
(6) Silica Fume, Metakaolin and Ultrafine Fly Ash - When silica fume,
metakaolin or ultrafine fly ash is used, it must be used in combination with fly ash or slag.
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a. Silica Fume - Ensure that the quantity of cementitious material replaced
with silica fume is 3% to 9% by weight.
b. Metakaolin - Ensure that the quantity of cementitious material replaced
with metakaolin is 8% to 12% by weight.
c. Ultrafine Fly Ash - Ensure that the quantity of cementitious material
replaced with ultrafine fly ash is 8% to 12% by weight.
d. Cure in accordance with the manufacturers recommendation and as
approved by the Engineer.
346-2.4 Coarse Aggregate Gradation: Produce all concrete using Size No. 57, 67 or 78
coarse aggregate. With the Engineers approval, Size No. 8 or Size No. 89 may be used either
alone or blended with Size No. 57, 67 or 78 coarse aggregate. The Engineer will consider
requests for approval of other gradations individually. Submit sufficient statistical data to
establish production quality and uniformity of the subject aggregates, and establish the quality
and uniformity of the resultant concrete. Furnish aggregate gradations sized larger than nominal
maximum size of 1.5 inch as two components.
For Class I and Class II, excluding Class II (Bridge Deck), the coarse and fine
aggregate gradation requirements set forth in Sections 901 and 902 are not applicable and the
aggregates may be blended; however, the aggregate sources must be approved by the
Department. Do not blend the aggregate if the size is smaller than Size No. 78.
346-2.5 Admixtures: Use admixtures in accordance with the requirements of this
subarticle. Chemical admixtures not covered in this subarticle may be approved by the
Department. Submit statistical evidence supporting successful laboratory and field trial mixes
which demonstrate improved concrete quality or handling characteristics.
Use admixtures in accordance with the manufacturers recommended dosage rate.
Do not use admixtures or additives containing calcium chloride (either in the raw materials or
introduced during the manufacturing process) in reinforced concrete.
346-2.5.1 Water-Reducer/Water-Reducer Retardant Admixtures: When a
water-reducing admixture is used, meet the requirements of a Type A. When a water-reducing
and retarding admixture is used, meet the requirements of a Type D.
346-2.5.2 Air Entrainment Admixtures: Use an air entraining admixture in all
concrete mixes except counterweight concrete. For precast concrete products, the use of air
entraining admixture is optional for Class I and Class II concrete.
346-2.5.3 High Range Water-Reducing Admixtures:
346-2.5.3.1 General: When a high range water-reducing admixture is
used, meet the requirements of a Type F or Type I. When a high range water-reducing and
retarding admixture is used, meet the requirements of a Type G or Type II. Do not use Type I, II,
F or G admixtures in drilled shaft concrete. When silica fume or metakaolin is incorporated into
a concrete mix design, the use of a high range water-reducing admixture Type I, II, F or G is
mandatory.
346-2.5.3.2 Flowing Concrete Admixtures for Precast/Prestressed
Concrete: Use a Type I, II, F or G admixture for producing flowing concrete. If Type F or G
admixture is used, verify the distribution of aggregates in accordance with ASTM C 1610 except
allow for minimal vibration for consolidating the concrete. The maximum allowable difference
between the static segregation is less than or equal to 15 percent. Add the flowing concrete
admixtures at the concrete production facility.
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346-2.5.4 Corrosion Inhibitor Admixture: Use only with concrete containing
Type II cement, or Type II (MH) cement, and a water-reducing retardant admixture, Type D, or
High Range Water-Reducer retarder admixture, Type G, to normalize the setting time of
concrete. Ensure that all admixtures are compatible with the corrosion inhibitor admixture.
346-2.5.5 Accelerating Admixture for Precast Concrete: The use of nonchloride admixtures Type C or Type E is allowed in the manufacturing of precast concrete
products that are used in slightly aggressive environments.
346-3 Classification, Strength, Slump and Air Content.
346-3.1 General: The separate classifications of concrete covered by this Section are
designated as Class I, Class II, Class III, Class IV, Class V and Class VI. Strength, slump, and air
content of each class are specified in Table 2.
Substitution of a higher class concrete in lieu of a lower class concrete may be
allowed when the substituted concrete mixes are included as part of the Contractors QCP, or for
precast concrete, the Precast Concrete Producers QCP. The substituted higher class concrete
must meet or exceed the requirements of the lower class concrete and both classes must contain
the same types of mix ingredients. When the compressive strength acceptance data is less than
the minimum compressive strength of the higher design mix, notify the Engineer. Acceptance is
based on the requirements in Table 2 for the lower class concrete.
Class of
Concrete
I (a)
I (Pavement)
II (a)
II (Bridge
Deck)
III (e)
III (Seal)
IV
IV (Drilled
Shaft)
V (Special)
V
VI
TABLE 2
Specified Minimum Strength
Target Slump Value
(28 day) (psi)
(inches) (c)
STRUCTURAL CONCRETE
3,000
3 (b)
3,000
2
3,400
3 (b)
Air Content
Range (%)
1.0 to 6.0
1.0 to 6.0
1.0 to 6.0
4,500
3 (b)
1.0 to 6.0
5,000
3,000
5,500
3 (b)
8
3 (b) (d)
1.0 to 6.0
1.0 to 6.0
1.0 to 6.0
4,000
8.5
0.0 to 6.0
6,000
6,500
8,500
3 (b) (d)
3 (b) (d)
3 (b) (d)
1.0 to 5.0
1.0 to 5.0
1.0 to 5.0
(a) For precast three-sided culverts, box culverts, endwalls, inlets,
manholes and junction boxes, the target slump value and air content will not apply. The
maximum allowable slump is 6 inches, except as noted in (b). The Contractor is permitted to use
concrete meeting the requirements of ASTM C 478 4,000 psi in lieu of Class I or Class II
concrete for precast endwalls, inlets, manholes and junction boxes.
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(b) The Engineer may allow a higher target slump when a Type F, G, I or
II admixture is used, except when flowing concrete is used. The maximum target slump shall be
7 inches.
(c) For a reduction in the target slump for slip-form operations, submit a
revision to the mix design to the Engineer.
(d) When the use of silica fume, ultrafine fly ash, or metakaolin is required
as a pozzolan in Class IV, Class V, Class V (Special) or Class VI concrete, ensure that the
concrete exceeds a resistivity of 29 KOhm-cm at 28 days, when tested in accordance with FM 5578. Submit three 4 x 8 inch cylindrical test specimens to the Engineer for resistivity testing
before mix design approval. Take the resistivity test specimens from the concrete of the
laboratory trial batch or from the field trial batch of at least 3 yd3. Verify the mix proportioning
of the design mix and take representative samples of trial batch concrete for the required plastic
and hardened property tests. Cure the field trial batch specimens similar to the standard
laboratory curing methods. Submit the resistivity test specimens at least 7 days prior to the
scheduled 28 day test. The average resistivity of the three cylinders, eight readings per cylinder,
is an indicator of the permeability of the concrete mix.
(e) When precast three-sided culverts, box culverts, endwalls, inlets,
manholes or junction boxes require a Class III concrete, the minimum cementitious materials is
470 lb/yd3. Do not apply the air content range and the maximum target slump shall be 6 inches,
except as allowed in (b).
346-3.2 Drilled Shaft Concrete: When drilled shaft concrete is placed in any wet shaft,
provide concrete in accordance with the following specified slump loss requirements.
Test each load of concrete for slump to ensure the concrete is within the limits of
346-6.4. Ensure that the slump loss is gradual as evidenced by slump loss tests described below.
The concrete elapsed time is the sum of the mixing and transit time, the placement time, the time
required for removal of any temporary casing that causes or could cause the concrete to flow into
the space previously occupied by the temporary casing and bolt/embedment installation.
346-3.2.1 Slump Loss Test Requirements: Provide slump loss tests before
drilled shaft concrete operations begin, demonstrating that the drilled shaft concrete maintains a
slump of at least 5 inches throughout the concrete elapsed time. Inform the Engineer at least
48 hours before performing such tests. Perform slump loss testing of the drilled shaft mix using
personnel meeting the requirements of Section 105. The Engineer may require a new slump loss
test in the event that the ambient temperature changes more than plus or minus 15F, the
environmental conditions change or the volume increases.
Perform the following procedures for slump loss tests:
(1) Begin all elapsed times when water is initially introduced into
the mixer. Ensure that the initial slump does not exceed 10 inches.
(2) The slump loss test is performed at a temperature consistent
with the highest ambient and concrete temperatures expected during actual concrete placement.
This test may be used for lower ambient temperature placements without any admixture
adjustments.
(3) Ensure that the mix is at least 3 cubic yards and is mixed in a
truck mixer with a valid mixer identification card.
(4) After initial mixing, determine the slump, ambient and concrete
temperatures and air content. Ensure that the concrete properties are within the required limits as
specified in 346-3.1, Table 2.
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(5) Verify the water to cementitious materials ratio and other
delivery ticket data meet design mix requirements.
(6) Mix the concrete intermittently for 30 seconds every 5 minutes,
at a speed greater than or equal to the midrange of the manufacturer's recommended mixing
speed. When concrete is not being mixed, agitate the mixer at the midrange of the manufacturer's
recommended agitating speed.
(7) Determine slump, ambient and concrete temperatures at
30 minute intervals until the slump is 5 inches or less. Remix the mix for one minute at the
mixing speed of the mixer before these tests are run.
(8) Ensure that the concrete maintains a slump of at least 5 inches
for the anticipated elapsed time.
(9) Cast cylinders to determine when 500 psi compressive strength
is obtained for the purpose of transporting field samples to the laboratory.
(10) Obtain the Engineers approval of slump loss test results in
terms of elapsed time before concrete placements.
346-3.3 Mass Concrete: When mass concrete is designated in the Contract Documents,
provide an analysis of the anticipated thermal developments in the mass concrete elements for all
expected project temperature ranges using the selected mix design, casting procedures, and
materials.
Use a Specialty Engineer competent in the design and temperature control of
concrete in mass elements. The Specialty Engineer shall follow the procedure outlined in
Section 207 of the ACI Manual of Concrete Practice to formulate, implement, administer and
monitor a temperature control plan, making adjustments as necessary to ensure compliance with
the Contract Documents. The Specialty Engineer shall select the concrete design mix proportions
that will generate the lowest maximum temperatures possible to ensure that a 35F differential
temperature between the concrete core and the exterior surface is not exceeded. The mass
concrete maximum allowable temperature is 180F. If either the differential temperature or the
maximum allowable temperature is exceeded, the Specialty Engineer shall be available for
immediate consultation.
Describe the measures and procedures intended for use to maintain a temperature
differential of 35F or less between the interior core center and exterior surface(s) of the
designated mass concrete elements during curing. Submit both the mass concrete mix design and
the proposed mass concrete plan to monitor and control the temperature differential to the
Engineer for acceptance. Provide temperature monitoring devices to record temperature
development between the interior core center and exterior surface(s) of the elements in
accordance with the accepted mass concrete plan.
The Specialty Engineer, or a qualified technician employed by the Specialty
Engineer, must personally inspect and approve the installation of monitoring devices and verify
that the process for recording temperature readings is effective for the first placement of each
size and type mass component. Submit to the Engineer for approval the qualification of all
technicians employed to inspect or monitor mass concrete placements. For placements other than
the first, designate an employee(s) approved by the Specialty Engineer, as qualified to inspect
monitoring device installation, to record temperature readings, to be in contact at all times with
the Specialty Engineer if adjustments must be made as a result of the temperature differential or
the maximum allowable temperature being exceeded, and to immediately implement adjustments
to temperature control measures as directed by the Specialty Engineer. Read the monitoring
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devices and record the readings at intervals no greater than 6 hours. The readings will begin
when the mass concrete placement is complete and continue until the maximum temperature
differential and the temperature is reached and a decreasing temperature differential is confirmed
as defined in the temperature control plan. Do not remove the temperature control mechanisms
until the core temperature is within 50F of the ambient temperature. Furnish a copy of all
temperature readings to the Engineer as they are recorded, the determined temperature
differentials and a final report within three days of completion of monitoring of each element.
If the 35F differential or the 180F maximum allowable temperature has been
exceeded, take immediate action as directed by the Specialty Engineer to retard further growth of
the temperature differential. Describe methods of preventing thermal shock in the temperature
control plan. Use a Specialty Engineer to revise the previously accepted plan to ensure
compliance on future placements. Do not place any mass concrete until the Engineer has
accepted the mass concrete plan(s). When mass concrete temperature differentials or maximum
allowable temperature has been exceeded, provide all analyses and test results deemed necessary
by the Engineer for determining the structural integrity and durability of the mass concrete
element, to the satisfaction of the Engineer. The Department will make no compensation, either
monetary or time, for the analyses or tests or any impacts upon the project.
346-3.4 Flowing Concrete for Precast/Prestressed Concrete: Produce flowing
concrete mix with target slump of 9 inches.
Subsequent to the laboratory trial batch, perform a field demonstration of the
proposed mix design by production and placement of at least three batches, 3 yd3 minimum size
each, of concrete containing flowing concrete HRWR admixture. Take representative samples
from each batch and perform slump, air content, density (unit weight), and temperature tests on
these samples. Cast specimens from each sample for compressive strength tests. Record the
ambient air temperature during the test. Ensure that the concrete properties are within the
required specification limits. The plants that are producing concrete with batch sizes of less than
3 yd3 are required to produce and place at least a total amount of 9 yd3 and perform the
aforementioned tests on at least three randomly selected batches.
Determine the workability of the demonstration concrete batches by performing
the slump tests on the samples taken at 15 minute intervals from each batch. Continue sampling
and testing until the slump measures 6 inches or less. From the plot of slump versus time,
determine the time for each batch when the slump is at 7.5 inches. The shortest time period
determined from three consecutive batches, at 7.5 inches slump, is considered the cutoff time of
the proposed concrete mix. For production concrete, ensure that the time between the batching
and depositing of each load of concrete is less than the cutoff time of the mix and also does not
exceed the allowable time limit specified in this Section.
Ensure that the demonstration concrete is mixed, delivered, placed, consolidated
and cured in accordance with the proposed method and sequence. Produce the flowing concrete
batches at slumps between 7.5 inches to 10.5 inches.
Perform inspection of the demonstration concrete during batching, delivery,
placement and post placement. During placement, ensure that the concrete batches meet all
plastic property requirements of the specifications and maintain their cohesive nature without
excessive bleeding, segregation, or abnormal retardation.
Dispose of concrete produced for demonstration purposes at no expense to the
Department. Subject to the Engineers approval, the Contractor may incorporate this concrete
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into non-reinforced concrete items and may be included for payment, provided it meets Contract
requirements for slump, entrained air, and strength.
After removal of the forms, perform the post-placement inspection of the in-place
concrete. Observe for any signs of honeycombs, cracks, aggregate segregation or any other
surface defects and ensure that the hardened concrete is free from these deficiencies. The
Engineer may require saw cutting of the mock-up products to verify the uniform distribution of
the aggregates within the saw cut surfaces and around the reinforcing steel and prestressing
strands. The Engineer will require saw cutting of the demonstration mock-up products for plants
that are demonstrating the use of the flowing concrete for the first time. Obtain core samples
from different locations of mock-up products to inspect the aggregate distribution in each sample
and compare it with the aggregate distribution of other core samples. Perform surface resistivity
tests on the core samples or test cylinders at 28 days.
Submit the results of the laboratory trial batch tests and field demonstration of
verified test data and inspection reports to the Engineer, along with certification stating that the
results of the laboratory trial batch tests and field demonstration tests indicate that the proposed
concrete mix design meets the requirements of the specifications. For the proposed mix design,
state the anticipated maximum time limit between the batching and when the concrete of each
batch is deposited during the production.
Upon the review and verification of the laboratory trial batch, field demonstration
test data, inspection reports and contractors certification statement, the Department will approve
the proposed mix design.
The Department may approve proposed flowing concrete mixes, centrally mixed
at the placement site, without the production of demonstration batches, provided that the
proposed mix meets the following two criteria:
(1) A previously approved flowing concrete mix of the same class has
demonstrated satisfactory performance under the proposed job placing conditions with a
minimum of fifteen consecutive Department acceptance tests, which met all plastic and hardened
concrete test requirements.
(2) The cementitious materials and chemical admixtures, including the
flowing concrete HRWR admixture, used in the proposed mix are the same materials from the
same source used in the previously approved mix, (1) above.
Do not produce or place concrete until the design mixes have been approved.
346-4 Composition of Concrete.
346-4.1 Master Proportion Table: Proportion the materials used to produce the various
classes of concrete in accordance with Table 3:
Class of
Concrete
I
I (Pavement)
II
II (Bridge Deck)
III
TABLE 3
Minimum Total Cementitious
3
Materials Content lb/yd
470
470
470**
611
611**
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*Maximum Water to Cementitious
Materials Ratio lb/lb
0.53
0.50
0.53
0.44
0.44
Class of
Concrete
III (Seal)
IV
IV (Drilled
Shaft)
V (Special)
V
VI
TABLE 3
Minimum Total Cementitious
3
Materials Content lb/yd
611
658**
*Maximum Water to Cementitious
Materials Ratio lb/lb
0.53
0.41***
658**
0.41
752
752
752
0.37***
0.37***
0.37***
*The calculation of the water to cementitious materials ratio (w/cm) is based on the total cementitious material including cement
and any supplemental cementitious materials that are used in the mix.
**The maximum total cementitious materials for mass concrete is 752 lb/yd3. In cases where a higher class of concrete is
substituted for a lower class of concrete, the maximum total cementitious materials for mass concrete is limited to 752 lb/yd3.
***When the use of silica fume or metakaolin is required, the maximum water to cementitious material ratio will be 0.35. When
the use of ultrafine fly ash is required, the maximum water to cementitious material ratio will be 0.30.
346-4.2 Chloride Content Limits for Concrete Construction:
346-4.2.1 General: Use the following maximum chloride content limits for the
concrete application and/or exposure environment shown:
TABLE 4
Maximum Allowable
Chloride Content,
lb/yd3
Non Reinforced Concrete
No Test Needed
Slightly Aggressive Environment
0.70
Reinforced Concrete
Moderately or Extremely Aggressive Environment
0.40
Prestressed Concrete
0.40
Application/Exposure Environment
346-4.2.2 Control Level for Corrective Action: If chloride test results exceed
the limits of Table 4, suspend concrete placement immediately for every mix design represented
by the failing test results, until corrective measures are made. Perform an engineering analysis to
demonstrate that the material meets the intended service life of the structure on all concrete
represented by the failing chloride test results. Supply this information within 30 business days
of the failing test results from a Professional Engineer, registered in the State of Florida and
knowledgeable in the areas of corrosion and corrosion control.
346-5 Sampling and Testing Methods.
Perform concrete sampling and testing in accordance with the following methods:
TABLE 5
Description
Slump of Hydraulic Cement Concrete
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Method
ASTM C 143
TABLE 5
Description
Method
Air Content of Freshly Mixed Concrete by the Pressure Method*
ASTM C 231
Air Content of Freshly Mixed Concrete by the Volumetric Method*
ASTM C 173
Making and Curing Test Specimens in the Field
ASTM C 31
Compressive Strength of Cylindrical Concrete Specimens**
ASTM C 39
Obtaining and Testing Drilled Core and Sawed Beams of Concrete
ASTM C 42
Early Sampling of Fresh Concrete from Revolving Drum Truck Mixers or
Agitators
Low Levels of Chloride in Concrete and Raw Materials
FM 5-516
Density (Unit Weight), Yield and Air Content (Gravimetric) of Concrete
ASTM C 138
Temperature of Freshly Mixed Portland Cement Concrete
Sampling Freshly Mixed Concrete
Static Segregation of Self Consolidating Concrete using Column Techniques
Slump Flow of Self Consolidating Concrete
Passing Ability of Self Consolidating Concrete by J-Ring
Concrete Resistivity as an Electrical Indicator of its Permeability
ASTM C 1064
ASTM C 172
ASTM C 1610
ASTM C 1611
ASTM C 1621
FM 5-578
FM 5-501
*Use the same type of meter for QC tests as the Department uses for Verification testing. When using pressure type meters, use
an aggregate correction factor determined by the concrete producer for each mix design to be tested. Record and certify test
results for correction factors for each type of aggregate at the concrete production facility.
**Use 4 x 8 or 6 x 12 inch cylinders for determination of the compressive strength.
346-6 Control of Quality.
346-6.1 General: Develop a QCP as specified in Section 105. Meet the requirements of
the approved QCP and Contract Documents. Ensure the QCP includes the necessary
requirements to control the quality of the concrete.
Perform QC activities to ensure materials, methods, techniques, personnel,
procedures and processes utilized during production meet the specified requirements. For
precast/prestressed operations, ensure that the QC testing is performed by the producer.
Accept the responsibility for QC inspections on all phases of work. Ensure all
materials and workmanship incorporated into the project meet the requirements of the Contract
Documents.
When concrete plastic properties (slump, air content and temperature) could be
significantly affected by handling between the point of delivery and the point of final placement,
including the use of pumps, conveyor belts, troughs, chutes, barge transport or other means,
include provisions in the QCP to sample the plastic concrete for all testing at the point of final
placement.
Ensure the QCP includes any anticipated requirements for adjusting the concrete
at the placement site. Include the testing procedures that will be implemented to control the
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quality of the concrete and ensure that concrete placed is within the tolerance range. Also,
include provisions for the addition of water to concrete delivered to the placement site at
designated level areas, to ensure the allowable amount of water stated on the concrete delivery
ticket or the maximum water to cementitious materials ratio on the approved design mix are not
exceeded. Ensure the anticipated ranges of jobsite water additions are described and the proposed
methods of measuring water for concrete adjustments are included.
Failure to meet the requirements of this Specification or the QCP will
automatically void the concrete portion of the QCP. To obtain QCP re-approval, implement
corrective actions as approved by the Engineer. The Engineer may allow the Contractor to
continue any ongoing concrete placement but the Engineer will not accept concrete for any new
placement until the QCP re-approval is given by the Engineer.
346-6.2 Concrete Design Mix: Provide concrete that has been produced in accordance
with a Department approved design mix, in a uniform mass free from balls and lumps. Discharge
the concrete in a manner satisfactory to the Engineer. Perform demonstration batches to ensure
complete and thorough placements in complex elements, when requested by the Engineer.
Do not place concretes of different compositions such that the plastic concretes
may combine, except where the Plans require concrete both with and without silica fume,
ultrafine fly ash, metakaolin or calcium nitrite in a continuous placement. Produce these
concretes using separate design mixes. For example, designate the mix with calcium nitrite as the
original mix and the mix without calcium nitrite as the redesigned mix. Ensure that both mixes
contain the same cement, fly ash or slag, coarse and fine aggregates and compatible admixtures.
Submit both mixes for approval as separate mix designs, both meeting all requirements of this
Section. Ensure that the redesigned mix exhibits plastic and hardened qualities which are
additionally approved by the Engineer as suitable for placement with the original mix. The
Engineer will approve the redesigned mix for commingling with the original mix and for a
specific project application only. Alternately, place a construction joint at the location of the
change in concretes.
346-6.3 Delivery Certification: Ensure that an electronic delivery ticket is furnished
with each batch of concrete before unloading at the placement site. The delivery ticket may be
proprietary software or in the form of an electronic spreadsheet, but shall be printed. Ensure that
the materials and quantities incorporated into the batch of concrete are printed on the delivery
ticket. Include the following information on the Delivery Ticket:
(1) Arrival time at jobsite,
(2) Time that concrete mix has been completely placed,
(3) Number of revolutions upon arrival at the jobsite,
(4) Total gallons of water added at the jobsite,
(5) Additional mixing revolutions when water is added,
(6) Total number of revolutions at mixing and agitating speed.
Items 3 through 6 do not apply to non-agitating concrete transporting vehicles.
Ensure the batcher responsible for production of the batch of concrete signs the
delivery ticket, certifying the batch of concrete was produced in accordance with the Contract
Documents.
Verify that the chloride test results on the delivery ticket meet the requirements of
Table 4.
Sign the delivery ticket certifying that the design mix maximum specified water to
cementitious materials ratio was not exceeded due to any jobsite adjustments to the batch of
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concrete, and that the batch of concrete was delivered and placed in accordance with the Contract
Documents.
346-6.4 Plastic Property Tolerances: Do not place concrete with a slump more than
plus or minus 1.5 inches from the target slump value specified in Table 2.
Reject concrete with slump or air content that does not fall within the specified
tolerances and immediately notify the concrete production facility that an adjustment of the
concrete mixture is required so that it will fall within specified tolerances. If a load does not fall
within the tolerances, test each subsequent load and the first adjusted load. If failing concrete is
not rejected or adjustments are not implemented, the Engineer may reject the concrete and
terminate further production until the corrections are implemented.
Do not allow concrete to remain in a transporting vehicle to reduce slump. Water may be
added only upon arrival of the concrete to the jobsite and not thereafter.
346-7 Mixing and Delivering Concrete.
346-7.1 General Requirements: Operate all concrete mixers at speeds and volumes per
the manufacturers design or recommendation as stipulated on the mixer rating plate.
346-7.2 Transit Mixing: When water is added at the jobsite, mix the concrete
30 additional drum mixing revolutions. When the total number of drum mixing revolutions
exceeds 160, do not make additional mix adjustments. Discharge all concrete from truck mixers
before total drum revolutions exceed 300. Seek approval from the Engineer prior to using a
central mixer and depositing the batch into a truck mixer.
346-7.3 Mixing at the Site: Include provisions in the QCP for the mixing at the site. Use
a mixer of sufficient capacity to prevent delays that may be detrimental to the quality of the
work. Ensure that the accuracy of batching equipment is in accordance with requirements of this
Section.
346-7.4 Concreting in Cold Weather: Do not mix or place concrete when the air
temperature is below 45F. Protect the fresh concrete from freezing until the concrete reaches a
minimum compressive strength of 1,500 psi unless the concrete is to be heat cured. The
requirements of concreting in cold weather are not applicable to precast concrete mixing and
placement operations occurring in a temperature controlled environment.
346-7.5 Concreting in Hot Weather: Hot weather concreting is defined as the
production, placing and curing of concrete when the concrete temperature at placing exceeds
85F but is less than 100F.
Unless the specified hot weather concreting measures are in effect, reject concrete
exceeding 85F at the time of placement. Regardless of special measures taken, reject concrete
exceeding 100F. Predict the concrete temperatures at placement time and implement hot
weather measures to avoid production shutdown.
346-7.6 Transit Time: Ensure compliance with the following maximum allowable time
between the initial introduction of water into the mix and depositing the concrete in place:
TABLE 6
Non-Agitator Trucks
45 minutes
75 minutes*
Agitator Trucks
60 minutes
90 minutes*
*When a water-reducing and retarding admixture (Type D, Type G or Type II) is used.
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346-7.7 Adding Water to Concrete at the Placement Site: Perform an initial slump test
before the addition of water at the jobsite. If the slump, as delivered, is outside the tolerance
range, reject the load. If the slump is within the tolerance range, that load may be adjusted by
adding water provided the addition of water does not exceed the water to cementitious materials
ratio as defined by the mix design. After adjusting the slump, perform a slump test to confirm the
concrete is within the slump tolerance range. Perform a slump test on the next load to ensure the
concrete is within the slump tolerance range. Do not place concrete represented by slump test
results outside of the tolerance range. Include water missing from the water storage tanks upon
arrival at the project site in the jobsite water added.
346-7.8 Sample Location: Describe concrete placement and sampling methods in the
QCP. Obtain samples from the point of final placement.
Where concrete buckets are used to discharge concrete directly to the point of
final placement or into the hopper of a tremie pipe, samples will be obtained from the discharge
of the bucket. When the concrete is discharged directly from the mixer into the bucket, within
25% of the total allowable transit time before discharge of the bucket, samples may be obtained
from the discharge of the mixer.
Where conveyor belts, troughs, pumps, or chutes are used to transport concrete
directly to the point of final placement or into the hopper of a tremie pipe, samples will be
obtained from the discharge end of the entire conveyor belt, trough, pump, or chute system.
Where concrete is placed in a drilled shaft or other element using a tremie pipe
and a concrete pump, samples will be obtained from the discharge of the pump line at the
location of the tremie hopper.
Where a concrete pump is used to deposit concrete directly into a drilled shaft
which is a wet excavation without the use of a tremie, or other applications as approved by the
Engineer, ensure the discharge end of the pump line remains immersed in the concrete at all
times after starting concrete placement.
Obtain Department approval for sampling at the discharge of the mixer in lieu of
sampling at the point of final placement. Use the following sampling correlation procedure when
sampling at the discharge of the mixer:
a. Develop a comparative sampling correlation between the discharge of
the mixer and the end of the pump line for slump and air results. Obtain one sample from the
discharge of the pump line using the full length of pump line and one sample from the discharge
of the mixer for five different loads. Average the five samples from each sample location and
compare the two averages to establish the comparative sampling correlation. Ensure the plastic
properties of the concrete sampled from the pump line are within the tolerance range.
b. Once the comparative sampling correlation is established, and approved
by the Engineer, apply this correlation to the plastic properties tolerances for samples obtained
from the discharge of mixer.
c. Obtain all other samples from the discharge of the mixer delivering
concrete to the pump. Ensure the plastic properties of the concrete being delivered to the pump
compare with the comparative sampling correlation.
d. If the ambient temperature changes by more than 10F, or the
configuration of the pumping system changes, the Engineer may require a new comparative
sampling correlation.
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346-8 Plastic Concrete Sampling and Testing.
QC tests include air content, temperature, slump, and preparing compressive strength
cylinders for testing at later dates. In addition, calculate the water to cementitious materials ratio
in accordance with FM 5-501 for compliance to the approved mix design.
Ensure that each truck has a rating plate and a valid mixer identification card issued by
the Department. Ensure that the revolution counter on the mixer is working properly, and
calibration of the water dispenser has been performed within the last twelve months. Reject any
concrete batches that are delivered in trucks that do not have mixer identification cards. Remove
the mixer identification card when a truck mixer is discovered to be in noncompliance and the
mixer deficiencies cannot be repaired immediately. When the mixer identification card is
removed for noncompliance, make note of the deficiency or deficiencies found, and forward the
card to the District Materials and Research Engineer who has Producer QC Plan acceptance
authority.
Perform plastic concrete tests on the initial delivery of each concrete design mix each
day. Ensure QC technicians meeting the requirements of Section 105 are present and performing
tests throughout the placement operation. Ensure one technician is present and performing tests
throughout the placement operation at each placement site. If a placement site has multiple
concrete trucks, identify the number of technicians in the QCP. If a placement site has multiple
trucks placing concrete, then have at least two technicians present at that site. Ensure that the
equipment used for delivery, placement and finishing meets the requirements of this
Specification. Do not proceed with the placement operation until QC tests confirm that the
delivered concrete complies with the plastic properties specified. When a truck designated for
QC testing arrives at the site of discharge, subsequent trucks may not discharge until QC testing
results are known. Reject non-complying loads at the jobsite. Ensure that corrections are made
on subsequent loads.
Furnish sufficient concrete of each design mix as required by the Engineer for
verification testing. When the Engineers verification test results do not compare with the QC
plastic properties test results, within the limits defined by the Independent Assurance (IA)
checklist comparison criteria, located in Materials Manual Chapter 5, disposition of the concrete
will be at the option of the Contractor.
On concrete placements consisting of only one load of concrete, perform initial sampling
and testing in accordance with this Section. The acceptance sample and plastic properties tests
may be taken from the initial portion of the load.
If any of the QC plastic properties tests fail, reject the remainder of that load, terminate
the LOT and notify the Engineer. Make cylinders representing that LOT from the same sample
of concrete.
Following termination of a LOT, obtain samples from a new load, and perform plastic
properties tests until such time as the water to cementitious materials ratio, air content,
temperature and slump comply with the Specification requirements. Initiate a new LOT once the
testing indicates compliance with Specification requirements.
Suspend production when any five loads in two days of production of the same design
mix are outside the specified tolerances. Make the necessary revisions to concrete operations and
increase the frequency of QC testing in the QCP to bring the concrete within allowable
tolerances. Obtain the Engineers approval of the revisions before resuming production. After
production resumes, obtain the Engineers approval before returning to the normal frequency of
QC testing.
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If concrete placement stops for more than 90 minutes, perform initial plastic properties
testing on the next batch and continue the LOT. Cylinders cast for that LOT will represent the
entire LOT.
When the Department performs Independent Verification, the Contractor may perform
the same tests on the concrete at the same time. The Department will compare results based on
the Independent Assurance Checklist tolerances.
When the Department's Independent Verification test results do not meet the
requirements of this Section, the Engineer may require the Contractor to revise the QCP.
346-9 Acceptance Sampling and Testing.
346-9.1 General: Perform plastic properties tests in accordance with 346-8 and cast a set
of three QC cylinders, for all structural concrete incorporated into the project. Take these
acceptance samples randomly as determined by a random number generator (acceptable to the
Department). The Department will independently perform verification plastic properties tests and
cast a set of verification cylinders. The verification cylinders will be the same size cylinder
selected by the Contractor, from a separate sample from the same load of concrete as the
Contractors QC sample.
The Department may perform inspections in lieu of plastic properties tests of the
precast plants producing Class I and II concrete.
For each set of QC cylinders verified by the Department, cast one additional
cylinder from the same sample, and identify it as the QC hold cylinder. The Department will
also cast one additional hold cylinder from each Verification sample. Provide curing facilities
that have the capacity to store all QC, Verification, hold and Independent Verification
cylinders simultaneously for the initial curing. All cylinders will be clearly identified as outlined
in the Sample/Lot Numbering System instructions located on the State Materials Office website.
Deliver the QC samples, including the QC hold cylinder to the final curing facility in
accordance with ASTM C 31. At this same time, the Department will deliver the Verification
samples, including the Verification hold cylinder, to their final curing facility.
Test the QC laboratory cured samples for compressive strength at the age of
28 days, or any other specified age, in a laboratory meeting and maintaining at all times the
qualification requirements listed in Section 105.
The QC testing laboratory will input the compressive strength test results into the
Departments sample tracking database within 24 hours. When the QC testing laboratory cannot
input the compressive strength test results into the Departments sample tracking database within
24 hours, the QC testing laboratory will notify the Verification testing laboratory within 24 hours
of testing the cylinder and provide the Verification testing laboratory the compressive strength
test results. Ensure the compressive strength results are input into the Departments sample
tracking database within 72 hours of determining the compressive strength of the cylinders.
The Department will average the QC compressive strength test data, average the
Verification compressive strength test data, and compare the averages. In the event that one set
of compressive strength data for a set of cylinders falls outside the range of the other set of
cylinders, use the lower Range of Average Compressive Strength to determine the comparison
criteria. Based on this comparison, the Department will determine if the Comparison Criteria as
shown in Table 7 has been met. When the difference between QC and Verification are less than
or equal to the Comparison Criteria, the QC data is verified. When the difference between QC
and Verification data exceeds the Comparison Criteria, the Engineer will initiate the resolution
procedure.
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Table 7
Range of Average Compressive Strength
Less than 3500 psi
3,501 4,500 psi
4,501 6,500 psi
6,501 8,500 psi
Greater than 8,500 psi
Comparison Criteria
420 psi
590 psi
910 psi
1,275 psi
1,360 psi
346-9.2 Sampling Frequency:
As a minimum, sample and test concrete of each design mix for water to
cementitious materials ratio, air content, temperature, slump and compressive strength once per
LOT as defined by Table 8. When a mix design is used for a different application, the LOT is
defined by the application. When more than one concrete production facility is used for the same
mix design, describe the method of sampling, testing and LOT numbering in the QC Plan. The
Engineer will randomly verify one of every four consecutive LOTs of each design mix based on
a random number generator. The Department may perform Independent Verification testing to
verify compliance with specification requirements. All QC activities, calculations, and
inspections will be randomly confirmed by the Department.
TABLE 8
Class Concrete
Maximum LOT Size
one days production
I (Pavement)
250 lane ft, or one days production, whichever is
less
II, II (Bridge Deck), III, IV, V (Special),
V, VI
50 yd3, or one days production, whichever is less
IV (Drilled Shaft)
III (Seal)
50 yd3, or two hours between placements, whichever
is less
Each Seal placement
346-9.2.1 Reduced Frequency for Acceptance Tests: When ten consecutive
strength test results from the same mix design for a Class IV or higher class of concrete are
produced at the same concrete production facility, on a given Contract have all been verified and
have attained an average strength greater than two standard deviations above the specified
minimum, then the LOT may represent a maximum production quantity of 100 yd3. When five
consecutive strength test results from the same mix design for a mix design lower than a
Class IV is produced at the same concrete production facility on a given Contract have all been
verified and have attained an average strength greater than two standard deviations above the
specified minimum, the LOT may represent a maximum production quantity of 100 yd3.
The average of the consecutive compressive strength test results, based on
the class of concrete, can be established using historical data from a previous Department
project. The data must also represent the same prime/subcontractor. The tests from the previous
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Department project must be within the last 60 calendar days or may also be established by a
succession of samples on the current project. Only one sample can be taken from each LOT. Test
data must be from a laboratory meeting the requirements of Section 105. Submit the test data to
the Engineer and obtain Department approval before beginning reduced frequency LOTs.
If at any time a strength test is not verified and/or the average strength of
the previous ten or five consecutive samples based on the class of concrete described above,
from the same mix design and the same production facility is less than the specified minimum
plus two standard deviations, the maximum production quantity represented by the LOT will
return to 50 yd3. In order to reinitiate reduced frequency, a new set of strength test results will be
required.
346-9.3 Strength Test Definition: The strength test of a LOT is defined as the average
of the compressive strengths tests of three cylinders cast from the same sample of concrete from
the LOT.
346-9.4 Acceptance of Concrete:
Accept or reject concrete on the basis of plastic property results in accordance
with 346-6.4.
Ensure that the hardened concrete strength test results are obtained in accordance
with 346-9.3. Do not discard a cylinder strength test result based on low strength (strength below
the specified minimum strength as per the provisions of this Section).
When one of the three QC cylinders from a LOT is lost, damaged or destroyed,
determination of compressive strength will be made by averaging the remaining two cylinders. If
more than one QC cylinder from a LOT is lost, damaged or destroyed, the Contractor will core
the structure at no additional expense to the Department to determine the compressive strength.
Acceptance of LOT may be based on verification data at the discretion of the Engineer. Obtain
the approval of the Engineer to core, and of the core location prior to coring.
For each QC cylinder that is lost, damaged or destroyed, payment for that LOT
will be reduced by $750.00 per 1,000 psi of the specified design strength [Example: loss of two
Class IV (Drill Shaft) QC cylinders that has no verification data will require the element to be
cored and a penalty will be assessed (4,000 psi / 1,000 psi) x $750 x 2 = $6,000. This reduction
will be in addition to any pay adjustment for low strength.
When QC compressive strength test results are not verified, the resolution
procedure will be used to accept or reject the concrete. Maintain the hold cylinders until the
verification of the compressive strength test results.
When QC test results are verified, the Engineer will accept the concrete based on
QC test results. The Engineer will accept at full pay only LOTs of concrete represented by
plastic property results which meet the requirements of the approved mix design and strength test
results which equal or exceed the respective specified minimum strength.
346-9.5 Resolution Procedure: The Department may initiate an IA review of sampling
and testing methods. The resolution procedure may consist of, but need not be limited to, a
review of sampling and testing of fresh concrete, calculation of water to cementitious materials
ratio, handling of cylinders, curing procedures and compressive strength testing. Core samples of
the hardened concrete may be required.
The Engineer will determine through the resolution procedure whether the QC
strength test results or the verification strength test results can be relied upon. When the Engineer
cannot determine that either the QC or verification strength test results are in error, the concrete
represented by the four consecutive LOTs will be evaluated based on the QC data. The Engineer
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will inform the QC and the Verification lab within four working days of the acceptance
compressive strength test to transport their hold cylinders to the resolution lab. The QC and
Verification laboratories will transport their own hold cylinder to the resolution testing
laboratory within 72 hours after the Engineer notifies the Contractor that a resolution is required.
In addition, the Engineer will ensure that the QC and verification hold cylinders are tested
within seven days of the acceptance strength tests.
The resolution investigation will determine the strength test results for each of the
four or less LOTs. When the QC strength test results are deemed to be the most accurate, the QC
strength test results will represent the four or less consecutive LOTs and the Department will pay
for the resolution testing and investigation. When the verification strength test results are deemed
to be the most accurate, the Department will assess a 5 percent reduction of payment for the
quantity represented by the Resolution Investigation.
The results of the resolution procedure will be forwarded to the Contractor within
five days after completion of the investigation. If the Department finds deficiencies based on the
Contractors QCP, the Engineer may suspend that part of the QCP. When the QC Plan is
suspended, submit corrective actions for approval to the Engineer. The Engineer may take up to
five working days to review corrective actions to the QCP. The Engineer will not allow changes
to contract time or completion dates. Incur all delay costs and other costs associated with QC
Plan suspension and re-approval.
346-9.6 Small Quantities of Concrete: When a project has a total plan quantity of less
than 50 yd3, that concrete will be accepted based on the satisfactory compressive strength of the
QC cylinders. Provide certification to the Engineer that the concrete was batched and placed in
accordance with the Contract Documents. Submit a QCP for the concrete placement operation in
accordance with Section 105. In addition, the Engineer may conduct Independent Verification
(IV) testing as identified in 346-9. Evaluate the concrete in accordance with 346-10 at the
discretion of the Engineer.
346-10 Investigation of Low Strength Concrete for Structural Adequacy.
346-10.1 General: When a concrete acceptance strength test result falls more than
500 psi below the specified minimum strength, from the specified minimum strength, and the
Department determines that an investigation is necessary, make an investigation into the
structural adequacy of the LOT of concrete represented by that acceptance strength test result at
no additional expense to the Department. The Engineer may also require the Contractor to
perform additional strength testing as necessary to determine structural adequacy of the concrete.
Furnish either a structural analysis performed by the Specialty Engineer to
establish strength adequacy or drilled core samples as specified in 346-10.3 to determine the inplace strength of the LOT of concrete in question at no additional expense to the Department.
Obtain the Engineers approval before taking any core samples. When the concrete is deemed to
have low strength, obtain and test the cores and report the data to the Engineer within 14 days of
the 28 day compressive strength tests. Core strength test results obtained from the structure will
be accepted by both the Contractor and the Department as the in-place strength of the LOT of
concrete in question. The core strength test results will be final and used in lieu of the cylinder
strength test results for determination of structural adequacy and any pay adjustment. The
Department will calculate the strength value to be the average of the compressive strengths of the
three individual cores. This will be accepted as the actual measured value.
346-10.2 Determination of Structural Adequacy: If core strength test results are less
than 500 psi below the specified minimum strength, consider the concrete represented by the
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cores structurally adequate. If the core strength test results are more than 500 psi below the
specified minimum strength, the Department will consider the concrete represented by the cores
structurally questionable. Submit a structural analysis performed by the Specialty Engineer. If
the results of the structural analysis indicate adequate strength to serve its intended purpose with
adequate durability, and is approved by the Department, the Contractor may leave the concrete in
place subject to the requirements of 346-11, otherwise, remove and replace the LOT of concrete
in question at no additional expense to the Department.
346-10.3 Coring for Determination of Structural Adequacy: Furnish three undamaged
core samples taken from the same approximate location where the questionable concrete is
represented by the low strength concrete test cylinders. Select the location of the drilled cores so
that the structure is not impaired and does not sustain permanent damage after repairing the core
holes. Obtain the Engineer's approval of the core location prior to coring.
346-10.4 Core Conditioning and Testing: The Department will test the cores in
accordance with ASTM C 2. The Engineer will make the determination whether to test the cores
in a dry or wet condition. If the Engineer decides to test the cores in a wet condition, immerse the
cores in water for at least 40 hours, and test the cores wet. The cores will be tested after
obtaining the samples within three days for wet cores and within six days for dry cores.
346-11 Pay Adjustments for Low Strength Concrete.
346-11.1 General: Any LOT of concrete failing to meet the specified minimum strength
as defined in 346-3, 346-9, 346-10 and satisfactorily meeting all other requirements of the
Contract Documents, including structural adequacy, the Engineer will individually reduce the
price of each low strength LOT in accordance with this Section.
346-11.2 Basis for Pay Adjustments: When an acceptance strength test result falls more
than 500 psi below the specified minimum strength, core samples may be obtained in accordance
with ASTM C 42 from the respective LOT of concrete represented by the low acceptance
strength test result for determining pay adjustments. Price adjustment will be applied to the
certified invoice price the Contractor paid for the concrete or the precast product.
Do not core hardened concrete for determining pay adjustments when the 28 day
acceptance cylinder strength test results are less than 500 psi below the specified minimum
strength.
Submit acceptable core samples to the Engineer for testing for determination of
payment reductions based upon the results of the strength tests. The results of strength tests of
the drilled cores, subject to 346-11.5 and 346-11.6, will be accepted as final and will be used in
lieu of the cylinder strength test results for determining pay adjustments.
In precast operations, excluding prestressed, ensure that the producer submits
acceptable core samples to the Engineer for testing. The producer may elect to use the products
in accordance with 346-11. Otherwise, replace the concrete in question at no additional cost to
the Department. For prestressed concrete, core sample testing is not allowed for pay adjustment.
The results of the cylinder strength tests will be used to determine material acceptance and pay
adjustment.
346-11.3 Coring for Determination of Pay Adjustments: Obtain the cores in
accordance with 346-10.3.
346-11.4 Core Conditioning and Testing: The Department will test the cores in
accordance with 346-10.4.
346-11.5 Core Strength Representing Equivalent 28 Day Strength: For cores tested
no later than 42 days after the concrete was cast, the Engineer will accept the core strengths
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obtained as representing the equivalent 28 day strength of the LOT of concrete in question. The
Engineer will calculate the strength value to be the average of the compressive strengths of the
three individual cores. The Engineer will accept this strength at its actual measured value.
346-11.6 Core Strength Adjustments: For cores tested later than 42 days after the
concrete was cast, the Engineer will establish the equivalency between 28 day strength and
strength at ages after 42 days based on test data developed by a Department approved testing
laboratory to relate strength at the actual test age to 28 day strength for the particular class of
concrete and design mix represented by the cores. Obtain such data at no additional expense to
the Department. When such data is not available and cannot be produced, as determined by the
Department, the Engineer will determine the equivalent 28 day strength by adjusting the tested
core strengths according to the following relationship:
346-11.6.1 Portland Cement Concrete without Pozzolan or Slag:
Equivalent 28 Day Strength, fc (28) = 1/F (Average Core Strength) x 100,
where:
2
F = 4.4 + 39.1 (ln x) -3.1 (ln x) (Type I Cement)
2
F = -17.8 + 46.3 (ln x) -3.3 (ln x) (Type II Cement)
2
F = 48.5 + 19.4 (ln x) -1.4 (ln x) (Type III Cement)
x = number of days since the concrete was placed
ln = natural log
346-11.6.2 Pozzolanic-Cement Concrete:
Equivalent 28 day compressive strength = f'C (28), where:
f c ( 28) = 0.490 f c(t )e
f c ( 28) = 0.730 f c(t )e
f c ( 28) = 0.483 f c(t )e
8.31
2.89
5.38
0.276
(Type I Cement)
0.514
(Type II Cement)
0.191
(Type III Cement)
f' (t) = Average Core Strength at time t (psi)
C
t = time compressive strength was measured (days)
346-11.6.3 Slag-Cement Concrete:
Equivalent 28 day compressive strength = f'C (28), where:
f c ( 28) = 0.794 f c(t )e
f c ( 28) = 0.730 f c(t )e
7.06
6.02
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1.06
(Type I Cement)
0.747
(Type II Cement)
f c ( 28) = 0.826 f c(t )e
2.36
0.672
(Type III Cement)
f' (t) = Average Core Strength at time t (psi)
C
t = time compressive strength was measured (days)
346-11.7 Calculating Pay Adjustments: The Engineer will determine payment
reductions for low strength concrete accepted by the Department and represented by either
cylinder or core strength test results below the specified minimum strength, in accordance with
the following:
Reduction in Pay is equal to the reduction in percentage of concrete cylinder
strength (specified minimum strength minus actual strength divided by specified minimum
strength).
For the elements that payments are based on the per foot basis, the Engineer will
adjust the price reduction from cubic yards basis to per foot basis, determine the total linear feet
of the elements that are affected by low strength concrete samples and apply the adjusted price
reduction accordingly.
346-12 Pay Reduction for Plastic Properties
If concrete is placed even when the result of plastic properties testing requires its
rejection, the payment for concrete represented by the plastic property tests will be reduced by
twice the invoice price per cubic yard for all concrete in the load that is placed. If the Engineer
authorizes placement of the concrete, there will be no pay reduction.
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SECTION 347
PORTLAND CEMENT CONCRETE - CLASS NS
347-1 Description.
The requirements of this Section are applicable to concrete designated as Class NS
hereinafter referred to as concrete. Use concrete composed of a mixture of portland cement,
aggregates, and water, with or without chemical admixtures, slag, or pozzolanic materials.
Deliver concrete to placement site in a freshly mixed, unhardened state. Ensure the concrete is
placed and cured in a manner to ensure that the strength and durability of the concrete is
maintained.
347-2 Materials.
347-2.1 General: Certify that all materials used in concrete are from Department
approved sources, and free from frozen or other detrimental matter.
Meet the following requirements:
Portland Cement..................................... Section 921
Coarse Aggregate ................................... Section 901
Fine Aggregate ....................................... Section 902
Water ...................................................... Section 923
Chemical Admixtures ............................ Section 924
Pozzolans and Slag ................................ Section 929
347-2.2 Admixture Requirements: Chemical admixtures may be added at the dosage
rates recommended by the manufacturer.
347-2.3 Substitution of Materials: Approved material sources may be substituted for
similar materials indicated on the originally approved mix design. Use originally approved mix
components and proportions, when unsatisfactory test results are obtained from the use of the
substituted material(s).
347-2.4 Material Storage: Use a concrete production facility that meets the following
requirements:
347-2.4.1 Cementitious Materials Storage: Provide a separate and clearly
labeled weatherproof facility to store each brand or type of cementitious material without mixing
or contamination. Provide a suitable, safe and convenient means of collecting cementitious
material samples at each storage facility.
347-2.4.2 Aggregate Storage: Provide suitable bins, stockpiles or silos to store
and identify aggregates without mixing, segregating or contaminating different grades or types
of materials. Identify Department approved pit number and aggregate type/gradation. Handle the
aggregates in a manner to minimize segregation and meet the specification requirements when
recovered from storage. Continuously and uniformly sprinkle coarse aggregate with water, for
24 hours preceding introduction into the concrete mix. Maintain stored aggregates in a
well-drained condition to minimize free water content. Provide access for the Engineer to sample
the aggregates from the recovery side of the storage facility.
347-3 Production, Mixing and Delivery.
347-3.1 Concrete Production Requirements: Deliver concrete from a production
facility that is certified by the National Ready-Mixed Concrete Association (NRMCA) or
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approved by the District Materials Office. The District Materials Office may inspect the concrete
production facilitys to verify compliance with the Specifications. Produce concrete utilizing
equipment that is in good operating condition and operated in a manner to ensure a consistent
product. Within two hours prior to each days batching, ensure that the concrete production
facility determines the free moisture for the coarse and fine aggregates. On concrete placements
expected to exceed three hours, perform an additional moisture test approximately half way
through the batching operations and adjust batch proportions accordingly.
Ensure that the calibration of the measuring devices of the concrete production
facilities meets the requirements of Chapter 531 of the Florida Statutes. At least quarterly, ensure
that all scales, meters and other weighing or measuring devices are checked for accuracy by a
qualified representative of a scale company registered with the Bureau of Weights and Measures
of the Florida Department of Agriculture. Have the accuracy of admixture measuring dispensers
certified annually by the admixture supplier.
When Volumetric Mixers are used, deliver concrete in accordance with the
requirements of Volumetric Mixer Manufactures Bureau (VMMB) and ensure that the vehicle
has a VMMB registered rating plate.
347-3.2 Mixers: Ensure that mixers are capable of combining the components of
concrete into a thoroughly mixed and uniform mass, free from balls or lumps of cementitious
materials, and capable of discharging the concrete uniformly. Operate concrete mixers at speeds
per the manufacturers design. Do not exceed the manufacturers rated capacity for the volume
of mixed concrete in the mixer, mixing drum, or container.
347-3.3 Delivery: The maximum allowable mixing and agitation time of concrete is
120 minutes.
347-3.4 Small Quantities of Concrete: With approval of the District Materials
Engineer, small quantities of concrete, less than 3 yd3 placed in one day and less than
0.5 yd3 placed in a single placement may be accepted using a pre-bagged mixture. The Engineer
will verify that the pre-bagged mixture is prepared in accordance with the manufactures
recommendations and will meet the requirements of this Specification.
347-4 Control of Quality.
347-4.1 Concrete Mix Design: Before producing any concrete, submit the proposed mix
design to the Engineer on a form provided by the Department. A similar form containing the
same information may be used. Also submit three compressive strength test results tested in
accordance with ASTM C 39 demonstrating the mix meets the minimum 28 day compressive
strength requirement. The test results must be within twelve months of the submittal of the mix
design. Use only concrete mix designs having prior approval of the Engineer.
Materials may be adjusted provided that the theoretical yield requirement of the
approved mix design is met. Show all required original approved design mix data and batch
adjustments and substituted material on the Department concrete delivery ticket. The Engineer
may disqualify any concrete production facility for non-compliance with Specification
requirements.
347-4.2 Sampling and Testing: The Engineer may sample and test the concrete at their
discretion to verify its quality. The minimum 28-day compressive strength requirement for this
concrete is 2,500 psi.
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347-4.3 Records: Maintain the following records for review for at least three years after
final acceptance of the project:
1. Approved concrete mix designs.
2. Materials source (delivery tickets, certifications, certified mill test reports).
3. A copy of the scale company or testing agency report showing the observed
deviations from quantities checked during calibration of the scales and meters.
4. A copy of the documentation certifying the admixture weighing/measuring
devices.
5. Recent NRMCA, VMMB or Department inspection records certifying the plant
or truck can produce concrete and documentation showing that action has been taken to correct
deficiencies noted during the inspections.
347-5 Certification and Acceptance.
347-5.1 General: Furnish a Delivery Ticket with each batch of concrete before
unloading at the placement site. The Department will provide an example of the Delivery Ticket
Form. The concrete producer may use an alternate form provided that it contains the required
information. Record material quantities incorporated into the mix on the Delivery Ticket. Ensure
that the Batcher responsible for producing the concrete, certifies that the batch was produced in
accordance with Specification requirements, signs the Delivery Ticket. Sign the Delivery Ticket
certifying that the concrete was batched, delivered and placed in accordance with these
Specifications.
Acceptance by the Department will be by Certification on the Delivery Ticket, as
described herein, by the Batcher and the Contractor. The Engineer will hold the Contractor
responsible for rejecting loads of concrete that do not meet the minimum compressive strength
requirements. Delineate and replace, at no cost to the Department, all concrete that does not meet
the 28-day compressive strength requirements or has any cracking greater than 1/4 inch in width
or 1/4 inch in vertical displacement. Any spalling or flaking off of the surface layer that exposes
the rough, pitted aggregate surface in excess of 10 square inches is to be removed and replaced
in accordance with 347-5.2. Sidewalk, ditch pavement, slope pavement, Traffic Separator, or
curb and gutter having any intersecting cracks visible in the dry concrete (regardless of size) will
be removed and replaced in accordance with 347-5.2.
At the sole option of the Department, the Engineer may accept concrete at a
reduced pay when it is determined that the concrete will serve its intended function.
If any uncontrolled cracks appear during the life of the Contract unacceptable to
the Engineer, remove and replace the concrete in accordance with 347-5.2 at no expense to the
Department.
347-5.2 Remedial Action: Remedial action will be the removal and replacement of all
concrete to the full depth and width.
Sidewalk, Curb and Gutter, Ditch Pavement and Traffic Separator: Begin saw
cutting 2 1/2 feet either side or above and below the crack or at the nearest joint, remove and
replace the 5 foot section encompassing the crack.
Slope Pavement: Saw cut each scored joint above and below the crack and replace
the entire section between the saw cuts, ensuring the section removed and replaced encompasses
the crack.
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SECTION 350
CEMENT CONCRETE PAVEMENT
350-1 Description.
Construct Portland cement concrete pavement in one course, on a prepared subgrade. Use
either the fixed-form or the slip-form method of construction. When reinforced cement concrete
pavement is specified or required, use concrete reinforced with steel bars or steel fabric, in
accordance with details shown in the Plans. The Engineer may require a demonstration of
equipment and paving operations.
If any uncontrolled cracks appear during the life of the Contract, remove and replace the
cracked concrete at no expense to the Department. Investigate and implement immediate
effective solutions to eliminate further cracks, in consultation with, and subject to the approval of
the Engineer.
Furnish the following information in the Quality Control Plan (QCP) as required in
Section 105:
1. A detailed sequence and schedule of concrete placement operations including,
but not limited to, width of pavement to be placed, proposed equipment, production rates,
working hours, concrete hauling, and placement, curing, sawing, and sealing methods. Identify
backup equipment and the procedures that will be followed in the case of a breakdown of
equipment.
2. A method to ensure the proper placement of reinforcing steel, tie bars and
dowel bars.
3. A traffic control plan that includes provisions for the placement and
maintenance of barriers required to protect the pavement from traffic, for a minimum of 14 days
after concrete placement.
4. Defined provisions for adequate lighting for all work done at night, including
finishing, curing, and sawing joints.
5. A method for ensuring pavement thickness is met and a consolidation
procedure is identified.
6. If forms are to be utilized define the material, dimensions, type, connections,
and staking of the forms.
7. Define the procedure for the protection of the fresh concrete pavement from
inclement weather.
350-2 Materials.
Meet the following requirements:
Concrete, Class I (Pavement)..............................Section 346
Grinding Concrete Pavement ..............................Section 352
Curing Materials .................................................Section 925
Embedded Items..................................................Section 931
Joint Seal .............................................................Section 932
350-3 Equipment.
350-3.1 General: Ensure the equipment and tools that are to be used meet the following:
The capability of handling materials and performing all parts of the work.
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To be of such capacity that the paver operates continuously and at a constant rate
of production, with starting and stopping held to a minimum.
When equipment operates on the side forms, use scraping devices to clean
accumulations from the top of the forms and wheels.
The forms will be a rigid material and mortar tight. Ensure that the alignment and
grade of all forms are in accordance with the contract documents, prior to the placing of
concrete.
350-3.2 Slip-Form Paver: Provide a slip-form paver that is self-propelled and equipped
to spread, strike-off, consolidate, screed, and float-finish the freshly placed concrete in one
complete pass of the equipment, in such a manner that a minimum amount of hand-finishing will
be necessary to provide a dense and homogeneous pavement. Ensure that the equipment is of
such dimensions and arrangement as to cover the full width of the pavement strip being placed.
Use equipment that is adjustable as to crown and superelevation and that can shape and compact
the concrete into a dense and stable mass, to the required cross-section. Ensure that the crown
adjustment is readily controllable for accuracy in crown transitions.
Operate the paver on tracks having sufficient contact area to prevent track
slippage under load. Ensure that the length of ground contact per track and the arrangement of
tracks are adequate to meet the straightedge and other riding-quality requirements specified.
Accomplish screeding by either: (1) oscillating screeds, (2) an extrusion device,
or (3) a combination of both.
If necessary, in order to produce a pavement of the required cross-section and
meeting the surface requirements, equip the slip-form paver with traveling side forms of
sufficient dimension and strength and of proper shape to support the concrete laterally for a
sufficient length of time during placing and finishing.
If using trailing forms, provide forms that are rigidly supported laterally.
Equip the slip-form paver with automatic guidance and grade controls which
operate by sensing from a taut line set true to line and grade. Erect and maintain the taut line.
Automatic grade controls are not required on the paver when the tracks of the
slip-form paver are operating on previously placed concrete pavement. The Engineer may waive
the use of automatic grade controls on the paver when the entire width of the tracks of the
slip-form paver are operating on a subgrade which has been consistently trimmed to a tolerance
of 1/8 inch above or below true grade as established by the taut line set for that purpose.
350-3.3 Vibratory Units: Consolidate the concrete for the full width of the strip being
placed with either surface pan type or internal type vibrators. Use a vibration method with
sufficient intensity and duration to ensure complete consolidation of the concrete without causing
segregation of the materials.
For the surface vibrators, use a frequency of not less than 3,500 impulses per
minute. For internal type vibrators, use a frequency of not less than 5,000 impulses per minute
for tube vibrators and not less than 7,000 impulses per minute for spud vibrators. When using
spud-type internal vibrators adjacent to forms, either hand-operated or attached to spreaders or
finishing machines, use a frequency of not less than 3,500 impulses per minute. Measure and
record the frequency of internal vibrators in plastic concrete and submit data to the Engineer.
Mount spud vibrators such that the free tip trails, and space spud vibrators at a maximum interval
of 30 inches.
Provide an amplitude of vibration with spud vibrators that is sufficient for the
vibration to be perceptible on the surface of the concrete along the entire width of the strip being
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placed. Measure and record the actual frequency of vibrations and submit data to the Engineer.
Control all vibration by the forward movement of the spreader or finishing machine so that
vibration automatically ceases when stopping the forward movement of the spreader.
350-3.4 Device for Application of Membrane Curing Compound: Provide equipment
for applying membrane curing compound that is self-propelled and capable of uniformly
applying the curing compound at the specified rate. Use equipment that continuously stirs the
curing compound, by effective mechanical means, and that thoroughly atomizes the curing
compound during the spraying operation so that the finished surface of the fresh concrete will
not be marred. Cover the entire surface of the pavement and, with slip-form type paving, the
vertical faces by a single pass of the machine. Only use spray nozzles that are equipped with
appropriate wind guards to ensure uniform application.
Power-spray equipment may be used to apply curing compound to areas where it
is impracticable to operate the self-propelled equipment.
350-3.5 Equipment for Paving Small or Narrow Areas: For variable width areas, other
than mainline, ramps, and shoulders, the Engineer will not require the full paving train as
specified for the standard run of paving. Use such equipment that is approved by the Engineer.
350-3.6 Hand Finishing Tools: Provide straightedges that have a blade length of 10 feet.
Use long-handled floats that have flat blades, approximately 4 feet long by 5 to 8 inches wide,
and that are designed so as to remain straight and true. Use a handle for both types of tool with a
length that exceeds 1/2 the width of the strip being placed by 3 feet.
350-4 Subgrade Preparation.
Keep construction of the subgrade completed for a distance of at least 500 feet ahead of
the paving operation. Maintain the finished subgrade in a smooth, compact condition, and restore
any areas which are disturbed prior to placing the concrete. Do not place concrete on a frozen
subgrade.
Ensure that the subgrade is within two percent of the optimum moisture content while
placing the concrete. Uniformly apply water ahead of the paving operations, as directed by the
Engineer.
Do not allow vehicles to travel on the prepared subgrade between the subgrade trimming
machine and the paving operations unless specifically authorized.
Accurately trim the subgrade to the required elevation. Trim high areas to proper
elevation. Fill low areas with suitable material, compacted to the specified density, or with
concrete placed integrally with the pavement. When slip-form paving, include in the width to be
trimmed the areas on which the tracks of the paver will operate.
Remove material planed from the subgrade before placing any concrete. The Engineer
may waive the use of the planer for small or isolated areas or any areas where its use would be
impracticable.
350-5 Setting Forms.
350-5.1 General: Accurately set the forms to line and grade and such that they rest
firmly, throughout their entire length, upon the subgrade surface. Join forms neatly and tightly,
and brace them to resist the pressure of the equipment operating on the forms. Obtain the
Engineers approval of the alignment and grade of all forms before and immediately prior to the
placing of concrete.
Fill any subgrade that is below the established grade at the form line to grade with
granular material, in lifts of 1/2 inch or less, for a distance of 18 inches on each side of the
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pavement edge, and thoroughly compact the material. As an exception, when placing forms on a
cement-treated subgrade, the Contractor may use wedging, provided that the wedging system
used adequately supports the forms without causing detrimental deflection under the weight of
the paving equipment.
350-5.2 Tamping: When placing forms on other than a cement-treated subgrade,
adequately tamp the materials below and adjacent to the forms with form-tamping machines.
350-5.3 Advance Preparation of Forms: Keep sufficient forms on hand at all times, and
set forms so that at least 500 feet of forms on each side of the roadway will be accurately set, and
maintained true to line and grade, in advance of the point where concrete is being placed.
Provide sufficient forms so that it is not necessary to remove them in less than 12 hours after
placing the concrete.
350-5.4 Cleaning Forms: Thoroughly clean the forms after each use and before placing
concrete against them. Apply a release agent in accordance with the manufacturers
recommendations.
350-6 Protection from Weather.
Meet the requirements of 400-7.1 when placing concrete. When rain appears imminent,
stop all paving operations, and cover the surface of the unhardened concrete with the protective
covering.
350-7 Placement of Reinforcement.
350-7.1 General: Where the Plans call for reinforced concrete pavement, place the steel
reinforcement in the pavement slab in accordance with the details shown in the Plans. At the
time of the concrete placement, ensure that the reinforcing steel is free from any of the following
which could impair bonding of the steel with the concrete: dirt, oil, paint, grease, mill scale, and
any loose or thick rust. Place the reinforcement as provided below.
350-7.2 Fabric: Place welded wire reinforcement at right angles to the centerline of the
pavement and accurately to the position and location shown in the Plans. Lap adjacent sheets of
welded wire reinforcement not less than 6 inches. Make the laps only in the longitudinal
members.
350-7.3 Bars: Place bar reinforcement as shown in the Plans. Securely wire together
transverse and longitudinal bars at their intersections. Lap splices not less than 20 times the
nominal diameter of the bar, and only in the longitudinal members.
350-8 Placing Concrete.
350-8.1 Distribution: Distribute the concrete on the subgrade to such depth that, when it
is consolidated and finished, the slab thickness required by the Plans will be obtained at all
points. The surface will at no point be below the grade specified for the finished surface. Place
the concrete on the subgrade in a manner which will require as little rehandling as possible.
Place concrete as near to expansion and contraction joint assemblies as possible
without disturbing them. Ensure that workers do not walk in the freshly placed concrete with
their boots or shoes coated with earth or other deleterious substances.
350-8.2 Use of Spreader: Place concrete on the subgrade by an approved spreading
device. Do not place concrete from the discharge bucket or hopper onto an assembly without
centering the bucket or hopper directly over the assembly.
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A spreader is not required in areas where the width of slab varies, intersections,
and small or isolated areas where it would be impractical to use a spreader. Perform the
necessary hand spreading with shovels (not with rakes or hoes).
350-8.3 Placement Widths: The Contractor may construct the pavement either in lanes
as determined by the longitudinal joints shown in the Plans, or for the full width in one
operation. Construct the pavement to the full width of the lane or slab in a single construction
operation. When constructing pavement in separate lanes, do not deviate the junction line from
the true line shown in the Plans by more than 1/2 inch at any point. Tool the edges of the
junction to the radius shown in the Plans.
When constructing pavement in separate lanes, place the lanes adjacent to the low
edge of the pavement, as shown on the typical section, first.
350-8.4 Consolidation Along Forms and Joints: Thoroughly consolidate concrete
against and along the faces of all forms, and along the full length on both sides of all joint
assemblies, by means of hand-operated, spud-type vibrators. Do not allow vibrators to come in
contact with a joint assembly, reinforcement, the subgrade or a side form.
350-8.5 Slip-Form Paver: When placing concrete with a slip-form paver, operate the
paver with a continuous forward movement. If for any reason it is necessary to stop the forward
movement of the paver, immediately stop operation of the vibrating or tamping elements. Do not
apply tractive force to the paving machine except that which is controlled from the machine.
In case of an emergency, have available for use at the project site at least 100 feet
of forms.
Do not insert steel tie-bars into the unsupported side of the freshly formed slab.
The Contractor may place tie-bars into position prior to extrusion from the paver by insertion
through the forms, by insertion through a temporary support form placed against the form slab,
or by other means approved by the Engineer. Use a method that results in placement of the tiebars at the specified locations with no damage or disruption of the concrete.
350-9 Striking-off, Consolidating, and Finishing Concrete.
350-9.1 General Requirements: Immediately after placing the concrete, strike-off,
consolidate, and finish it to produce a finished pavement in accordance with the cross-section,
width, and surface finish required by the Contract Documents. Perform the sequence of
operations as follows: strike-off; vibratory consolidation; screeding; floating; removal of
laitance; straightedging; and final surface finish. Except as specified, perform strike-off,
consolidation, screeding, and floating by the machine method.
Use equipment that is fully and accurately adjustable to produce a pavement
meeting project requirements. Use equipment that is capable of operating in a consistent and
smooth manner under all conditions of use.
As soon as possible after screeding while the concrete is plastic, correct all flaws
such as cavities, blemishes, marks, or scratches that will not be removed by planing. .
Provide a concrete surface true to grade, cross slope and superelevation, and free
of irregularities. If the Engineer permits adding water to assist the finishing operations, apply
water as a fog spray by means of approved spray equipment.
350-9.2 Machine Method: Operate the machine over each area of pavement as few times
and at such intervals as is necessary to give proper consolidation and to leave a surface of
uniform texture. Avoid excessive operation over a particular area.
Perform strike-off, consolidation, and finishing in a manner such as to avoid
damage to, or misalignment of, joint assemblies, reinforcing steel, dowels, and other embedded
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items. Smooth the surface of the concrete and remove the excess mortar from the surface. Carry
a small amount of mortar ahead of the float device as it moves on the surface of the concrete.
Operate the machine over the surface of the concrete as many times as required to obtain an
acceptable surface, meeting the requirements specified herein. Discard excess mortar beyond the
edge of the slab.
350-9.3 Hand Methods:
350-9.3.1 Conditions under which Allowed: Use hand methods in areas of
narrow width or irregular dimensions, where operation of mechanical equipment is
impracticable.
350-9.3.2 Strike-off and Screeding: Use a portable screed of an approved
design, constructed either of metal or of other suitable material shod with metal, to strike-off and
screed the concrete. Use a screed that is sufficiently rigid to retain its shape and is at least 2 feet
longer than the maximum width of the strip to be screeded.
350-9.3.3 Consolidation: Use hand-operated spud-type vibrators to consolidate.
350-9.3.4 Floating: Use long-handled floats to float the concrete. Take the
necessary care to avoid creating depressions or ridges during this operation.
350-9.4 Work Bridges: Provide work bridges or other devices necessary for access to
the pavement surface for the purpose of inspection, finishing, straightedging, and performing
corrective work.
350-10 Final Finish.
350-10.1 Finishing: As the water sheen disappears from the surface of the pavement and
just before the concrete achieves its initial set, drag a seamless length of damp burlap that
extends the full width of the strip of the constructed pavement, longitudinally along the surface
to produce a uniform gritty texture.
Use a burlap drag that consists of two layers of medium weight burlap with the
trailing edge of the lower layer extending approximately 2 inches behind the upper layer.
Support the burlap drag in a manner so that a length of at least 3 feet of burlap is in contact with
the pavement.
Except in areas where using hand methods to construct the pavement, support the
lead end of the burlap drag by a traveling bridge. Maintain the drag clean and free from
encrusted mortar. Replace the burlap with new material as necessary.
350-10.2 Edging: After applying the final finish, but before the concrete has become
nonplastic, carefully round the edges to a 1/4 inch radius on each side of transverse expansion
joints and construction joints and along any structure extending into the pavement. Produce a
well-defined and continuous radius, and obtain a smooth, dense mortar finish. Completely
remove all concrete from the top of the joint filler.
Check all joints with a straightedge before the concrete has become nonplastic,
and, if one side of the joint is higher than the other or the entire joint is higher or lower than the
adjacent slabs, make corrections as necessary.
350-11 Curing.
350-11.1 General: After completing the finishing operations and as soon as the concrete
has hardened sufficiently to not mar the surface, cover and cure the entire surface and, when the
slip-form method is used, cover and cure the edges of the newly placed concrete in accordance
with one or more of the methods described below. In cases where curing requires the use of
water, ensure that curing has prior right to use all water supplies. If the Contractor fails to
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provide sufficient curing materials to adequately cure the concrete in place in a timely manner,
that portion of the concrete pavement section addressed in the QCP will be suspended. Do not
leave the concrete exposed for a period in excess of 30 minutes between stages of curing or
during the curing period.
Continuously cure the freshly placed concrete for a period of 72 hours, exclusive
of any periods when the temperature of the surface of the concrete falls below 50F.
350-11.2 White-Pigmented Curing Compound: Under this method, uniformly apply
white-pigmented curing compound to the surfaces to be cured, in a single coat, continuous film,
at the minimum rate of 1 gallon to every 200 ft2, by a mechanical sprayer.
At the time of use, thoroughly mix the compound in accordance with the
manufacturers recommendation.
Do not apply curing compound during periods of rainfall. Do not apply curing
compound to the inside faces of joints to be sealed. Should the film become damaged from any
cause within the required curing period, repair the damaged portions immediately with additional
compound. If using side forms, upon their removal, immediately coat the sides of the slabs
exposed to provide a curing treatment equal to that provided for the surface.
350-11.3 Burlap Mats: Thoroughly saturate the mats with water before placing them.
Use mats of such dimensions that as laid they extend to at least 2 feet beyond the edges of the
strip of concrete placed. Place and weigh down the mats throughout the curing period to ensure
contact with the surface being cured. Maintain the mats fully moist and in position for the entire
portion of the required curing period.
350-11.4 Removal of Forms: Do not remove forms from freshly placed concrete for at
least 12 hours after placement. Remove forms carefully so as to avoid damage to the pavement.
After removing the forms, immediately cure the sides of the slab in the same manner as the
surface of the pavement.
350-12 Joints.
350-12.1 General: Construct joints at the locations and in accordance with the details
shown in the Design Standards, Index Nos. 305 and 306 and the Contract Documents.
350-12.2 Longitudinal Joints:
350-12.2.1 Longitudinal Construction Joints: Where the pavement is poured in
strips less than the full width of the pavement, construct longitudinal construction joints in
accordance with the details shown in the Plans.
350-12.2.2 Longitudinal Lane-tie Joints: Construct longitudinal lane-tie joints
within the limits of a strip of pavement, in accordance with the details shown in the Plans.
Construct the plane of weakness by sawing a groove in the hardened concrete. Complete sawing
as soon as possible but in no case longer than 72 hours after placing the concrete.
350-12.2.3 Tie Bars and Bolt Assemblies: Place deformed steel tie bars or tie
bolt assemblies at the required depth, parallel to the finished surface, at right angles to the joint
and at the uniform spacing specified or required in the Plans. Place them in the plastic concrete
using approved equipment, or rigidly support them on the subgrade by approved devices capable
of preventing displacement prior to placing of the concrete. Do not paint or coat the bars with
any material before placing them in the concrete.
If placing tie bars along a longitudinal construction joint using the method
of inserting bars with a 90 degree bend in the edge of the plastic concrete and after the concrete
hardens straightening these bars, use Grade 40 reinforcing steel for such tie bars. Replace any bar
broken while being straightened in an approved manner.
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350-12.3 Transverse Joints:
350-12.3.1 Transverse Construction Joints: Construct transverse construction
joints at the end of all pours and at other locations where the paving operations are stopped for as
long as 30 minutes. Do not place construction joints, however, within 10 feet of any other
transverse joint or within 10 feet of either end of a section of pavement. If sufficient concrete has
not been placed to form a slab at least 10 feet long, remove the excess concrete, back to the last
preceding joint. Form the joints by placing a wood or metal bulkhead accurately and securely in
place, in a plane perpendicular to the profile and centerline of the pavement. Install dowel bars at
the construction joints. Saw or form construction joints, in a manner similar to contraction joints,
so that a groove will be formed for holding the joint sealing compound.
350-12.3.2 Transverse Contraction Joints: Construct transverse contraction
joints at the interval indicated in the Plans consisting of planes of weakness created by sawing a
groove in the surface of the hardened concrete. Place the groove perpendicular to the surface of
the pavement. Install load transfer devices in transverse contraction joints.
Ensure that the sawing equipment does not damage the pavement, and saw
the transverse contraction joints as soon as the pavement has hardened to the degree that tearing
and raveling are not excessive and before uncontrolled shrinkage cracking begins.
Accomplish the joint sawing in two steps. Make the initial cut 1/8 inch
wide by a depth at least 1/3 of the pavement thickness and as soon as possible but in no case
longer than 12 hours after placing the concrete. Make a second saw cut, to provide the joint
dimensions indicated in the Plans, just prior to sealing the load transfer device.
In cases where a strip of pavement is being placed immediately adjacent to
a previously constructed strip of pavement, construct transverse contraction joints using extreme
care to time sawing so as to prevent uncontrolled cracks.
Repair any uncontrolled cracks at no expense to the Department by
removing and replacing the pavement across the full width of all affected lanes or shoulders and
to the nearest transverse joint in each direction.
After the final sawing, clean the joint, install the bond breaker, and seal
the joint.
350-12.3.3 Transverse Expansion Joints: Form transverse expansion joints
using preformed joint filler, and provide them with dowel load transfer, in accordance with the
details shown on the Design Standards, or in the Plans.
Form the joints during the placing of the concrete, by securely staking a
metal bulkhead accurately in place at the joint location or by other methods which will securely
brace and support the joint filler. Where using approved devices to keep the expansion joint filler
and dowels securely in place, the Engineer will not require a bulkhead. Protect all transverse
expansion joints at the bottom and side edges by a sheet metal strip as specified in 931-2.1 and as
shown in the Contract Documents.
Cut the filler to the crown and shape of the slab cross-section and
extended it to the subgrade. After installation, ensure that the top is not less than 1 inch, and not
more than 1.25 inches, below the finished surface. Furnish the joint filler in lengths not less than
the lane widths being poured, except that the Engineer will not require lengths greater than
12 feet. Where more than one section is allowed and used in a joint, securely lace or clip the
sections together.
Place the filler normal to the pavement surface. Stake the assembly into
position in such a way as to hold the assembly securely in position throughout construction.
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Ensure that the assembly is true to the line prescribed, subject to a tolerance of 1/4 inch in the
width of the slab. Obtain the Engineers approval of the assembly and its installation before
placing any concrete against it. Obtain the Engineers approval of the cross-section and length of
the stakes.
When laying the pavement in partial width slabs, place transverse joints in
the succeeding slab in line with the like joints in the first slab. In the case of widening existing
pavement, place transverse joints in line with like joints in the existing pavement or as otherwise
shown in the Plans.
350-12.4 Load-Transfer Devices: Provide dowel load-transfer devices in all transverse
joints. Firmly hold dowel bars in a position parallel to the surface and the centerline of the slab,
by approved steel supports and spacers of a type shown in the Plans. The Engineer may approve
the use of dowel bar supports or assemblies other than those specifically detailed in the Plans.
Allow the dowels to be free to move in one slab as the concrete contracts and expands. Paint
each dowel with one coat of zinc rich primer or red oxide alkyd based primer meeting the
requirements of SSPC Paint 25 Type I or Type II. Wait a minimum of 7 days before coating onehalf of the dowel with a petroleum based lubricant grease to inhibit bonding to the concrete.
Provide a cap for the free end of expansion joint dowels.
Position each dowel such that its final deviation from parallel to the surface of the
pavement and parallel to the longitudinal centerline of the pavement does not exceed 1/2 inch.
Position each dowel such that its final deviation from being centered on the joint does not exceed
2 inches. Position each dowel such that at no point in its length does it deviate from the surface
of the pavement as shown in the Plans in excess of 1 inch. Confirm the position of dowel bars by
suitable means acceptable to the Engineer, which may include non-destructive testing methods.
350-12.5 Expansion Joints Around Structures:
350-12.5.1 Expansion Joints at Manholes, Meter Boxes and other
Projections: Form expansion joints by placing premolded expansion joint material about all
structures and features projecting through, into or against the pavement. Ensure that such joints
are 1/2 inch in width.
350-12.5.2 Bridge Approach Expansion Joints: Construct in accordance with
Design Standards, Index No. 306.
350-12.6 Cleaning Joints and Cracks:
350-12.6.1 Cleaning Joints in New Pavement:
350-12.6.1.1 Sawed Joints: Immediately after sawing the joints which
require sealing, completely remove the resulting slurry from the joint and the immediate area by
flushing with a jet of water under pressure and by using other tools as necessary.
After flushing, blow out the joints with compressed air. After the
flushed joints have dried, sandblast the joint faces to thoroughly remove all foreign material.
Perform sandblasting in two passes, once for each face.
Patch all spalled edges with an epoxy compound.
Immediately prior to joint seal installation, clean the joints using
compressed air to remove all traces of debris and dust within and on the joint surfaces.
350-12.6.1.2 Non-Sawed Joints: Thoroughly clean joints which require
sealing of all foreign material for the full depth of the seal installation.
With the exception of slurry removal due to sawing, meet the
cleaning requirements as specified for sawed joints.
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350-12.6.2 Cleaning Joints in Existing Pavement: Remove all existing jointsealing material and foreign material for the full depth of the new joint seal by sawing, wire
brushing, sandblasting, or other methods approved by the Engineer.
Remove any existing sealant or parting strip material below the tape or
backer rod bond breaker and replace it with additional bond breaker. When conditions require
removal and replacement with additional bond breaker below the new joint seal, obtain the
Engineers approval of the type of bond breaker and its installation procedure. Perform cleaning
by any method or combination of methods, as detailed in the Plans.
Flush the joint with a pressurized jet of water, and use other tools as
necessary, to remove loose remnants and debris.
After flushing, blow out the joints with compressed air. After the flushed
joints have dried, sandblast the joint faces to thoroughly remove all foreign material. Perform
sandblasting in two passes, once for each face.
Patch all spalled edges with an epoxy compound.
Immediately prior to joint seal installation, clean the joints using
compressed air to remove all traces of debris and dust within and on the joint surfaces.
350-12.6.3 Cleaning Random Cracks in Existing Pavement: Do not begin
cleaning random cracks in existing pavement until all other concrete pavement repairs have
progressed to the point where those operations will not adversely affect the installation of the
new seal.
Cut the random cracks to be repaired and sealed into grooved joints to the
depth and width detailed in the Plans. Clean the joints as specified in 350-12.6.2.
350-12.7 Sealing Joints and Cracks: Seal joints in new pavement before allowing any
traffic or construction equipment on the pavement. Complete sealing within 72 hours (weather
permitting) of sawing. If traffic is going to be on the pavement prior to any grinding, then seal
the joints with a temporary material acceptable to the Engineer.
When using silicone and non-silicone sealants in the transverse and longitudinal
joints, respectively, always use the silicone sealants first to prevent contamination at the
intersection of the joint faces. Remove non-silicone sealant 1 foot in each direction from the
transverse joints, and replace it with silicone sealant.
Use equipment equipped with nozzles that discharge the sealant at the bottom of
the groove. Ensure that the apparatus develops sufficient pressure to extrude the joint sealer from
the nozzles satisfactorily and to control the rate of application so as to completely fill the joint to
within 1/4 inch of the surface of the pavement without spillage. Use an apparatus so constructed
that it maintains the proper temperature of the sealing material within the manufacturers
recommendation.
350-12.7.1 Hot-Poured Type Sealant: When the Plans require hot poured sealant
for specific joints, fill the joint thoroughly, without trapping air, ensuring the sealant is recessed
below the pavement surface as required, and control the pouring rate to avoid spilling of sealant
onto the adjacent pavement surface. If any spilling of sealant occurs, immediately remove and
clean the entire surplus amount from the pavement surface. Place poured material when the
ambient air temperature is 50F or greater.
Use an indirect heating or double boiler type heating kettle that uses oil as
a heat transfer medium, for hot poured sealer. Use a heating kettle that has a thermostatically
controlled heat source, a built-in automatic agitator, and thermometers installed to indicate both
the temperature of the melted sealing material and that of the oil bath.
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350-12.7.2 Low Modulus Silicone Sealant: Use low modulus silicone sealant of
either Type A (non-self-leveling silicone sealant), or Type B and/or Type C (self-leveling
silicone sealant). Because Type A will not flow into the proper shape under its own weight,
install and tool it so that the sealant is in firm contact with the joint faces and is formed into the
appropriate shape as specified. Types B and C will normally flow into the proper shape without
tooling. Exercise care to provide the required depth of recess above the sealant surface and below
the pavement surface. Install the silicone sealant at temperatures above 40F.
350-13 Surface Requirements.
Produce, by grinding in accordance with Section 352, a pavement surface that is true to
grade and uniform in appearance with a longitudinal line type texture.
350-14 Thickness Determinations.
350-14.1 General: After completing the concrete pavement, including any corrective
work to meet ride requirement, determine the thickness by one of following methods. The
Engineer will select the locations for testing and make the determination of thickness. Sample
locations will be taken at various points on the cross-section so that each test represents an area
not exceeding 2,500 yd2. Provide traffic control, non-destructive equipment, coring equipment,
and operator to obtain the samples.
350-14.1.1 Core Borings: To determine the actual thickness, drill cores from the
pavement and measure thickness in accordance with ASTM C174. Replace the portions of the
pavement removed by the borings at no expense to the Department.
350-14.1.2 Non-destructive Testing: For a determination using the impact-echo
method, measure the thickness of the pavement in accordance with ASTM C1383. The initial
thickness measurement will be validated by having a core boring taken at that location in
compliance with 350-14.1.1. If the results from the impact-echo test vary by plus or minus
0.15 inches from the core boring, then the non-destructive test method can not be used on the
pavement. In such case, the core boring will be used for acceptance of that LOT of concrete. The
Engineer has the option to verify the accuracy of the results at any time.
350-14.2 Method of Calculating Average Thickness: The Department will determine
the average thickness of the pavement by using the following method of calculation:
(a) The Department will not take into account in the calculation, any areas of
pavement which are left in place, but for which no payment will be made.
(b) When the thickness of the pavement is more than 1/2 inch greater than the
specified thickness, the Department will consider it in the calculation as the specified thickness
plus 1/2 inch.
(c) The Department will calculate the average thickness for the entire job as a
unit.
350-15 Deficient Thickness.
350-15.1 General: The Department will not pay for any pavement which is more than
1/2 inch less than the specified thickness. Any deficient pavement will be just cause for that
portion of the concrete pavement addressed in the QCP to be suspended until the corrections are
to the satisfaction of the Engineer. When the pavement contains no longitudinal construction
joint, the Department will not pay for the area of such pavement that is the product of the full
width of the strip placed as a unit times the sum of the distances each way from the short core or
cores to the cores on each side which show measurements within the tolerance limits. When the
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pavement contains longitudinal construction joints, for the width, the Department will use the
width between longitudinal construction joint and the edge of pavement.
350-15.2 Deficient Pavement Requiring Removal: The Engineer will evaluate areas of
pavement found deficient in thickness by more than 1/2 inch and if, in his judgment, the
deficiency is enough to seriously impair the anticipated service life of the pavement, remove
such areas and replace them with concrete of the thickness shown in the Plans. The Department
will not pay for the area of pavement removed or for the materials or labor involved in its
removal. When removing a section of pavement, remove the full length between transverse
joints.
350-15.3 Deficient Pavement Left in Place: If the Engineer determines that the
deficiency will not seriously impair the anticipated service life of the pavement, the pavement
may be left in place, at no compensation.
350-15.4 Additional Borings: If the number of cores taken is not sufficient to indicate
the thickness of the pavement, additional boring locations may be requested, with prior approval
from the Engineer at no additional cost to the Department.
350-16 Opening Pavement to Traffic.
Construct an earth berm along each edge of the pavement within 36 hours of finishing
any newly placed concrete pavement. Build the berm to the full height of the pavement and at
least 18 inches wide, and sufficiently compacted to prevent underwash of the pavement.
Maintain the berm until the final shoulders are complete.
Except as provided below, keep the pavement closed to traffic for a minimum period of
14 calendar days after placement of the concrete. The Engineer may permit opening of a section
of pavement to traffic at an earlier time provided that representative test cylinders, made in
accordance with ASTM C31 and tested in accordance with ASTM C39, indicate a compressive
strength of at least 2200 psi. Cure these test cylinders in a manner identical to the corresponding
section of pavement.
Protect the pavement from all traffic, including construction operations, until the
specified period of time has elapsed. Protect the pavement from ambient temperatures below
50F for the calendar days or until the required compressive strength has been attained.
350-17 Method of Measurement.
350-17.1 Concrete Pavement: The quantities to be paid for will be the plan quantity, in
square yards, of plain cement concrete pavement and of reinforced cement concrete pavement,
omitting any areas not allowed for payment under the provisions of 350-15.3 and adjusted for
average thickness as provided herein.
For purposes of payment, the average thickness of pavement will determine the
final pay quantities for this pavement as follows:
The area of pavement represented by the difference between the calculated
average thickness and the specified thickness will be converted into equivalent square yards of
specified thickness pavement, and the quantity thereby obtained will be added to, or deducted
from, the quantity of pavement to be paid for, subject to the limitation that the maximum average
of over-thickness permitted in the adjustment of the quantity of pavement to be paid for will be
1/4 inch.
Where the Plans call for cement concrete pavement that is to be covered with
asphalt concrete surface course, payment will be made for the total thickness of the combination
as plain cement concrete pavement.
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In such cases, price and payment will also include all costs of the asphalt concrete
surface course constructed in accordance with Section 334. Reinforcing steel, placed and
accepted, will be measured and paid for as provided in Section 415.
350-17.2 Joints and Cracks: Include the cost for cleaning and sealing joints in the cost
of the newly constructed pavement for: (1) transverse and longitudinal joint construction for new
pavement; and (2) abutting joints between existing pavement and new pavement.
For replacing joint seals and sealing random cracks in existing portland cement
concrete pavement, the quantity to be paid for will be as specified below:
(a) The length of pavement joint satisfactorily cleaned and sealed in
existing portland cement concrete pavement, as determined by field measurement along the
joints, will be paid for at the Contract unit price per foot for cleaning and resealing joints.
(b) The length of random cracks in existing portland cement concrete
pavement that have been satisfactorily cut, cleaned, and sealed, as determined by field
measurement along the joints, will be paid for at the Contract unit price per foot for cleaning and
sealing random cracks.
350-17.3 Bridge Approach Expansion Joint: The quantity to be paid for will be plan
quantity, in feet of bridge approach expansion joint installed in accordance with Design
Standards, Index No. 306, calculated across the pavement at right angles to the centerline of the
roadway pavement, completed and accepted.
350-18 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including any preparation of the subgrade not included in the work to be paid for under another
Contract item; all transverse and longitudinal joint construction, including tie-bars and dowel
bars; the furnishing of test specimens; repair of core holes; and all incidentals necessary to
complete the work.
Payment will be made under:
Item No. 350- 1Plain Cement Concrete Pavement - per square yard.
Item No. 350- 2Reinforced Cement Concrete Pavement - per square yard.
Item No. 350- 72Cleaning and Resealing Joints - per foot.
Item No. 350- 78Cleaning and Sealing Random Cracks - per foot.
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SECTION 352
GRINDING CONCRETE PAVEMENT
352-1 Description.
Grind existing concrete pavement in the areas designated on the Plans.
Grind new concrete pavement the full width of the travel lanes. Do not grind shoulders
unless indicated in the Plans or required to promote drainage.
352-2 Equipment.
Identify all equipment for grinding concrete pavement in the Quality Control Plan (QCP)
as required in Section 105. Provide a power driven self-propelled machine that is specifically
designed to grind portland cement concrete pavement with diamond-impregnated grinding
blades. Provide, operate, and maintain in working condition all necessary equipment to ensure
performance of the work in the allotted time. Use equipment of the size, shape, and dimensions
that does not restrict the movement of traffic in areas outside the designated limits of
construction. The equipment will be of a size that can cut or plane at least 3 feet wide or as
approved by the Engineer. Use equipment that is capable of grinding specified surfaces without
causing spalls at cracks, joints, or other locations. The equipment will be capable of removing
any slurry or residue resulting from the grinding operation.
352-3 Construction Methods.
Schedule and proceed with the construction operation in a manner that produces a
uniform finished surface. Grind in a manner that eliminates joint or crack faults while providing
positive lateral drainage by maintaining a constant cross-slope between grinding extremities in
each lane. Grind transition, auxiliary or ramp lane as required from the mainline edge to provide
positive drainage and an acceptable riding surface.
Grind parallel to the centerline until the pavement surfaces of adjacent sides of transverse
joints and cracks are in the same plane. Grind the concrete pavement to eliminate the faulting at
joints and cracks, maintain the overall smoothness within the limits specified, and texture over
the majority of the pavement surface. Take all necessary precautions to minimize the number of
minor depressions in the first place and only resolve to grind such areas if necessary. Continue
grinding if accumulated total areas of minor depressions exceed 30% of the total area of a
0.1 mile section or if directed by the Engineer. Maintain the cross slope of the pavement as
shown in the Plans.
Establish and obtain the Engineers approval for a means to continuously remove
grinding residue.
Remove solid residue from pavement surfaces before traffic action or wind blows such
residue. Do not allow residue to flow across lanes or shoulders used by public traffic or into
gutters or other drainage facilities. Do not allow the discharge of any residue runoff into adjacent
rivers, streams, lakes, ponds, or other bodies of water.
352-4 Final Surface Finish.
After the curing period, use a grinding process that produces a pavement surface that is
true to grade and uniform in appearance with a longitudinal line type texture. Provide a line type
texture that contains parallel longitudinal corrugations that present a narrow ridge with a
corduroy type appearance. Provide a surface finish with the peaks of the ridges approximately
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1/32 inch higher than the bottoms of the grooves and with approximately 60 evenly spaced
grooves per foot.
Grind to produce areas of uniform and neat surface appearance, beginning and ending at
lines perpendicular to the pavement centerline.
352-5 Acceptance Testing for Surface Tolerance.
Test the pavement surface for smoothness with a 10 foot long straightedge, a 10 foot long
rolling straightedge, or a California Type Profilograph while the Engineer observes the
operations as described below. For pavement surfaces not meeting the smoothness requirements,
provide corrective work and retesting to ensure conformity approved by the Engineer.
(a) Testing with a 10 foot straightedge: Use this straightedge for longitudinal
profiling, parallel to centerline, within 15 feet of a bridge approach or existing pavement which
is being joined. Use it for all transverse profiling of cross slopes, approaches, and as otherwise
directed with respect to (b) or (c) below.
Furnish and operate a 10 foot straightedge. When portland cement
concrete pavement abuts bridge approaches or pavement not under this Contract, ensure that the
longitudinal slope deviations of the finished pavement do not exceed 1/8 inch in 10 foot length.
Produce transverse slope deviations of the finished pavement that do not
exceed 1/8 inch with the straightedge laid in a direction perpendicular to the centerline.
(b) Testing with a 10 foot rolling straightedge: Use this straightedge for
longitudinal profiling of short pavement sections up to 250 feet long, including mainline and
non-mainline sections on tangent sections and on horizontal curves with a centerline radius of
curve less than 1,000 feet and the pavement within the superelevation transition of such curves,
turn lanes, ramps, tapers, and other non-mainline pavements as directed.
Furnish and operate the straightedge. Provide and operate a 10 foot rolling
straightedge of a design acceptable to the Engineer, able to accurately measure surface
irregularities exceeding 1/8 inch in a 10 foot effective length of the straightedge.
When tested with a straightedge, ensure that the finished pavement profile
provides a uniform surface with no deviation greater than 1/8 inch in a 10 foot length. Perform
the profiling in lines parallel to the centerline, at not more than 4 foot transversal spacing, and
extending across the transverse joints.
The Contractor may confine checking through traffic lanes with the
straightedge to joints and obvious irregularities as directed.
(c) Testing With A California Type Profilograph:
1. General: Use the profilograph on all longitudinal profiling of mainline
full width pavement lanes longer than 250 feet and as otherwise directed.
The following terms are defined:
a. Profilograph: A longitudinal profile testing apparatus used to
measure a pavements surface profile deviations.
b. Profile Trace or Profilogram: A surface profile record generated
along the individual wheel paths using a profilograph. Such a record is analyzed to determine the
rate of roughness (or smoothness) and to identify changes in the longitudinal pavement surface
elevation that exceed a specified threshold along the pavement length traversed by the
profilograph.
c. Profile Index (PI): A profile measurement is a series of numbers
representing elevation relative to a specified reference. A Profile Index (PI) is a summary value
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calculated from these numbers above and below a blanking band over a specified length of
pavement.
d. Blanking Band: A band of 0.2 inch uniform height with its
longitudinal center positioned optimally between the highs and the lows of the profilogram
depicting at least 100 ft of pavement.
2. Equipment: Furnish, calibrate, and operate a California Type
Profilograph device in accordance with FM 5-558E. The electronic model of a California Type
Profilograph performs computerized data analysis, and is manufactured by Cox and Sons, Inc. of
Colfax, California - Model CS 8200 or better.
3. Surface Test: Produce a riding surface meeting the requirements of
FM 5-558E and having a Profile Index meeting the requirements herein. Start and terminate the
profile 15 feet from each bridge approach or existing pavement, which is being joined.
Take at least two pavement profile traces with bump option turned
on. Locate the position of the profiles in the traffic wheel paths. Take the profiles in the direction
of the traffic and parallel to and approximately 3 feet from the outside edges of each traffic lane.
The Contractor may take additional profiles to define the limits of an out-of-tolerance surface
variation.
Upon completion of each days testing, submit the profilograms to
the Engineer for review to determine the pavement section in compliance with these
requirements. The Engineer will retain those profilograms meeting these requirements. The
Engineer will return profilograms with deficiencies to the Contractor for use to correct section
deficiencies. The Engineer will retain the corrected profilograms, along with the deficient
profilograms, for comparison purposes of the circumstances between the two profilograms.
Ensure that pavement tested meets the Profile Index requirements
and is applicable to the profilogram for each profile trace:
a. Ensure that pavement on tangent alignment and
horizontal curves having a centerline radius of curve 2,000 feet or more has a Profile Index of
5 inches per mile or less.
b. Ensure that pavement on horizontal curves having a
centerline radius of curve 1,000 feet or more but less than 2,000 feet and pavement within the
superelevation transition of such curves has a Profile Index of 7 inches per mile or less.
c. Ensure that the pavement riding surfaces have all
deviations in excess of 0.3 inch in 25 feet removed.
The Engineer will evaluate the pavement in 0.1 mile consecutive
sections. Grind all areas represented by individual points having deviations in excess of 0.3 inch
in 25 feet or less pavement length, until such points do not exceed 0.3 inch.
After removing all individual deviations in excess of 0.3 inch in
25 feet, perform additional grinding as necessary to reduce the Profile Index to the specified
requirements.
Surface smoothness tests with a California Type Profilograph on
bridges are specified in 400-15. Ensure that the pavement within 15 feet of a bridge approach (or
existing pavement which is being joined) complies with the testing requirements of a 10 foot
straightedge.
Visually inspect transverse joints and random cracks to ensure that
the adjacent surfaces are in the same plane. Where misalignment of the planes of the surfaces on
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adjacent sides of the joints or cracks is in excess of 1/16 inch, grind the pavement until the
surfaces are flush.
352-6 Surface Corrections.
After the curing period, test the surface for pavement surface smoothness in accordance
with 352-5. Plainly mark all variations from the required tolerances. Where pavement surfaces
do not meet the smoothness requirements, the Engineer will require corrective work and retesting
to ensure conformity.
Eliminate high spots exceeding 1/8 inch in 10 feet, but not in excess of 0.3 inch in
25 feet, by grinding either with an approved machine or with a carborundum brick and water. Do
not use bush-hammering or other destructive means for removing irregularities. As directed by
the Engineer, retexture corrected high areas to give skid resistance comparable to the
surrounding area.
Operate all milling, cutting, or grinding equipment to produce a reasonably uniform
finished surface without spalling the pavement joints within corrected areas. The Engineer will
not require extra grinding to eliminate minor depressions in order to provide 100% texturing of
the pavement surface. Maintain the cross slope of the pavement as shown in the Plans. Repair all
joint seals destroyed by grinding at no expense to the Department.
Remove and replace any area of pavement which, after grinding, still shows a deviation
in excess of the allowable tolerance. Ensure that the area removed and replaced is the full length
between transverse joints and the full width of the lane involved. Replace any area of concrete
pavement with concrete that meets the requirements of Sections 353.
Bear the costs of all surface corrections required and of all required removal and
replacement of defective surface concrete. If the grinding operation removes more than a total
length of 100 consecutive feet of the grooves, then re-groove the entire width of the pavement
for the deficient area.
352-7 Method of Measurement.
The quantity to be paid for will be the area, in square yards, determined by calculation,
completed and accepted.
352-8 Basis of Payment.
Price and payment will be full compensation for all work and materials specified in this
Section, including furnishing all labor, materials, tools, equipment, testing, and incidentals and
for doing all work involved in grinding existing or new concrete pavement, removing residue,
and cleaning the pavement, including necessary disposal of residue and furnishing any water or
air used in cleaning the pavement.
Contract Unit Price adjustments will be made in accordance with the following
schedules.
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Average Profile Index (inches/mile)
per 0.1 mile Section
Curvature Radius
1,000 ft Curvature Radius
2,000 ft
< 2,000 ft
PI 2
PI 4
2 < PI 5
4 < PI 7
PI > 5
PI > 7
Contract Unit Price Adjustments
Percent of Pavement
Unit Bid Price
103
100
Corrective work required
Pay (Price) Adjustments for Incentives will be based on the initial measured average
Profile Index, prior to any corrective work.
The Unit Bid Adjusted Price will be computed using the plan surface area of grinding
concrete pavement. This Unit Bid Price will apply to the total area of the 0.1 mile section for the
lane width represented by the profilograms for the average Profile Index.
Payment will be made under:
Item No. 352- 70Grinding Concrete Pavement - per square yard.
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SECTION 353
CONCRETE PAVEMENT SLAB REPLACEMENT
353-1 Description.
Replace the existing defective area of concrete pavement with portland cement concrete.
Repair the damaged area of adjacent slabs, caused by slab removal at no cost to the Department.
353-2 Materials.
Meet the following requirements:
Portland Cement Concrete ..................................Section 346
Coarse Aggregate ................................................Section 901
Fine Aggregate ....................................................Section 902
Portland Cement..................................................Section 921
Water ...................................................................Section 923
Admixtures..........................................................Section 924
Curing Materials .................................................Section 925
Epoxy Compounds ..............................................Section 926
Pozzolans and Slags* ..........................................Section 929
Embedded Items..................................................Section 931
Calcium Chloride ......................... AASHTO M-144, Type 1
*For concrete pavement slab replacement, the use of pozzolans and slag is
optional.
Concrete pavement containing only dowel bars will be considered non-reinforced
concrete.
353-3 Composition of Concrete.
353-3.1 Mixture Proportions: Designate the actual proportions to be used to produce a
concrete with a minimum 6-hour compressive strength of 2,200 psi and a minimum 24-hour
compressive strength of 3,000 psi.
Prior to producing concrete, submit the design mix for approval on a form
acceptable to the Department. Ensure the 24-hour acceptance strength has a minimum over
design of 400 psi. Indicate slump before and after addition of accelerator. Use mixes approved
by the Department and from an approved concrete production facility meeting the requirements
of Section 105.
When an accelerating admixture is used in solution, the amount of water in the
solution is considered to be part of the mixing water. Make necessary adjustment to the concrete
mix-water to account for the amount of water in the accelerating admixture solution. Test the
concrete for consistency subject to the following values from the approved mix design values:
Slump Tolerance** .........................plus or minus 1.5 inches
Entrained Air**...................................................... 1% to 6%
Temperature not to exceed 100F
**For values as specified in the approved Design Mix prior to the addition of
accelerating admixture.
353-3.2 Certification: Provide certification in accordance with 346-6.3.
353-3.3 Demonstration Slab: Prior to batching production concrete, demonstrate the
ability to furnish replacement slabs by constructing a demonstration slab on site. Demonstrate
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production techniques for slab removal, dowel installation, concrete placement, finishing, slab
curing, sample preparation and curing, and proper timing of joint sawing. Demonstrate the ability
to achieve the required compressive strengths. Demonstrate the ability of the slabs to achieve the
maturity needed for opening to traffic within the required time. Schedule construction of the
demonstration slab during the same time period specified in the Contract Documents. If the
Engineer determines that elements of the demonstration slab fail to meet requirements of the
Contract Documents, propose adjustments to the construction processes and/or materials for the
Engineers approval. The Engineer may require additional demonstration slabs until a
demonstration slab conforms with the Contract Documents.
353-4 Batching and Mixing Concrete.
Obtain concrete that meets the requirements of 346-7 with the following additional
requirements:
Add all the concrete ingredients, excluding the accelerator to the truck mixer at the plant.
Mix each batch at the plant at the mixing speed for 70-100 revolutions of the drum.
Agitate the concrete en route to the job site at a speed of no more than three revolutions
per minute. Add the accelerator to the concrete at the job site. Mix the concrete for 40 additional
revolutions at mixing speed after the accelerator is added to the mixer. Do not add accelerator to
any concrete which has attained the age of 60 minutes, measured from the beginning of the
initial mixing at the plant.
Incorporate the accelerator into the concrete design mix in accordance with the
recommendations of the admixture supplier.
353-5 Test Requirements.
Perform concrete sampling and testing in accordance with Section 346-5. Perform the
plastic property tests in accordance with 346-8, except when the mix design contains an
accelerator; perform the plastic property tests prior to the addition of the accelerator. The
requirements of 346-9 apply to this Section with the following modification: 28-day
requirements will be replaced with 24-hours and if the design mix includes an accelerator, then
the compressive strength cylinders will be fabricated after all ingredients, including the
accelerator, are added.
Make a minimum of four test cylinders from the last slab for each day of placement to
assess strength for protection and opening to traffic (protection set). Cure the protection set of
cylinders by methods identical to those used in curing the concrete replacement slabs. Cure the
acceptance set of cylinders identical to the protection set of cylinders for the first 6-hours, then
by laboratory cured conditions thereafter until the 24-hour strength test. Provide a location and
curing facility for initial curing of verification cylinders.
Test two cylinders from the protection set within 6-hours of sampling and consider the
average compressive strength of these two tests to be the 6-hour compressive strength. If the
compressive strength is below 2,200 psi, test the remaining 2 cylinders from the protection set no
longer than 6-hours from sampling. The Maturity Method specified in 353-10.2 may be used as
an alternate to the protection set of concrete cylinders.
Test the acceptance and verification cylinders at 24-hours from the time of sampling.
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353-6 Concrete Slab Acceptance.
Reject any Concrete not meeting the plastic property requirements of 353-5. Acceptance
will be based on plastic properties, achieving the 2,200 psi compressive strength prior to opening
the slabs to traffic and the 24-hour compressive strength.
If the compressive strength of any set of test cylinders fails to meet the strength
requirements, take immediate corrective measures to ensure that concrete placed in the future
meets the specified strength requirements. The Engineer will evaluate the particular
circumstances in each instance where a strength deficiency occurs. If the Engineer determines
that there will be a significant effect on the service life of the replacement slab, replace the
concrete at no expense to the Department.
If any uncontrolled cracks appear during the life of the contract, remove and replace the
cracked slab at no expense to the Department. Repair by removing and replacing the pavement
across the full width of all affected lanes or shoulders and to the nearest transverse joint in each
direction. Investigate and implement immediate effective solutions to eliminate further cracks, in
consultation with, and subject to the approval of, the Engineer.
353-7 Placing, Striking Off, Consolidating and Finishing Concrete.
Place concrete as specified in 350-8.
The requirements of 350-9 and 350-10 are applicable to this Section.
Perform straight edging while the concrete is still in plastic state after floating is
completed and the excess water removed. Furnish and operate a 10 foot straightedge meeting the
requirements of 350-3.6. Hold the straightedge in successive positions parallel to the road
centerline, in contact with the surface, testing until the replacement slab is straight edged from
one side to the other. Advance along the road in successive stages of not more than one-half the
length of the straightedge. Fill any depressions immediately with freshly mixed concrete, strikeoff, consolidate and refinish. Cut down and refinish any high areas. Continue straightedge testing
and surface correction until the entire surface conforms to the required grade and cross section.
Ensure that transverse slope deviations of the finished pavement do not exceed 1/8 inch with the
straightedge laid in a direction perpendicular to the centerline. When portland cement concrete
pavement abuts bridge approaches or pavement not under this Contract, ensure that the
longitudinal slope deviations of the finished pavement do not exceed 1/8 inch in 10 foot length.
Produce a uniform, gritty textured final finish longitudinally along the pavement by dragging a
broom or seamless strip of damp burlap, having at least 3 feet in contact with the pavement.
When required in the Contract Documents, produce a pavement surface that is true to
grade and uniform in appearance with a longitudinal line type texture by grinding in accordance
with Section 352.
353-8 Curing.
Cure the slab as specified in 350-11, except for time and temperature restrictions. Use
curing compounds as specified in 350-11.2 after completing the finishing operations. After the
curing compound has been applied, cover the surface and exposed edges with two layers of white
burlap-polyethylene curing blanket conforming to Section 925 or insulating blankets approved
by the Engineer. Cover the slab with the curing materials as soon as the slab hardens enough to
resist marring the concrete surface. Continue curing the slab until the concrete achieves the
required 6-hour strength.
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353-9 Joints.
353-9.1 General: Construct transverse joints as specified in 350-12 and as shown on the
Design Standards, except that dowels bars are installed per 353-9.2. Tie bars will not be placed
along the longitudinal joints unless shown in the Contract Documents. Apply a liquid bond
breaker recommended by the manufacturer for the intended application to all vertical faces of the
adjacent slabs.
353-9.2 Dowel Bars: Provide dowel bars in accordance with the details shown in the
Contract Documents.
353-9.2.1 Dowel Bars at Transverse Joint Between two Replacement Slabs:
Follow the requirements of 350-12 when providing dowel bars at a transverse joint between two
freshly placed replacement slabs.
353-9.2.2 Dowel Bars at Transverse Joints Between Existing and
Replacement Slabs: Follow the requirements of 350-12, except drill holes and install dowel bars
into the sawed face or end of the existing slab. Develop load transfer between existing and
freshly placed replacement slab. The dowels shall be free to move inside the replacement slab
and epoxy-bonded into the existing slab.
353-9.2.3 Dowel Bar Installation: Install dowel bars in accordance with
Section 416 except as modified herein. Use a gang drill (several drills mounted parallel in a rigid
frame), when enough operating space is available. Drill parallel to the centerline of the concrete
pavement.
Inject epoxy into the hole after cleaning and prior to dowel insertion. Start
injection at the back of the hole to force the epoxy to move forward during dowel insertion.
Twist the dowel a minimum of one full turn during the insertion to ensure that the epoxy
completely surrounds the dowel. The injection process and viscosity of the epoxy shall be
adequate to insure that the space between the surface of the dowel and the inside of the hole is
completely filled with epoxy.
Do not allow the epoxy to escape from the front of the hole after inserting
the dowel in the hole. Use a grout retention disk 1/8 inch thick, fabricated from nylon or plastic,
to hold epoxy in the hole during dowel insertion.
353-10 Protection and Opening to Traffic.
353-10.1 General: The requirements of 350-6 apply to this Section. Keep the slab closed
to traffic until the compressive strength requirement of 2,200 psi is achieved. Verify the
achievement of the required strength by cylinder testing as specified in 353-5 or the use of the
maturity method test as described in 353-10.2. Provide documentation that 6-hour strength was
achieved prior to opening to traffic, by either a cylinder test report or a printed maturity meter
monitoring record.
Protect the pavement from all traffic, including construction vehicles, until the
specified 2,200 psi strength has been obtained. Include in the Quality Control Plan (QCP) what
actions will be used to protect the pavement. The protective measures shall be arranged so as not
to interfere with traffic lanes being utilized for required maintenance of traffic.
353-10.2 Maturity Method Testing: Provide and perform, with the assistance of the
Engineer, Maturity Method Testing as specified in ASTM C1074 using Maturity Meter
apparatus specified therein.
Maturity Method Testing may be used to estimate the in-place strength of that
days production of concrete slabs. Temperature sensors will be embedded at locations designated
by the Engineer.
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When this method is used, a strength-maturity relationship chart, as outlined in
ASTM C1074, will be prepared and tested at the concrete producers design mix trial batch
laboratory, or at other approved laboratory facilities designated by the Engineer. Compressive
strength tests, as specified in ASTM C1074, will be generated to produce a five point curve with
points before and after the target and with prior approval by the Engineer.
The Engineer may require compressive strength testing as outlined in 353-5.
Fabricate six test cylinders for protection strength and Maturity Meter correlation testing. The
compressive strength cylinder and maturity meter correlation testing will be performed for the
first production day and at the discretion of the Engineer for each remaining placement week, or
until terminated by the Engineer.
353-11 Method of Measurement.
The quantity to be paid for will be the volume, in cubic yards, of concrete placed and
accepted. The quantity will be calculated on the basis of field-measured horizontal dimensions
and pavement design thickness. No additional compensation will be allowed for additional
concrete required to bring the proposed concrete slab up to finished grade.
353-12 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section and
shall include demonstration slab construction, all joint construction, including tie bars and
dowels, furnishing of test specimens, and all necessary incidentals.
Payment will be made under:
Item No. 353- 70Concrete Pavement Slab Replacement - per cubic yard.
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SECTION 355
VALUE ADDED PORTLAND
CEMENT CONCRETE PAVEMENT
355-1 Description.
Construct Value Added Portland Cement Concrete Pavement (Concrete Pavement),
subject to a five year warranty period after final acceptance of the Contract in accordance with 511. This Section applies only to new pavements, including added lanes.
Furnish a copy of each mix design to the Engineer at least 14 days prior to any paving
work.
Perform all the associated work specified in this Section including continued
responsibility for performing all remedial work associated with pavement distresses exceeding
threshold values determined in accordance with this Section and as to which notice was provided
to the Contractor.
The work specified in this Section will not be paid for directly, but will be considered as
incidental to other Contract items.
355-2 Materials and Construction Requirements.
Meet the requirements of the following:
Portland Cement Concrete ..................................Section 346
Cement Concrete Pavement ................................Section 350
Grinding Concrete Pavement ..............................Section 352
355-3 Statewide Disputes Review Board.
The Statewide Disputes Review Board in effect for this Contract will resolve any and all
disputes that may arise involving administration and enforcement of this Specification. The
Contractor and the Department acknowledge that use of the Statewide Disputes Review Board is
required, and the determinations of the Statewide Disputes Review Board for disputes arising out
of this Specification will be binding on both the Contractor and the Department, with no right of
appeal by either party.
Meet the requirements of 8-3.
355-4 Pavement Evaluation and Remedial Work.
355-4.1 General: The Departments Pavement Condition Survey Program along with
observations by the Engineer will be used as the basis for determining the extent and the
magnitude of the pavement distresses occurring on the project. In the event the level of distress
exceeds any of the threshold values defined below, remedial work as described in 355-5 by the
Contractor will be required.
The Department will monitor the pavement for distresses and may require
remedial action at any time. The Department may conduct a Pavement Condition Survey of the
value added pavement following the final acceptance of the project, and at intermediate times
throughout the warranty period with findings provided when considered by the Department to be
the obligation of the Contractor.
The final survey, if determined by the Engineer to be necessary, will be conducted
before the end of the warranty period with results provided to the Contractor for those conditions
exceeding contract threshold values requiring remedial action that the Department believes to be
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an obligation of the Contractor. The Department will be responsible for all costs associated with
the surveys.
If the survey findings, intermediate or final, are to be disputed by the Contractor,
written notification must be provided to the Engineer within 30 calendar days of the date of
receipt of the information from the Department.
During the warranty period, the Contractor may monitor the pavement using
nondestructive methods and may participate with the Department in the Pavement Condition
Surveys upon request. Do not conduct any coring, milling or other destructive methods without
prior approval by the Engineer.
355-4.2 Distress Indicators: The Department will use Ride, Spalling and Cracking, as
distress indicators in accordance with the Rigid Pavement Condition Survey Handbook to
evaluate the Concrete Pavement. Ride Number (RN) will be established by Laser Profiler in
accordance with FM 5-549. For ride evaluation purposes, the project will be subdivided into lots
of 0.1 mile per lane and partial lots which are segments that are less than 0.1 mile. For the
purposes of threshold values and remedial work, partial lots and lots will be treated as lots.
355-4.3 Threshold Values and Remedial Work: Threshold values and associated
remedial work for the Concrete Pavement are specified in Table 355-1.
TABLE 355-1
Concrete Pavement Threshold Values and Remedial Work
Type of Distress
Threshold Values
Remedial Work
Grind all deficient lots and
partial lots in accordance with
Section 352.
Four areas in any Lane Mile
Full depth slab replacement
exceeding 1 inch in width and
for a minimum of 6 feet in
exceeding 6 inches in length OR length and the full width of
Spalling in the wheel path
any single area exceeding 3 inches the slab in accordance with
in width.
Section 353.
Four areas in any Lane Mile
Full depth slab replacement
exceeding 1 1/2 inches in width for a minimum of 6 feet in
Spalling outside the wheel path and 12 inches in length OR any length and the full width of
single area exceeding 3 inches in the slab in accordance with
width and 12 inches in length.
Section 353.
Full depth slab replacement
Four Cracks in any Lane Mile
for a minimum of 6 feet in
Cracking
with width exceeding 1/8 inch OR length and the full width of
any Crack exceeding 3/16 inch. the slab in accordance with
Section 353.
Cracking patterns that divide the
Full slab replacement in
Shattered Slab
slab into three or more segments accordance with Section 353.
Ride
Ride Number < 3. 50
355-5 Remedial Work.
Perform all necessary remedial work described in this Section at no cost to the
Department. Should an impasse develop in any regard as to the need for remedial work or the
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extent required, the Statewide Disputes Review Board will render a final decision by majority
vote.
Remedial work will not be required if any one of the following conditions is found to
apply:
a. Determination that the pavement thickness design as provided by the
Department is deficient. The Department will make available a copy of the original pavement
thickness design package and design traffic report to the Contractor upon request. The Contractor
will be responsible for performing all remedial work associated with the pavement distress if the
pavement design is provided by the Contractor.
b. Determination that the Accumulated ESALs (Number of 18 Kip Equivalent
Single Axle Loads in the design lane) have increased by 25% or more than the Accumulated
ESALs used by the Department for design purposes for the warranty period for the pavement
design life. In calculating ESALs, the Average Annual Daily Traffic (AADT) will be obtained
from the Departments traffic count data and the T24 (Percent Heavy Trucks during a 24 hour
period) will be obtained from the Departments traffic classification survey data.
c. Determination that the deficiency was due to the failure of the existing
underlying layers that were not part of the Contract work.
d. Determination that the deficiency was the responsibility of a third party or its
actions, unless the third party was performing work included in the Contract.
If a measured distress value indicates remedial action is required per Table 355-1, begin
remedial work within 45 calendar days of notification by the Department or a ruling of the
Statewide Disputes Review Board. The Statewide Disputes Review Board will determine the
allowable duration for the completion of the remedial work, but not to exceed 6 months.
If remedial action is necessary and forensic information is required, it is the responsibility
of the Contractor to determine the source of the distress. The Contractor will not be responsible
for damages to the pavement as a result of any forensic activities conducted at the discretion of
the Engineer.
As applicable to distress criteria for ride, when two lots requiring remedial action or a
partial lot and a lot are not separated by three or more lots not requiring remedial action, the
remedial work shall be required for the total length of all such contiguous lots and partial lots,
including the intermediate lots not requiring remedial action.
The Contractor has the first option to perform all remedial work, as determined by the
Department. If, in the opinion of the Engineer, the problem poses an immediate danger to the
traveling public and the Contractor cannot provide temporary mitigation for the defect within
4 hours of written notification and restore the pavement to its original design condition within
72 hours of written notification, the Engineer has the authority to have the remedial work
performed by other forces. Temporary mitigation includes the use of traffic control systems such
as barricades, drums, or other approved devices to secure the area including lane closures if
necessary, and constructing temporary repairs making it safe for the roadway user until the
defect can be restored to its original design condition. The Contractor is responsible for all
incurred costs of the work performed by other forces should the problem (remedial work) be
determined to be the responsibility of the Contractor. Remedial work performed by other forces
does not alter any of the requirements, responsibilities or obligations of the Contractor.
Complete all remedial work to the satisfaction of the Engineer. Any disputes regarding
the adequacy of the remedial work will be resolved by the Statewide Disputes Review Board.
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Approval of remedial work does not relieve the Contractor from continuing responsibility under
the provisions of this Specification.
Notify the Engineer in writing prior to beginning any remedial work. Meet the
requirements of the Departments Standard Specifications for Road and Bridge Construction and
implemented modifications hereto when performing any remedial work. Perform all signing and
traffic control in accordance with the Departments Design Standards for Design, Construction,
Maintenance and Utility Operations on the State Highway System. Provide Maintenance of
Traffic during remedial work at no additional cost to the Department. Lane closure restrictions
listed in the original Contract will apply to remedial work. Written requests to obtain permission
for lane closures for either forensic investigation or remedial work must be made to the Engineer
48 hours in advance of any lane closures. Do not perform any lane closures until written
permission is given by the Engineer.
If remedial work necessitates a corrective action to the pavement markings, adjacent
lanes, or roadway shoulders, perform these corrective actions using similar products at no cost to
the Department.
355-6 Failure to Perform.
Failure to timely submit any dispute to the Statewide Disputes Review Board, failure to
satisfactorily perform any remedial work, or failure to compensate the Department for any
remedial work performed by the Department and determined to be the Contractors responsibility
in accordance with this Specification, the Department will suspend, revoke or deny the
Contractors certificate of qualification under the terms of Section 337.16(d)(2), Florida Statutes,
for a minimum of 6 months or until the remedial work has been satisfactorily performed (or full
and complete payment for remedial work performed by others made to the Department),
whichever is longer. Should the Contractor choose to challenge the Departments notification of
intent for suspension, revocation or denial of qualification and the Departments action is upheld,
the Contractor will have its qualification suspended for an additional minimum of 6 months.
The remedial work is not an obligation of the Contractors bond required by
Section 337.18, Florida Statutes.
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SECTION 370
BRIDGE APPROACH EXPANSION JOINTS
370-1 Description.
Construct special expansion joints for concrete pavement near the bridge approach slabs
that consist of a section of reinforced concrete subslab supporting the roadway concrete
pavement, with a portion of the roadway pavement over the subslab interrupted by a galvanized
sheet metal strip, in accordance with the details shown in the Design Standards, Index No. 306
and the Contract Documents.
370-2 Materials.
Bar Reinforcement: Use bar reinforcing steel meeting the requirements of 931-1.1.
Concrete: For the expansion joint subslab, use concrete meeting the requirements of
Section 347.
Galvanized Sheet Metal: Use galvanized sheet metal meeting the requirements shown in
the Plans.
Seal: Use compression seals in accordance with Section 932 and Design Standards
Index No. 306.
370-3 Construction Methods.
Construct the expansion joints in accordance with the applicable requirements of
Sections 346, 347, 350, 415, Design Standards, Index No. 306 and as directed by the Engineer.
370-4 Method of Measurement.
The quantity to be paid for will be plan quantity, in feet, calculated across the pavement
at right angles to the centerline of the roadway pavement, completed and accepted.
370-5 Basis of Payment.
Price and payment will be full compensation for all work and materials specified in this
Section or required for the expansion joint, including concrete subslab, sheet metal strip,
reinforcing steel, compression seal and all additional excavation required.
Payment will be made under:
Item No. 370- 1Bridge Approach Expansion Joint - per foot.
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STRUCTURES
SECTION 400
CONCRETE STRUCTURES
400-1 Description.
Construct concrete structures and other concrete members, with the exception of
pavement and incidental concrete construction (which are specified in other Sections).
Refer to Section 450 for prestressed construction requirements additional to the
requirements of this Section.
For precast concrete structures meet the requirements of Section 450 for inserts and
lifting devices, handling, storage, shipping, and erection.
Obtain incidental precast products from a plant that is currently on the Departments list
of Producers with Accepted Quality Control Programs. Producers seeking inclusion on the list
shall meet the requirements of 105-3.
400-2 Materials.
Meet the following requirements:
Concrete .............................................. Sections 346 and 347
Penetrant Sealer ................................................. Section 413
High Molecular Weight Methacrylate (HMWM)**
........................................................................... Section 413
Reinforcing Steel ............................................... Section 415
Water .................................................................. Section 923
Curing Materials* .............................................. Section 925
Epoxy Bonding Compounds** ........... Sections 926 and 937
Joint Materials**................................................ Section 932
Bearing Pads ...................................................... Section 932
Non-Shrink Grout** .......................................... Section 934
Class 5 Applied Finish Coatings** .................... Section 975
Galvanizing Compound** ................................. Section 562
Dowel Bar Assembly** ..................................... Section 931
Filter Fabric........................................................ Section 985
*The Engineer will allow clean sand and sawdust for certain curing, when and as
specified.
**Use products listed on the Departments Qualified Products List (QPL).
400-3 Depth of Footing.
Refer to Section 455, D. SPREAD FOOTINGS.
400-4 Falsework.
400-4.1 Plans: At the Engineers request, furnish detailed plans for falsework or
centering to the Department. The Contractor is responsible for results obtained by using these
plans.
400-4.2 Design and Erection: Design and construct all falsework to provide the
necessary rigidity and to support the loads without appreciable settlement or deformation. Use
screw jacks or hardwood wedges to take up any settlement in the framework, either before or
during the placing of concrete. If any weakness develops and the centering shows undue
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settlement or distortion, stop the work, remove any masonry affected, and strengthen the
falsework before resuming work. Support falsework which cannot be founded on a satisfactory
footing on piling. Space, drive, and remove the piling in an approved manner.
400-4.3 Camber: Provide camber to correct for settlement and deflection of falsework.
Give bridges permanent camber only when shown in the Plans.
400-5 Forms.
400-5.1 General: Provide forms, either of wood or metal, that are as follows: (a)
externally secured and braced where feasible; (b) substantial and unyielding; (c) of adequate
strength to contain the concrete without bulging between supports and without apparent
deviation from the neat lines, contours, and shapes shown in the Plans. Design forms to
withstand the additional forces of vibration without apparent deviation from the desired shape or
position. Assemble forms to be mortar-tight. If using lumber forms, construct them of dressed
wood of uniform thickness. Use form liners on wooden forms where Class 3 surface finish is
specified. Construct assembled forms to render a concrete surface of smooth, uniform finish.
Make provisions to remove forms without injury to concrete surfaces. Remove blocks and
bracing with the forms, and do not leave any portion of the forms in the concrete. Use the same
form system for a type of work throughout.
400-5.2 Inspection and Approval: Do not place concrete in a form until the form has
been inspected and approved. Although the Engineer inspects and approves the forms, the
Contractor is responsible for obtaining satisfactory concrete surfaces, free from warping,
bulging, or other objectionable defects. Pay special attention to the ties and bracing. Where the
forms appear to be insufficiently braced or unsatisfactorily built, stop and correct defects to the
satisfaction of the Engineer.
400-5.3 Non-metallic Form Materials:
400-5.3.1 Lumber: For all surfaces, use lumber that is not less than 3/4 inch in
thickness, dressed, and free of knot holes, loose knots, cracks, splits, warps, and other defects.
Proportion the spacing of studs, joists, and wales to exclude warps and bulges and to produce
true and accurate concrete surfaces. Only use structurally sound lumber.
400-5.3.2 Form Liners: Use form liners of durable, abrasion resistant materials
that are unaffected by water. Use liners with a hard surface texture capable of rendering concrete
surfaces of a smooth, uniform texture, without grain marks, patterns, or blemishes. Use form
liner material of sufficient thickness to eliminate the reflection of irregularities, undesirable
patterns, and marks from the forms to the surfaces. Replace liners as necessary to produce a
consistent concrete surface texture. Use form liners in large sheets and with true, tight-fitted
joints which are logically located. Obtain the Engineers approval of the layout of sheets. Do not
use liners which have been patched. Use liner material of the same stock throughout.
400-5.3.3 Plywood: The Contractor may use plywood of not less than 5/8 inch in
thickness manufactured with waterproof glue or protected with an approved impervious coating.
Do not use pieces with bulged plies or raveled, untrue edges.
400-5.4 Special Requirements:
400-5.4.1 Re-entrant Angles: Use chamfered forms for exterior concrete corners
and filleted forms for interior concrete corners. Use chamfers and fillets that are 3/4 inches by
3/4 inches and are mill-dressed on all sides to uniform dimensions. The Contractor may use
plastic or metal chamfers and fillets provided they perform satisfactorily in producing uniform,
smooth concrete corner surfaces without honeycomb.
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400-5.4.2 Handrails and Parapets: Construct barriers and parapets in
accordance with Section 521.
400-5.4.3 End-bent Caps: Do not place forms for end-bent caps until the
embankment has been constructed to within 12 inches of the bottom of the cap. Place a mass of
embankment that is sufficient to produce the subsidence, displacement, and settlement which
may result from the construction of the total embankment.
400-5.4.4 Footings: Where footing concrete can be placed in dry excavation, the
Contractor may omit cribs, cofferdams, and forms, subject to compliance with the following
limitations and conditions:
(a) Use this procedure only in locations not exposed to view from traveled
roadways.
(b) Obtain required elevations shown in the Plans.
(c) Obtain neat line dimensions shown in the Plans.
(d) Fill the entire excavation with concrete to the required elevation of the
top of the footing.
(e) The Engineer will determine the volume of footing concrete to be paid
for from the neat line dimensions shown in the Plans.
400-5.5 Form Alignment, Bracing, and Ties: Construct forms in such manner that they
may be adequately secured for alignment, shape, and grade. Use bracing systems, ties, and
anchorages that are substantial and sufficient to ensure against apparent deviation from shape,
alignment, and grade. Do not drive nails into existing concrete. Do not use bracing systems, ties,
and anchorages which unnecessarily deface or mark, or have an injurious or undesirable effect
on surfaces that will be a part of the finished surface.
If metal ties and anchorages are to remain in the concrete, construct them so as to
permit the removal of metal to at least 1 inch beneath the finished surface of concrete. Use
accessories for metal ties and anchorages that allow the removal of metal to the prescribed depth
while leaving the smallest possible repairable cavity.
When using wire ties, cut or bend them back from the finished surface of the
concrete a minimum of 1 inch. Do not use internal ties of wire when forming surfaces that are
exposed to view.
400-5.6 Preparation and Cleaning: Meet the following requirements for the condition
of forms at the time of beginning concrete casting:
(a) Treat all forms with an approved form-release agent before placing concrete.
Do not use material which adheres to or discolors the concrete.
(b) Clean forms of all concrete laitance from previous use and all dirt, sawdust,
shavings, loose wire ties and other debris.
(c) Close and secure all inspection and cleanout holes.
400-5.7 Stay-In-Place Metal Forms:
400-5.7.1 General: Utilization of stay-in-place metal forms is permitted in lieu of
removable forms to form concrete bridge decks between beams and between the webs of
individual box girders when designated in the Plans. Stay-in-place metal forms may be of the
cellular, non-cellular or non-cellular with top cover sheet type. The flutes of non-cellular stay-inplace metal forms may be filled with polystyrene foam or concrete. When polystyrene foam is
used to fill the forms, fill form flutes completely; do not allow any portion of the polystyrene
foam to extend beyond the limits of the flutes. Ensure that the polystyrene foam remains in its
required position within flutes during the entire concrete placement process. Do not use
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reinforcing steel supports or other accessories in such a manner as to cause damage to the
polystyrene foam. Replace all damaged polystyrene foam to the satisfaction of the Engineer.
Apply polymer sheeting to stay-in-place metal forms in accordance with
the requirements in the following table. Apply polymer sheeting to all faces and edges (including
sheared edges) of support angles used on bridges with moderately and extremely aggressive
superstructure environmental classifications (as shown in the Plans). No polymer sheeting is
required for beam attachment straps or clips partially embedded in concrete, and for support
angles used on bridges with a slightly aggressive superstructure environmental classification.
Use polymer sheeting materials and application methods as described herein.
Polymer Sheeting Usage Requirements
Form Type
Superstructure Environmental Classification (as shown in Plans)
Slightly Aggressive Moderately Aggressive Extremely Aggressive
Non-cellular form
with concrete
filled flutes
No polymer sheeting
required
Non-cellular form
with polystyrene
foam filled flutes
Polymer sheeting
required on inside
Polymer sheeting
Polymer sheeting
required on bottom side required on bottom side
Polymer sheeting
required on both sides*
Polymer sheeting
required on both sides*
Top
NonPolymer sheeting
Polymer sheeting
Polymer sheeting
cellular Cover
required on bottom side required on bottom side required on bottom side
Sheet
form
with Top NonPolymer sheeting
Polymer sheeting
Polymer sheeting
Cover cellular
required
on
top
side
required
on
both
sides*
required
on both sides*
Sheet
form
No polymer sheeting
Cellular form
Not permitted
Not permitted
allowed or required
* Polymer sheeting not required on bottom side of form located within box girders and U-beams.
Prior to using stay-in-place metal forms, submit detailed plans for
approval of the forming system, including method of support and attachment and method of
protecting the supporting structural steel components from welding effects. Submit design
calculations for the forming system, which have been signed and sealed by the Specialty
Engineer. Detail stay-in-place metal forms such that they in no way infringe upon the concrete
outline of the slab shown in the Plans. Use stay-in-place metal forms that provide and maintain
the dimensions and configuration of the original slab in regards to thickness and slope.
Do not weld stay-in-place metal form supports and connections to the
structural steel components. Do not connect polymer coated angles or other hardware that
support polymer coated metal forms to the beam attachment straps or clips by welding. Electrical
grounding to reinforcing steel is prohibited.
Protect structural steel components from damage by using a shield to
guard against weld splatter, weld overrun, arc strikes, or other damaging effects of the welding
process. Upon completion of welding, rest the metal form support flush on the supporting steel
component. Should any weld spatter, weld overrun, arc strike, or other effects of the welding
process be evident or occur to the structural steel component, immediately stop in-place welding
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of the metal form supports for the remainder of the work. In this event, weld all metal form
supports off of the structure and erect the forms after prefabrication, or use an alternate approved
method of attaching the form supports. Remove improper weldment, repair the supporting steel
component for any improper welding. Perform all required verification and testing at no expense
to the Department and to the satisfaction of the Engineer.
Do not use stay-in-place metal forms until the forming system has been
approved by the Engineer. The Contractor is responsible for the performance of the stay-in-place
forms.
Structures designed, detailed, and dimensioned for the use of removable
forms: Where stay-in-place metal forms are permitted, the Contractor is responsible and shall
obtain the approval of the Engineer for any changes in design, etc. to accommodate the use of
stay-in-place forms. The Engineer will compute pay quantities of the various components of the
structure which are paid on a cubic yard basis from the design dimensions shown in the Plans
with no allowance for changes in deflection or dimensions necessary to accommodate the stayin-place forms or concrete to fill the form flutes. The Engineer will limit pay quantities of other
Contract items that the Contractor increases to accommodate the use of stay-in-place forms to
the quantity required for the original Plan design.
Submit all changes in design details of bridge structural members that
support stay-in-place forms, showing all revisions necessary to enable the supporting
components to withstand any additional weight of the forms and the weight of any extra concrete
that may be required to fill the forms. Include with the design calculations a comparative
analysis of the stresses in the supporting components as detailed in the Contract Plans and as
modified to support the forms. Use the identical method of analysis in each case, and do not
allow the stresses in the modified components to exceed those of the component as detailed in
the Contract Plans. Include with the design the adjusted cambers for any changes in deflection
over those shown on the original Plans. Modify the beams to provide additional strength to
compensate for the added dead loads imposed by the use of stay-in-place forms. Obtain the
additional strength by adding strands to the pre-stressed beams or by adding steel material to
increase the section modulus of steel girders. Substantiate the added strength by the comparative
calculations. Do not use stay-in-place forms until the forming system and all necessary design
revisions of supporting members have been approved by the Engineer.
Structures designed, detailed, and dimensioned for the use of stay-in-place
metal forms:
Prior to using stay-in-place metal forms, submit detailed plans for
approval of the forming system (including method of support and attachment) together with
design calculations. Include an analysis of the actual unit weight of the proposed forming system
over the projected plan area of the metal forms. If the weight thus calculated exceeds the weight
allowance for stay-in-place metal forms and concrete required to fill the forms shown in the
Plans, then modify the supporting components to support the excess weight as specified by the
Contractors Specialty Engineer.
For all structures utilizing structural steel supporting components, paint
the vertical sides of the top flange prior to installation of the stay-in-place metal forms in
accordance with Section 560.
For non-polymer sheeting form surfaces, use zinc paint coating in
accordance with Section 562 to all accessories cut from galvanized sheets, which are not
embedded in concrete.
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400-5.7.2 Design: Meet the following criteria for the design of stay-in-place
bridge deck forms:
1. The maximum self weight of the stay in place metal forms, plus the
weight of the concrete or expanded polystyrene required to fill the form flutes (where used),
shall not exceed 20 psf.
2. Design the forms on the basis of dead load of form, reinforcement, and
plastic concrete plus 50 pounds per square foot for construction loads. Use a unit working stress
in the steel sheet of not more than 0.725 of the specified minimum yield strength of the material
furnished, but not to exceed 36,000 psi.
3. Do not allow deflection under the weight of the forms, reinforcement,
and plastic concrete to exceed 1/180 of the form span or 1/2 , whichever is less, for form spans of
10 feet or less, or 1/240 of the form span or 3/4 inch, whichever is less, for form spans greater
than 10 feet. In all cases, do not use a total loading (psf) that is less than 20 plus the product of
the deck thickness measured in inches times 12.5.
4. Use a design span of the form equal to the clear span of the form plus
2 inches. Measure the span parallel to the form flutes.
5. Compute physical design properties in accordance with requirements of
the AISI Specifications for the Design of Cold Formed Steel Structural Members, latest
published edition.
6. For all reinforcement, maintain the design concrete cover required by
the Plans.
7. Maintain the plan dimensions of both layers of primary deck
reinforcement from the top surface of the concrete deck.
8. Do not consider the permanent bridge deck form as lateral bracing for
compression flanges of supporting structural members.
9. Do not use permanent steel bridge deck forms in panels where
longitudinal deck construction joints are located between stringers.
10. Secure forms to the supporting members by means other than welding
directly to the member.
400-5.7.3 Materials:
400-5.7.3.1 Metal Forms: Fabricate stay-in-place metal forms and
supports from steel meeting the requirements of ASTM A653 having a coating designation
G165. Do not use form materials that are less than 0.03 inch uncoated thickness.
400-5.7.3.2 Polymer Sheeting: Use polymer sheeting comprised of at
least 85% ethylene acrylic acid copolymer capable of being applied to both G165 and G210 steel
sheet as described in ASTM A742. Ensure that the polymer sheeting has a nominal thickness of
12 mils as manufactured and a minimum thickness of 10 mils after lamination to the steel sheet.
Ensure that the polymer sheeting remains free of holes, tears and discontinuities and sufficiently
flexible to withstand the forming process without any detrimental effects to bond, durability or
performance. Ensure that the polymer sheeting is UV stabilized and contains antioxidants.
Ensure that the as-manufactured polymer sheeting (prior to
application) has an Oxidative Induction Time (OIT) of 60 to 75 minutes at 170C in air when
tested according to ASTM D3895. Perform additional OIT tests on samples taken from the
finished product (polymer sheeting applied to forms) resulting in a minimum OIT according to
ASTM D3895 of 32 minutes at 170C in air. Ensure that the polymer sheeting adheres to
galvanized metal sufficient to prevent undercutting at penetrations made through the polymer
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sheeting or metal forms to the satisfaction of the Engineer. Ensure that edges subjected to shear
cutting are coated by the form manufacturer with two coats of a compatible liquid coating repair
material before delivery to the site. Ensure that steel used to produce polymer laminated metal
forms is appropriately cleaned and prepared per NCCA (National Coil Coating Association)
standard continuous coil coating practices. Ensure that pretreatment for use in conjunction with
the manufacturers polymer sheeting material is approved as compatible by the polymer sheeting
manufacturer. Apply pretreatment in accordance with the polymer sheeting manufacturers
procedures. Apply polymer sheeting in accordance with the manufacturers recommendations
and procedures. Ensure that all steel has the polymer sheeting applied prior to fabrication of the
stay-in-place forms and accessories.
Ensure that the screws to be used in the fastening of the
stay-in-place laminated metal forms have a corrosion resistant cladding that will not have an
adverse effect to the system due to the contact of dissimilar metals.
400-5.7.3.3 Certification: Provide a written certification from the manufacturer
stating the product meets the requirements of this specification along with the delivery of the
coated forms to the jobsite. Ensure that the certification conforms to the requirements of
Section 6. Ensure that the manufacturer has a Quality Control (QC) Program conforming to ISO
9001:2000 standards.
400-5.7.3.4 Polystyrene Foam: Use polystyrene foam comprised of expanded
polystyrene manufactured from virgin resin of sufficient density to support the weight of
concrete without deformation. Extrude the polystyrene foam to match the geometry of the flutes
and provide a snug fit. Use polystyrene foam that has a density of not less than 0.8 pounds per
cubic foot. Use polystyrene foam that has water absorption of less than 2.6% when tested
according to ASTM C272. Provide a written certification from the manufacturer stating the
product meets the requirements of this Specification along with the delivery of the product.
400-5.7.4 Construction: Install all forms in accordance with approved
fabrication and erection plans.
Do not rest form sheets directly on the top of the stringer of floor beam
flanges. Fasten sheets securely to form supports, and maintain a minimum bearing length of
1 inch at each end for metal forms. Place form supports in direct contact with the flange of the
stringer or floor beam. Make all attachments for coated metal forms by bolts, clips, screws, or
other approved means.
400-5.7.4.1 Form Galvanizing Repairs: For any permanent exposed steel
where the galvanized coating has been damaged, thoroughly clean, wire brush, and paint it with
two coats of galvanizing compound in accordance with Section 562 to the satisfaction of the
Engineer. Do not touch up minor heat discoloration in areas of welds.
400-5.7.4.2 Polymer Sheeting Repairs: Inspect and identify areas for
damage to the polymer sheeting and repair with liquid polymer coating similar and compatible
with respect to durability, adhesion and appearance in accordance with ASTM A762, as
furnished by the stay-in-place form manufacturer. Ensure that the inspection includes checking
the polymer sheeting for cuts, tears, cracking, surface pits, peeling, dirt, grease, oil, stains, rust or
bare areas. Reject any panels that show coating blistering, peeling or cracking. Repair all
polymer sheeting damage according to the following:
a. Surface Preparation: Ensure that all surfaces to be repaired are
clean and free of any deleterious substances. Remove all traces of dirt, soil, oil deposits, greases,
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and other surface contaminates in accordance with the polymer sheeting and coating
manufacturers written specifications prior to touch-up and recoating.
b. Application Procedures: Ensure that the liquid polymer repair
coating is applied to a clean dry surface and in accordance with the manufacturers written
specifications. Apply the repair coating using a suitable paintbrush or other means acceptable to
the Engineer. Apply a first coat of product to the surface at 2-4 mils in thickness. Let the first
coat air dry. Apply a second coat to form a complete layer and increase the thickness,
immediately after verifying the first coat is dry to the touch (15 - 25 minutes depending on the
local air drying temperature and atmospheric conditions). Apply the second coat at the same
coating thickness as the first at 2-4 mils. Ensure that the total dry film thickness of the two coats
is not less than 6 mils. Apply additional coats in this same manner until desired coating thickness
is achieved.
400-5.7.5 Placing of Concrete: Vibrate concrete to avoid honeycomb and voids,
especially at construction joints, expansion joints, valleys and ends of form sheets. Use approved
pouring sequences. Do not use calcium chloride or any other admixture containing chloride salts
in the concrete.
400-5.7.6 Inspection: The Engineer will observe the Contractors method of
construction during all phases of the construction of the bridge deck slab, including the
installation of the metal form system; location and fastening of the reinforcement; composition
of concrete items; mixing procedures, concrete placement, and vibration; and finishing of the
bridge deck. Should the Engineer determine that the procedures used during the placement of the
concrete warrant inspection of the underside of the deck, remove at least one section of the metal
forms in each span for this purpose. Do this as soon after placing the concrete as practicable in
order to provide visual evidence that the concrete mix and the procedures are obtaining the
desired results. Remove an additional section in any span if the Engineer determines that there
has been any change in the concrete mix or in the procedures warranting additional inspection.
If, in the Engineers judgment, inspection is needed to check for defects in
the bottom of the deck or to verify soundness, sound the metal forms with a hammer as directed
by the Engineer after the deck concrete has been in place a minimum of two days. If sounding
discloses areas of doubtful soundness to the Engineer, remove the metal forms from such areas
for visual inspection after the concrete has attained adequate strength. Remove metal bridge deck
forms at no expense to the Department.
At locations where sections of the metal forms have been removed, the
Engineer will not require the Contractor to replace the metal forms. Repair the adjacent metal
forms and supports to present a neat appearance and to ensure their satisfactory retention and
where they are polymer sheeted, coat all exposed surfaces of stay-in-place metal form system
elements that are not coated or are damaged with a field applied liquid polymer coating as
specified in 400-5.7.4.2. As soon as the form is removed, the Engineer will examine the concrete
surfaces for cavities, honeycombing, and other defects. If irregularities are found, and the
Engineer determines that these irregularities do not justify rejection of the work, repair the
concrete as directed, and provide a General Surface Finish in accordance with 400-15. If the
Engineer determines that the concrete where the form is removed is unsatisfactory, remove
additional metal forms as necessary to inspect and repair the slab, and modify the method of
construction as required to obtain satisfactory concrete in the slab. Remove and replace all
unsatisfactory concrete as directed, at no expense to the Department.
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If the method of construction and the results of the inspections as outlined
above indicate that sound concrete has been obtained throughout the slabs, the amount of
sounding and form removal may be reduced when approved by the Engineer.
Corrosion of assembly screws will not be considered a structural or
aesthetic problem and is considered acceptable.
Provide the facilities for the safe and convenient conduct of the inspection
procedures.
400-5.8 Stay-In-Place Concrete Forms:
400-5.8.1 General: Permanent stay-in-place precast reinforced concrete forms
may be used in lieu of removable forms to form concrete bridge deck slabs subject to the
conditions contained herein. Precast reinforced concrete stay-in-place forms are not permitted to
construct a composite concrete deck. Do not use precast prestressed concrete stay-in-place forms
to form any permanent bridge decks.
When detailed plans for structures are dimensioned for the use of
removable forms, provide additional slab thickness, elevation changes, changes in design, etc. to
accommodate the use of stay-in-place forms, subject to the Engineers approval. The Engineer
will compute pay quantities of the various component members of the structure which are paid
on a cubic yard basis from the design dimensions shown in the Plans with no allowance for
changes in deflection and changes in dimensions necessary to accommodate the stay-in-place
forms. The Engineer will limit pay quantities of other Contract items which are increased to
accommodate the use of stay-in-place forms to the quantity required for the original plan design.
Prior to using stay-in-place forms, submit for approval detailed plans of
the forming system and design calculations. Indicate on the plans the form panel sizes, placing
patterns, type of mastic or felt bearing material and type and method of caulking between panels.
Also, submit appropriate changes in design details of structural members supporting stay-inplace forms showing any revisions necessary to enable the supporting components to withstand
the additional weight of the forms and perform equally as contemplated in the Plans. All
calculations and details submitted shall be sealed by the Contractors Engineer of Record.
Modify the beams to provide additional strength to compensate for the added dead loads
imposed by the use of stay-in-place forms. Obtain this strength by adding additional strands to
prestressed girders or increasing the section modulus for steel girders. Do not use stay-in-place
forms until the forming system and any necessary design revisions of supporting structural
members have been approved by the Engineer. The Department is not responsible for the
performance of the stay-in-place forms by its approval.
400-5.8.2 Materials: Construct permanent concrete forms of precast reinforced
concrete with a Class 3 Surface Finish. As a minimum, use the same class of concrete and 28 day
minimum compressive strength as being used to construct the bridge deck. Use welded steel wire
reinforcement meeting the requirements of Section 931.
400-5.8.3 Design: Use the following criteria for the design of permanent bridge
deck forms:
(1) Design the forms on the basis of deadload of form, reinforcement, and
plastic concrete plus an unfactored live load of 50 psf for construction loads. Meet the AASHTO
design requirements for service loads and ultimate loads as applicable.
(2) Deflection under the weight of the forms, reinforcement, and the
plastic concrete shall not exceed 1/180 of the form span or 1/2 inch, whichever is less. In all
cases, do not use a loading that is less than 120 psf total.
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(3) Use a design span of the form equal to the clear span of the form
between supports. Measure the span of concrete forms parallel to the centerline of the form
panels.
(4) Compute physical design properties of concrete forms in accordance
with current AASHTO design procedures.
(5) Ensure that all steel reinforcement contained in the cast-in-place
concrete has the minimum cover shown in the Plans or not less than 1 inch, whichever is greater.
Measure the minimum cover normal to the plane of the bottom of the cast-in-place concrete. For
stay-in-place concrete forms with other than plane surfaces in contact with the cast-in-place
concrete, such as regularly spaced geometrical shapes projecting above the plane of the bottom
of the cast-in-place concrete, meet the following special requirements:
(a) Space geometrical shapes projecting above the bottom plane of
the cast-in-place concrete used to provide support for reinforcement no closer than 3 feet apart
and of sufficient height to maintain the required concrete cover on the bottom mat of reinforcing
steel.
(b) Construct all other geometrical shapes projecting above the
plane of the bottom of the cast-in-place concrete to provide a minimum vertical clearance of
3/4 inch between the closest surface of the projections and the secondary longitudinal reinforcing
steel in the deck slab.
(c) Do not allow a minimum horizontal distance from the surface
of any transverse reinforcing steel to surfaces of the stay-in-place form of less than 1-1/2 inches.
For all steel reinforcement for the stay-in-place form
panels, provide a minimum of 1 inch concrete cover except that, for construction in a salt or
other corrosive environment, provide a minimum of 1-1/2 inches concrete cover.
(6) Maintain the Plan dimensions of both layers of primary deck
reinforcement from the top surface of the concrete deck. Measure the minimum cover of the
bottom mat of steel normal to the top of the precast concrete form panel.
(7) Do not consider the permanent bridge deck form as lateral bracing for
compression flanges of supporting structural members.
(8) Do not use permanent concrete bridge deck forms in panels where
longitudinal deck construction joints are located between stringers.
(9) Do not allow the maximum weight of the concrete form to exceed
40 pounds per square foot of form surface.
400-5.8.4 Construction: Install all forms in accordance with approved
fabrication and erection plans.
For concrete forms, provide a minimum bearing length of at least 11/2 inches but not exceeding 2-1/2 inches. Support concrete forms on the beams or girders by
continuous layers of an approved mastic or felt bearing material that will provide a mortar tight
uniform bearing. Use a mastic or felt bearing material that has a minimum width of 1 inch and a
maximum width of 1-1/2 inches. Seal joints between concrete form panels with caulking, tape, or
other approved method.
400-5.8.5 Placing of Concrete: Place the concrete in accordance with the
requirements of 400-5.7.5. Immediately prior to placing the slab concrete, saturate concrete
stay-in-place form panels with water.
400-5.8.6 Inspection: Inspect the concrete in accordance with the requirements of
400-5.7.6.
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After the deck concrete has been in place for a minimum period of two
days, inspect the forms for cracks and excessive form deflection, and test for soundness and
bonding of the forms by sounding with a hammer as directed by the Engineer. Remove, for
visual inspection, form panels found to be cracked that show evidence of leakage and form
panels which have a deflection greater than adjacent panels by 1/2 inch or more which show
signs of leakage. If sounding discloses areas of doubtful soundness to the Engineer, remove the
form panels from such areas for visual inspection after the concrete has attained adequate
strength. Remove permanent bridge deck form panels at no expense to the Department.
At locations where sections of the forms have been removed, the Engineer
will not require the forms to be replaced. Repair the adjacent forms and supports to present a
neat appearance and to ensure their satisfactory retention. As soon as the form is removed, the
Engineer will examine the concrete surfaces for cavities, honeycombing, and other defects. If
irregularities are found, and the Engineer determines that these irregularities do not justify
rejection of the work, repair the concrete as directed and provide a General Surface Finish in
accordance with 400-15. If the concrete where the form is removed is unsatisfactory, as
determined by the Engineer, additional forms shall be removed as necessary to inspect and repair
the slab, and modify the methods of construction as required to obtain satisfactory concrete in
the slab. Remove and replace all unsatisfactory concrete as directed at no expense to the
Department.
If the methods of construction and the results of the inspections as
outlined above indicate that the Contractor has obtained sound concrete throughout the slabs, the
Contractor may moderate the amount of sounding and form removal, when approved.
Provide all facilities for the safe and convenient conduct of the inspection
procedures.
400-6 Underdrain and Weep Holes.
Provide weep holes in all abutments and retaining walls.
Provide a continuous underdrain for box culverts in accordance with Design Standards,
Index No. 289. Provide weep holes that are at least 3 inches in diameter and not more than
10 feet apart. Place the outlet ends of the weep holes just above the ground line in front of
abutments and retaining walls. Cover the exterior openings of all weep holes with galvanized
wire mesh and a minimum of 2 cubic feet of clean, broken stone or gravel wrapped in Type D 3
filter fabric, to allow free drainage but prevent the fill from washing through.
400-7 Placing Concrete.
400-7.1Weather Restrictions:
400-7.1.1 Concreting in Cold Weather: Do not place concrete when the air
temperature at placement is below 45F.
Meet the air temperature requirements for mixing and placing concrete in
cold weather as specified in Section 346. During the curing period, if NOAA predicts the
ambient temperature to fall below 35F for 12 hours or more or to fall below 30F for more than
4 hours, enclose the structure in such a way that the air temperature within the enclosure can be
kept above 50F for a period of three days after placing the concrete or until the concrete reaches
a minimum compressive strength of 1,500 psi.
Assume all risks connected with the placing and curing of concrete.
Although the Engineer may give permission to place concrete, the Contractor is responsible for
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satisfactory results. If the placed concrete is determined to be unsatisfactory, remove, dispose of,
and replace the concrete at no expense to the Department.
400-7.1.2 Concreting in Hot Weather: Meet the temperature requirements and
special measures for mixing and placing concrete in hot weather as specified in Section 346.
When the temperature of the concrete as placed exceeds 75F, incorporate
in the concrete mix a water-reducing retarder or water reducer if allowed by Section 346.
Spray reinforcing steel and metal forms with cool fresh water just prior to
placing the concrete in a method approved by the Engineer.
Assume all risks connected with the placing and curing of concrete.
Although the Engineer may give permission to place concrete, the Contractor is responsible for
satisfactory results. If the placed concrete is determined to be unsatisfactory, remove, dispose of,
and replace the concrete at no expense to the Department.
400-7.1.3 Wind Velocity Restrictions: Do not place concrete for bridge decks if
the forecast of average wind velocity at any time during the planned hours of concrete placement
exceeds 15 mph. Obtain weather forecasts from the National Weather Service Hourly Weather
Graph for the city closest to the project site.
400-7.2 Lighting Requirements: Provide adequate lighting for all concrete operations
conducted at night. Obtain approval of the lighting system prior to starting the concrete
operations.
400-7.3 Inspections before Placing Concrete: Do not place concrete until the depth and
character of the foundation and the adequacy of the forms and falsework have been approved by
the Engineer. Do not deposit any concrete until all reinforcement is in place and has been
inspected and approved by the Engineer.
400-7.4 Exposure to Water: Do not expose concrete other than seal concrete in
cofferdams to the action of water before final setting. Do not expose such concrete to the action
of salt or brackish water for a period of seven days after placing the concrete. Protect the
concrete during this period by keeping salt or brackish water pumped out of cofferdams.
400-7.5 General Requirements for Placing Concrete: Do not place any concrete prior
to approval of the Contractors Quality Control (QC) Plan in accordance with 105-3. Deposit
concrete as nearly as possible in its final position. Do not deposit large quantities at one point
and then run or work it along the forms. Take special care to fill each part of the forms, to work
coarse aggregate back from the face, and to force concrete under and around reinforcing bars
without displacing them.
Use a method and manner of placing concrete that avoids the possibility of
segregation or separation of aggregates. If the Engineer determines that the quality of concrete as
it reaches its final position is unsatisfactory, remove it and discontinue or adjust the method of
placing until the Engineer determines that the quality of the concrete as placed is satisfactory.
Use metal or metal-lined open troughs or chutes with no aluminum parts in
contact with the concrete. As an exception, chutes made of aluminum with a protective coating
for ready mixed concrete trucks, no longer than 20 feet, may be used. This exception does not
apply to any other means of concrete conveyance. Where steep slopes are required, use chutes
that are equipped with baffles or are in short lengths that reverse the direction of movement.
Where placing operations would involve dropping the concrete freely more than 5 feet, deposit it
through pipes, troughs, or chutes of sheet metal or other approved material. Use troughs, chutes,
or pipes with a combined length of more than 30 feet only with the Departments authorization.
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Keep all troughs, chutes, and pipes clean and free from coatings of hardened concrete by
thoroughly flushing them with water after each run or more often if necessary.
Place concrete against supporting material that is moist at the time of concrete
placement. If additional water is required, uniformly apply it ahead of the concrete placement as
directed by the Engineer. Do not place concrete on supporting material that is frozen. The
Contractor may use a moisture barrier in lieu of controlling the foundation grade moisture when
approved by the Engineer.
400-7.6 Placing Concrete by Belt Conveyor: Place concrete by means of a belt
conveyor system with written Department authorization. Remove conveyor belt systems which
produce unsatisfactory results before continuing operations. Take concrete samples for assurance
testing at the discharge end of the belt conveyor system. Make available to the Engineer the
necessary platform to provide a safe and suitable place for sampling and testing. Remove any
concrete placed in an unsatisfactory manner at no expense to the Department before continuing
operations.
Use conveyor belt systems that do not exceed a total length of 550 feet, measured
from end to end of the total assembly. Arrange the belt assembly so that each section discharges
into a vertical hopper arrangement to the next section. To keep segregation to a minimum, situate
scrapers over the hopper of each section to remove mortar adhering to the belt and to deposit it
into the hopper. Equip the discharge end of the conveyor belt system with a hopper and a chute
or suitable deflectors to cause the concrete to drop vertically to the deposit area.
In order to avoid delays due to breakdowns, provide stand-by equipment with an
alternate power source prior to the beginning of the placement.
After the beginning of the placement, direct the discharge from the belt conveyor
so that the concrete always falls on freshly placed concrete.
400-7.7 Placing Concrete by Pumping: In general, use concrete pumping equipment
that is suitable in kind and adequate in capacity for the work proposed. Use a pump discharge
line that has a minimum diameter of 4 inches. Use a pump and discharge lines that are
constructed so that no aluminum surfaces are in contact with the concrete being pumped. Operate
the pump to produce a continuous stream of concrete, without air pockets. When using cement
slurry or similar material to lubricate the discharge line when pumping begins, collect such
material at the point of discharge. Dispose of the collected slurry in areas provided by the
Contractor. Control the pump discharge locations so that the placement locations of the various
LOTs of concrete represented by strength test cylinders can be identified in the event the test
cylinders indicate deficient strength. When concrete is placed by pumping, take all test samples
of concrete at the end of the discharge line, except in accordance with the provisions of
Section 346.
400-7.8 Consolidation: Consolidate the concrete by continuous working with a suitable
tool in an acceptable manner, or by vibrating as set forth in 400-7.11. When not using vibrators,
thoroughly work and compact all thin-section work with a steel slicing rod. Spade all faces, and
flush the mortar to the surface by continuously working with a concrete spading implement.
400-7.9 Obstructions: In cases where, because of obstructions, difficulty is encountered
in puddling the concrete adjacent to the forms, bring the mortar content of the mix into contact
with the interior surfaces by vibrating the forms. Produce the vibrations by striking the outside
surfaces of the forms with wooden mallets or by other satisfactory means. In placing concrete
around steel shapes place it only on one side of the shape until it flushes up over the bottom
flange of the shape on the opposite side, after which place it on both sides to completion. After
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the concrete has taken its initial set, exercise care to avoid jarring the forms or placing any strain
on the ends of projecting reinforcing bars.
400-7.10 Requirements for Successive Layers: Generally, place concrete in continuous
horizontal layers, approximately 12 inches thick. To avoid obtaining a plane of separation
between batches, do not allow the time before placing the next successive layer to exceed
20 minutes, unless the Engineer determines that adequate fluidity exists in the underlying layer.
Generally, leave each layer of concrete unfinished to secure efficient bonding with the overlying
layer. To minimize the visibility of joints on exposed faces, finish the top surface of the concrete
immediately adjacent to the forms of the exposed face, smoothing with a plaster masons trowel.
Where required, use inset form work to eliminate featheredges and to obtain concrete layers with
a minimum thickness of 6 inches. Conduct the operation of depositing and consolidating the
concrete so as to form a dense, impervious mass of uniform texture with smooth faces on
exposed surfaces. Remove, dispose of, and replace defective concrete as directed by the
Engineer and at no expense to the Department.
400-7.11 Vibration of Concrete:
400-7.11.1 General: Consolidate all concrete except seal, steel pile jackets, and
concrete for incidental construction by the use of mechanical vibrators.
400-7.11.2 Vibrators: Provide adequate vibrators on the project that are
approved by the Engineer before beginning concrete work. Generally, provide vibrators of the
internal type. For thin sections, where the forms are especially designed to resist vibration, the
Contractor may use external vibrators. Use a vibrator with a minimum frequency of
4,500 impulses per minute with sufficient intensity and duration to cause complete consolidation
of the concrete without causing segregation of the materials. For vibrating thin, heavily
reinforced sections, use heads of such size to secure proper vibration of the concrete without
disturbance of either the reinforcing steel or the forms.
400-7.11.3 Number of Vibrators Required: Use a sufficient number of vibrators
to secure the compaction of each batch before the next batch is delivered, without delaying the
delivery. In order to avoid delays due to breakdowns, provide at least one stand-by vibrator, with
an appropriate power source.
400-7.11.4 Method of Vibration: Use vibrators to consolidate properly placed
concrete. Do not use them to move concrete about in the forms. Insert the vibrators in the surface
of concrete at points spaced to ensure uniform vibration of the entire mass of the concrete. Insert
the vibrator at points that are no further apart than the radius over which the vibrator is visibly
effective. Allow the vibrator to sink into the concrete by its own weight, and allow it to penetrate
into the underlying layer sufficiently so that the two layers are thoroughly consolidated together.
After thoroughly consolidating the concrete, withdraw the vibrator slowly to avoid formation of
holes.
400-7.11.5 Hand Spading: When necessary in order to secure well-filled forms,
free from aggregate pockets, honeycomb, bubbles, etc., spade the concrete by hand, along the
surfaces of the forms and in all corners, following the vibration.
400-7.12 Columns: Place concrete in columns in one continuous operation for each lift
as shown in the Plans.
400-7.13 Slabs and Bridge Decks:
400-7.13.1 Bulkheads, Screed Rails, and Screeding Devices: Strike-off the
concrete using an approved metal screed operating on rails or bulkheads. Use devices which do
not contain aluminum parts. Prior to placing concrete, provide an approved screed capable of
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striking-off and screeding the surface of the slab or deck to the required shape. Set all necessary
bulkheads and screed rails to the required grade. Use bulkheads, screed rails, and screeding
devices that permit vertical profile adjustment to the grade, satisfactory for providing straight
transverse slopes, differing transverse slopes broken as shown in the Plans and/or transverse
slopes with changing grade along the longitudinal length of slab or deck. Locate the screed rails
so the entire placement surface can be screeded to grade without using intermediate screed rails,
unless approved otherwise by the Engineer.
Use a screed consisting of a truss or heavy beams that will retain its shape
under all working conditions, and a set of rotating drums with a diameter sufficient to carry a
2 inch mortar roll in front of and parallel to the axis of the drums, while making an initial pass.
Adjust the drums to prevent mortar buildup forming behind the trailing edges of the drums. For
long bridges, as defined in 400-15.2.5.1, provide a device that automatically smoothes the
concrete surface to an untextured finish and that is attached to, and is moved by, the rolling drum
screed. As an alternate to the drum type screed, a mechanical screed with a metal strike-off may
be used. Equip the mechanical screed with mechanical vibrators to provide continuous uniform
vibration to the entire length unless otherwise authorized by the Engineer. Small and irregularly
shaped areas that cannot be mechanically screeded may be screeded in a manner approved by the
Engineer.
400-7.13.2 Screed Demonstration: Subsequent to the placement of all
reinforcing steel and prior to placing any slab or deck concrete, demonstrate that the proposed
equipment and methods can finish the concrete to the specified grades while maintaining the
specified cover over the reinforcement. Provide the demonstration over the entire length and
width of the spans to be placed.
400-7.13.3 Screeding Operations: Perform concrete placement and screeding as
independently controlled mechanical operations. Ensure that the passing of the screed and
forward movement of the screeding equipment are independent of the movement of concrete
placement equipment.
Level the concrete in front of the screed as near to the finished grade as
possible to prevent the screed from rising off the rail and forming uneven ridges behind the
screed. Pass the screed over the slab or deck as many times as necessary to obtain a satisfactory
surface and provide a concrete surface true to grade and crown, and free of irregularities.
Do not add water to the concrete surface to assist in finishing operations
unless specifically authorized by the Engineer. If the Engineer permits the addition of water,
apply only a fog mist, above the concrete surface, by means of approved power driven spray
equipment.
For long bridges, as defined in 400-15.2.5.1, do not manually or
mechanically float the concrete surface or apply a texture by broom or any other device to the
concrete surface produced by the screeding process. Correct isolated surface irregularities in
accordance with 400-15.2.5.3.
400-7.13.4 Placing Operations: Select an approved concrete design mix which
ensures complete placement of all slab or deck concrete between construction joints before
initial set begins in the plastic concrete. On placements of 50 cubic yards or less, the minimum
placement rate is 20 cubic yards per hour. On placements of greater than 50 cubic yards, the
minimum placement rate is 30 cubic yards per hour.
The Engineer will not permit slab or deck placements until an acceptable
plan for meeting the minimum placement rate is approved.
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400-7.13.5 Concrete Decks on Steel Spans: Where concrete decks are placed on
steel spans, release the temporary supports under the bridge before placing any concrete.
400-7.13.6 Concrete Decks on T-Beams: For cast-in-place T-beam construction,
cast the slabs and beams in one continuous operation. As an exception, where special shear
anchorage or keys are provided for in the Plans or approved by the Engineer, the beams and
slabs may be constructed in successive placements.
400-7.13.7 Diaphragms: Place concrete diaphragms at least 48 hours before the
bridge deck slabs are placed unless otherwise indicated in the Plans.
400-7.13.8 Weather Protection: Provide an approved means of protecting
unhardened concrete from rain. Position the protection system to shield the concrete from rain
and running water. Provide a shield impervious to water over the slab or deck concrete, of
sufficient size to protect all areas of slab or deck concrete subject to water damage, and include a
means of intercepting and diverting water away from freshly placed concrete. Arrange the
equipment so that the weather protection system can be erected over unhardened concrete. When
there is a possibility of rain during concrete placement operations, place the weather protection
system in stand-by readiness, capable of being deployed in a timely manner. Use the weather
protection immediately when rain begins so that slab or deck concrete damage will not occur. Do
not place concrete during rain.
Assume responsibility for damage to the slab or deck in the case of failure
of the weather protection system.
Describe the weather protection materials and methods in the Contractors
QC Plan.
400-7.14 Concrete Box Culverts: In general, place the base slab or footing of concrete
box culverts, and allow them to set before constructing the remainder of the culvert. In this case,
make suitable provision for longitudinal keys. Construct bottom slabs, footings, and apron walls
as a monolith if practicable. Where transverse construction joints are necessary, place them at
right angles to the culvert barrel, and make suitable provision for keys.
In the construction of box culverts having walls 6 feet or less in height, the
sidewalls and top slab may be constructed as a monolith or may place the concrete in the walls
and allow it to set before placing the top slab concrete.
Where the height of the box culvert walls exceed 6 feet, place the walls, and allow
the concrete to set at least 12 hours before placing the top slab concrete. In such cases, form keys
in the sidewalls.
When casting the walls and top slabs of box culverts as a monolith, ensure that
any necessary construction joints are vertical. Design all construction joints with formed keys.
Provide keys that are beveled as shown in the Plans or as directed, but do not allow the edge of
the beveled material forming the key to be less than 1-1/2 inches from the edge of the concrete.
Construct each wingwall, if possible, as a monolith. Ensure that construction
joints, where unavoidable, are horizontal and so located that no joints will be visible in the
exposed face of the wing above the ground line.
Precast box culvert sections may be used in lieu of cast-in-place box culvert
construction provided the provisions in Section 410 are satisfied.
400-8 Seals.
400-8.1 General: Wherever practicable, dewater all foundation excavations, and deposit
the concrete in the dry as defined in 455-15.2. Where conditions are encountered which render it
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impracticable to dewater the foundation before placing concrete, the Engineer may authorize the
construction of a concrete foundation seal of the required size. Then, dewater the foundation, and
place the balance of the concrete in the dry.
When required to place seal concrete, the Contractor is responsible for the
satisfactory performance of the seal in providing a watertight excavation for placing structural
concrete. The Department will provide and pay for the seal concrete as an aid to the construction
of the structure. Repair seal concrete as necessary to perform its required function at no expense
to the Department.
400-8.2 Method of Placing: Carefully place concrete deposited under water in the space
in which it is to remain by means of a tremie, a closed-bottom dump bucket of not less than 1 yd3
capacity, or other approved method. Do not disturb the concrete after depositing it. Deposit all
seal concrete in one continuous placement. Do not place any concrete in running water, and
ensure that all form work designed to retain concrete under water is watertight.
400-8.3 Use of Tremie: Use a tremie consisting of a tube having a minimum inside
diameter of 10 inches, constructed in sections having water-tight joints. Do not allow any
aluminum parts to have contact with the concrete. Ensure that the discharge end is entirely seated
at all times, and keep the tremie tube full to the bottom of the hopper. When dumping a batch
into the hopper, keep the tremie slightly raised (but not out of the concrete at the bottom) until
the batch discharges to the bottom of the hopper. Stop the flow by lowering the tremie. Support
the tremie such as to permit the free movement of the discharge end over the entire top surface of
the work and to permit its being lowered rapidly when necessary to choke off or retard the flow.
Provide a continuous, uninterrupted flow until completing the work. Exercise special care to
maintain still water at the point of deposit.
400-8.4 Time of Beginning Pumping: Do not commence pumping to dewater a sealed
cofferdam until the seal has set sufficiently to withstand the hydrostatic pressure, and in no case
earlier than 72 hours after placement of the concrete.
400-9 Construction Joints.
400-9.1 Location: Make construction joints only at locations shown in the Plans or in the
placement schedule, unless otherwise approved in writing. If not detailed in the Plans or
placement schedule, or in case of emergency, place construction joints as directed.
400-9.2 Provisions for Bond and Transmission of Shear: Use shear key reinforcement
where necessary to transmit shear or to bond the two sections together.
400-9.3 Preparations of Surfaces: Before depositing new concrete on or against
concrete which has hardened, re-tighten the forms. Roughen the surface of the hardened concrete
in a manner that will not leave loosened particles, aggregate, or damaged concrete at the surface.
Thoroughly clean the surface of foreign matter and laitance, and saturate it with water.
400-9.4 Placing Concrete: Continuously place concrete from joint to joint. Carefully
finish the face edges of all joints which are exposed to view true to line and elevation.
400-9.5 Joints in Sea Water or Brackish Water: For concrete placed in sea water or
brackish water, do not place any construction joints between points 2 feet below the mean low
water elevation and 6 feet above the mean high water elevation.
400-9.6 Joints in Long Box Culverts: For long concrete box culverts, vertical
construction joints may be placed at a spacing not less than 30 feet. When using transverse
construction joints, ensure that longitudinal reinforcing steel is continuous through the joint and
that the joint is vertical.
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400-9.7 Crack Control Grooves in Concrete Bridge Decks: When the Plans require
crack control grooves in the top surface of decks, either install a tooled V groove prior to
initial concrete set or saw a groove using an early entry dry cut saw. When using an early entry
dry cut saw, operate in accordance with the manufacturers recommendations. Commence
sawing as soon as the concrete has hardened enough to permit standing on the surface without
leaving visible tracks or impressions and before uncontrolled concrete cracks occur.
400-10 Expansion Joints.
400-10.1 General: After meeting the smoothness criteria in 400-15, construct expansion
joints to permit absolute freedom of movement. Carefully remove all loose or thin shells of
mortar likely to cause a spall with movement at a joint from all expansion joints as soon as
possible.
400-10.2 Sealed Joints: Fill expansion joints with a preformed joint filler. Cut the filler
to conform to the cross-section of the structure, and furnish it in as few pieces as practicable,
using only a single piece in each curb section. Do not use small pieces that would tend to come
loose. Prepare joints to be sealed and apply the sealer in accordance with approved
manufacturers directions.
400-10.3 Joint System Installation: Install expansion joints before or after the deck
planing required by 400-15.2.5.5 following the manufacturers instructions. When installed after
deck planing, install the edge rail assemblies in the blockouts on a profile tangent between the
ends of the deck and/or approach slab to within a plus 0 inch and minus1/4 inch variation.
When installed before deck planing, install the edge rail assemblies 3/8 inch, plus
or minus 1/16 inch, below the top surface of the deck or approach slab to compensate for
concrete removal during planing.
400-11 Contact and Bearing Surfaces.
400-11.1 Separation of Surfaces: In general, separate all contact surfaces between
superstructure and substructure or end walls and between adjacent superstructure sections by a
layer of 55 lb roofing felt.
400-11.2 Finishing of Bearing Surfaces: Construct bearings surfaces (areas) to the
tolerances as specified herein and in the other parts of the Contract Documents. When using
neoprene bearing pads, finish the concrete surface to a uniform rough texture using a burlap
drag, fine bristle broom or float. For metal or high load rotational bearings, fill minor
depressions, 1/8 inch maximum, caused by finishing, bush hammering, or grinding with a lowviscosity epoxy meeting the requirements of 926-1, Type F-2, applied by the use of a squeegee.
Bearing surfaces may be ground to final position with carborundum. Check all bearing surfaces
with a metallic straightedge prior to setting bearings or neoprene pads.
400-11.2.1 Deviation from Specified Elevations for Steel Beam
Superstructures: Construct to the elevation shown in the Plans plus or minus 0.01 feet and do
not exceed a 0.01 feet difference between specified elevations of bearing areas of adjacent
bearings measured between the centerlines of bearing areas.
400-11.2.2 Deviation from Specified Elevations for Concrete Beam
Superstructures: Construct to the elevation shown in the Plans plus or minus 0.02 feet.
400-11.2.3 Projecting Irregularities: Projecting irregularities will not exceed
1/16 inch.
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400-11.2.4 Variations in Flatness for Neoprene Pads: In any direction, the pad
is to be flat to within 1/16 inch. Pads designated to be sloped are not to deviate from the
theoretical slope by the same amount.
400-11.2.5 Variations in Flatness for Metal or High Load Rotational
Bearings: Construct the bearing area to the tolerance indicated for the measured length along the
orthogonal axes.
Bearing area length up to 30 inches long to plus or minus 1/16 inch.
Bearing area length over 30 inches up to 45 inches long to plus or minus
3/32 inch.
Bearing area length over 45 inches long to plus or minus 1/8 inch.
400-11.3 Bearing Pads: Use bearing pads for seating bridge shoes, ends of beams, and
slabs of the types specified or required in the Plans.
Furnish and install composite neoprene pads as detailed in the Plans. Place
neoprene pads, where specified or required, directly on masonry surfaces finished in accordance
with the requirements of this Article. Ensure that pads, bearing areas of bridge seats, and metal
bearing plates are thoroughly cleaned and free from oil, grease, and other foreign materials.
Exercise care in fabrication of related metal parts to avoid producing conditions
detrimental to the performance of the pads, such as uneven bearing, excessive bulging, etc.
The Engineer will evaluate the degree of deformation and condition of bearing
pads in the completed bridge on or before the final inspection required by 5-10 or when
requested by the Contractor. As directed by the Engineer, correct horizontal bearing pad
deformations that at the time of inspection exceed 50% of the bearing pad thickness or that the
Engineer predicts will exceed 50% of the bearing pad thickness during future high or low
temperature periods. Payment for this correction effort will be considered extra work in
accordance with 4-3.
400-12 Anchor Bolts and Dowels.
Set anchor bolts and dowels as specified in Section 460.
Galvanize all anchor bolts as specified in Section 962.
400-13 Epoxy Bonding Compounds.
Where epoxy bonding compounds for bonding concrete are specified or required, apply
the epoxy bonding materials only to clean, dry, structurally sound concrete surfaces. Provide
surface preparation, application, and curing of epoxy bonding compound in strict accordance
with the manufacturers recommendations for each particular application. Use an epoxy bonding
compound listed on the Departments Qualified Products List.
400-14 Removal of Forms.
Use the table below as the criterion for minimum time or compressive strength required
before removal of forms or supports.
When using the time period criterion, include in the time period all days except days in
which the temperature falls below 40F.
Use the specified 28 day minimum compressive strength value as stated in 346-3.1 for
each Class of Concrete utilized.
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Minimum Time for Form Minimum (%) of 28 day
Removal for any Strength Compressive Strength for
Concrete*
Form Removal
(1) Deck slabs, top slabs of culverts and bottom of caps, forms under sidewalks, and safety curb
overhangs extending more than 2 feet
(a) Class II (Bridge Deck)
7 days**
75**
(b) Class II (Other than Bridge Deck)
7 days
75
(c) Class III
7 days
70
(d) Class IV
7 days
60
(e) Class V
7 days
50
(2) Walls, piers, columns, sides of beams
24 hours***
50***
and other vertical surfaces
(3) Front face form of curbs
6 hours
70
Location of Concrete Placement
* For mass concrete, remove forms in accordance with 346-3.3
** Reference 400-16.4
***Do not place additional load on the section until 70% of the specified 28 day concrete strength is attained. Also, refer to
400-7.4.
When using the percent of required strength, cast test cylinders for each mix for
compressive strength determination or develop a curing concrete strength versus time curve (S/T
Curve) which can be used in lieu of multiple test cylinders to determine when percent of required
strength has been met.
Prior to curve use; obtain the Engineers approval of the S/T Curve and its supporting
data. An approved testing laboratory may be used to provide this information with approval of
the Engineer. Plot S/T Curves using at least three different elapsed times that begin once test
cylinders are cast; however, one of the elapsed times must be prior to the Contractors intended
form removal. Each elapsed time plotted must have a corresponding compressive strength
computed by averaging the compressive strength of two test cylinders.
Cure such test cylinders as nearly as practical in the same manner as the concrete in the
corresponding structural component, and test them in accordance with ASTM C39 and
ASTM C31. Perform cylinder casting, curing, and testing at no expense to the Department and
under the observation of the Engineer. When the S/T Curve indicates a compressive strength
equal to or greater than the percentage of specified strength shown in the table above for form
removal, the Contractor may remove the forms. When the ambient air temperature falls 15F or
more below the ambient air temperature that existed during development of an S/T Curve, use an
S/T Curve that corresponds to the lower temperature and that is developed in accordance with
this Section.
Do not remove forms at any time without the consent of the Engineer. Even when the
Engineer provides consent to remove the forms, the Contractor is responsible for the work.
400-15 Finishing Concrete.
400-15.1 General Surface Finish (Required for All Surfaces): After placing and
consolidating the concrete, strike-off all exposed surfaces to the lines and grades indicated in the
Plans in a manner that will leave a surface of uniform texture free of undesirable surface
irregularities, cavities, and other defects. Cut back metal ties supporting reinforcement, conduit,
and other appurtenances a minimum of 1 inch from finished surface. After removing excess
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mortar and concrete and while the concrete is still in a workable state, carefully tool all
construction and expansion joints. Leave joint filler exposed for its full length with clean edges.
Ensure that finished work in addition to that specified above is compatible and complementary to
the class of surface finish required.
Immediately after removing forms from any exposed concrete surface, remove all
fins and irregular projections flush with the surface. Clean, saturate with water, and point all
holes, tie cavities, honeycomb, chips and spalls with an approved high-strength, non-metallic,
non-shrink grout meeting the requirements of Section 934, mixed and applied in accordance with
the manufacturers recommendations. Exercise care during the roughening process to prevent
additional defacement and damage to the formed surface.
In the event unsatisfactory surfaces are obtained, repair these surfaces by methods
approved by the Engineer or the affected concrete will be rejected. Repair any surface or remove
rejected concrete at no expense to the Department.
400-15.2 Surface Finishes:
400-15.2.1 General: In addition to the general surface work specified for all
exposed concrete surfaces, the Engineer may require one of the classes of surface finish listed
below. For all such exposed surfaces, begin finish work for the applicable class specified, along
with the general finish work, immediately after removal of the forms. In order to further ensure
the required quality of the finish, remove forms no later than the minimum time specified for the
forms to remain in place. Satisfactorily repair finished concrete surfaces which are subsequently
disfigured or discolored at no expense to the Department.
Provide the required class of surface finish for the various items of
structural concrete as shown in the Plans.
400-15.2.2 Class 1 Surface Finish: As soon as the pointing has sufficiently set,
thoroughly saturate the exposed surfaces with water, and rub them with a medium coarse
carborundum stone. Continue rubbing until the surface has been ground to a paste and remove all
form marks, irregularities, and projections. In this process, do not introduce any additive material
other than water. After the rubbing has produced a smooth surface of uniform color, allow the
material which has been ground to a paste to reset under proper curing conditions. Subsequently,
as a second operation, re-saturate the concrete surfaces with water, and thoroughly rub them with
a fine carborundum stone. Continue this rubbing until the surface has a smooth, fine grain
texture of uniform color.
The Contractor may substitute a Class 5 applied finish coating in
accordance with 400-15.2.6 as an alternate surface finish on all areas where Class 1 surface
finish is specified.
400-15.2.3 Class 2 Surface Finish: As soon as pointing has sufficiently set,
thoroughly saturate the exposed concrete surfaces with water and rub them with a medium
coarse carborundum stone. Continue rubbing until the surface has been ground to a paste and
remove all form marks, irregularities, and projections. In this process, do not introduce any
additive material other than water.
After rubbing has produced a smooth surface finish, of uniform color,
carefully brush the material which has been ground to a paste to a uniform texture, and allow it
to reset under proper curing conditions. Carefully protect these surfaces from disfigurement and
discoloration during subsequent construction operations.
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400-15.2.4 Class 3 Surface Finish: Where this surface finish is specified, use
metal forms or timber forms with a form liner. Where specified or required in the Plans, use
No. 89 coarse aggregate for concrete.
After concrete has been placed in the forms and compacted, finish all
exposed surfaces which are not contained by the forms to produce a surface texture as nearly
equal to that produced by the form as practicable. Generally, finish unformed surfaces to a
smooth, dense surface with a steel trowel.
Perform all work, including general surface finish work, in a manner that
will preserve the same surface texture and color produced by the form. Pointed areas may be
rubbed with a dry carborundum stone.
400-15.2.5 Class 4 Deck Finish:
400-15.2.5.1 General: Apply a Class 4 finish on bridge decks and
concrete approach slabs. On Short Bridges (bridges having a length less than or equal to
100 feet), and on Miscellaneous Bridges (Pedestrian, Trail and Movable Spans) regardless of
length, meet the finish and smoothness requirements of 400-15.2.5.2 and 400-15.2.5.4. On Long
Bridges (bridges having a length greater than 100 feet) meet the finish and smoothness
requirements of 400-15.2.5.3 and 400-15.2.5.5. When an existing bridge deck is widened, see the
Plans for the finish and smoothness requirements of the existing bridge deck and its new
widened section. After meeting the screeding requirements of 400-7.13 and curing requirements
of 400-16 and the smoothness requirements, herein, groove the bridge deck and approach slabs.
Regardless of bridge length, finish decks with less than 21/2 inches of top cover in accordance with the requirements for Short Bridges.
400-15.2.5.2 Plastic Surface Finish for Short and Miscellaneous
Bridges: After screeding is completed, check the surface of the plastic concrete with a 10 foot
straightedge, positioning and half-lapping the straightedge parallel to the centerline to cover the
entire surface. Immediately correct deficiencies of more than 1/8 inch, measured as an ordinate
between the surface and the straightedge.
Finish the concrete surface to a uniform texture using a burlap
drag, fine bristle broom or float. Finish the deck to a smooth surface having a sandy texture
without blemishes, marks or scratches deeper than 1/16 inch.
400-15.2.5.3 Plastic Surface Finish for Long Bridges: Do not moisten,
manually float or apply texture to the concrete surface after the screed, with attached smoothing
device, has passed unless correction of isolated surface irregularities is warranted and this should
be done as soon as possible after screeding while the concrete is plastic. Correct all flaws such as
cavities, blemishes, marks, or scratches that will not be removed by planing.
If the Engineer permits the addition of water when correcting
flaws, apply moisture to the concrete surface only if required and only in the immediate vicinity
of the isolated irregularity. Apply a quantity of moisture not greater than what is needed to
facilitate correction of the irregularity and apply only a fog mist, above the concrete surface, by
power driven spray equipment approved by the Engineer.
400-15.2.5.4 Smoothness Requirements for Short Bridges and
Miscellaneous Bridges (including approach slabs): Perform a final straightedge check with a
10 foot straightedge, positioning and half-lapping the straightedge parallel to the centerline,
approximately 5 feet apart to cover the entire surface. Correct all irregularities greater than
3/16 inch measured as an ordinate to the straightedge, by grinding. Perform grinding by the
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abrasive method using hand or power tools or by machine, to leave a smooth surface within a
1/8 inch tolerance.
400-15.2.5.5 Smoothness Evaluation and Concrete Surface Planing,
Long Bridges (including approach slabs): Prior to planing, provide a smoothness evaluation of
the completed bridge deck and exposed concrete surfaces of approach slabs by a computerized
Cox California-type profilograph in accordance with the criteria herein and FM 5-558E. Furnish
this evaluation through an independent provider approved by the Engineer, using equipment
calibrated by the Engineer. All bridge deck and concrete approach slab surfaces to within 2 feet
of gutter lines are subject to this smoothness evaluation.
Prior to initial profilograph testing, complete work on the bridge
deck and approach slabs. Thoroughly clean and clear the bridge deck and approach slab areas to
be evaluated for smoothness of all obstructions and provide the smoothness evaluation. Ensure
that no radio transmissions or other activities that might disrupt the automated profilograph
equipment are allowed during the evaluation.
Average the Profile Index Value for the bridge deck, including the
exposed concrete surfaces of the approach slabs, for the left and right wheel path of each lane.
The maximum allowable Profile Index Value for acceptable smoothness is 10 inches per mile
utilizing the 0.2 inch blanking band. Apply these criteria to a minimum of 100 feet of each lane.
Additionally, correct individual bumps or depressions exceeding a cutoff height of 0.3 inch from
a chord of 25 feet (see ASTM E1274) on the profilograph trace. Ensure that the surface meets a
1/4 inch in 10 feet straightedge check made transversely across the deck and approach slabs if
determined necessary by the Engineer. Provide additional profilograph testing as necessary
following longitudinal planing and any other actions taken to improve smoothness, until a profile
meeting the acceptance criteria is obtained.
Regardless of whether expansion joints are installed before or after
deck planing is complete, plane off the concrete deck surface to a minimum depth of 1/4 inch
and also meet or exceed the profilograph smoothness criteria. Longitudinally plane the entire
bridge deck and exposed concrete surfaces of the approach slabs using a self-propelled planing
machine with gang mounted diamond saw cutting blades specifically designed for such work.
Use the profilograph generated smoothness data, to establish the optimum planing machine
settings. Plane the deck surface to within 2 feet of the gutter line so that there is a smooth
transition, without vertical faces or sudden surface discontinuities, from the fully planed surface
to the unplaned surface. Use a machine with a minimum wheel base length of 15 feet,
constructed and operated in such manner that it does not cause strain or damage to deck or
approach slab surfaces, excessive ravels, aggregate fractures or spalling. The equipment shall be
approved by the Engineer. Perform longitudinal planing parallel to the roadway centerline, and
provide a consistent, textured surface. Clean the surface of all slurry/debris generated during this
work concurrently with operation of the machine.
After the deck has been planed the minimum 1/4 inch, reevaluate
the surface smoothness using the profilograph testing described above. Perform cycles of planing
and profilograph retesting as necessary until the deck and exposed concrete surfaces of approach
slabs are in compliance with the smoothness criteria but do not exceed the maximum concrete
removal depth of 1/2 inch.
400-15.2.5.6 Grooving: After the concrete surface profile, as required by
400-15.2.5, has been accepted by the Engineer, and prior to opening the bridge to traffic, groove
the bridge deck and approach slabs perpendicular to the centerline of the structure. Do not
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groove the deck surface of pedestrian or trail bridges unless otherwise shown in the Contract
Documents. Cut grooves into the hardened concrete using a mechanical saw device which will
leave grooves nominally 1/8 inch wide and 3/16 inch deep. Space the grooves apart in random
spacing center of grooves in the following sequence: 3/4 inch, 1-1/8 inch, 5/8 inch, 1 inch,
5/8 inch, 1-1/8 inch, 3/4 inch in 6 inch repetitions across the width to be grooved in one pass of
the mechanical saw device. One 6 inch sequence may be adjusted by 1/4 sequence increments to
accommodate various cutting head widths provided the general pattern is carried out. The
tolerance for the width of the grooves is plus 1/16 inch to minus 0 inch and the tolerance for the
depth of grooves is plus or minus1/16 inch. The tolerance for the spacing of the grooves is plus
or minus1/16 inch.
Cut grooves continuously across the deck or approach slab to
within 18 inches of gutter lines at barrier rail, curb line and median divider. At skewed metal
expansion joints in bridge deck surfaces, adjust groove cutting by using narrow width cutting
heads so that all grooves of the bridge deck surface or approach slab surface end within 6 inches,
measured normal to centerline of the joint, leaving no ungrooved surface adjacent to each side of
the joint greater than 6 inches in width. Ensure that the minimum distance to the first groove,
measured normal from the edge of the concrete joint or from the junction between the concrete
and the metal leg of the armored joint angle, is 1 inch. Produce grooves that are continuous
across construction joints or other joints in the concrete surface less than 1/2 inch wide. Apply
the same procedure described above where the gutter lines at barrier rails, curb lines and median
dividers are not parallel to the centerline of the bridge to maintain the 18 inches maximum
dimension from the grooves to the gutter line. Cut grooves continuously across formed concrete
joints.
400-15.2.6 Class 5 Applied Finish Coating:
400-15.2.6.1 General: Place an applied finish coating upon all concrete
surfaces where the Plans indicate Class 5 applied finish coating. Apply the finish coating after
completion of the general surface work specified for all exposed concrete surfaces. Select an
applied finish coating from the QPL meeting the requirements of Section 975.
400-15.2.6.2 Material: For the coating material, use a commercial
product designed specifically for this purpose. Use only coating material that is manufactured by
one manufacturer and delivered to the job site in sealed containers bearing the manufacturers
original labels. Submit a copy of the manufacturers printed instructions to the Engineer.
400-15.2.6.3 Surface Preparation: Prepare the surface prior to the
application of an applied finish coating by providing a surface finish in accordance with the
requirements of 400-15.1. The Engineer will not require surface voids that are 1/4 inch or less in
width and depth to be grouted prior to application of the finish coating. Fill surface voids larger
than 1/4 inch in width and depth an approved high strength, non metallic, non shrink grout
meeting the requirements of Section 934, mixed and applied in accordance with the
manufacturers recommendations. Apply the grout by filling the surface voids using burlap pads,
float sponges, or other acceptable methods. As soon as the grout has taken its initial set, brush
the surface to remove all loose grout, leaving the surface smooth and free of any voids. Ensure
that the surface to be coated is free from efflorescence, flaking coatings, curing compound, dirt,
oil, and other substances deleterious to the applied finish coating. Prior to application of the
finish coating onto precast or cast-in-place concrete surfaces, test the concrete surface at 30 foot
intervals for the presence of curing compound using one or two drops of muriatic acid placed on
the concrete surface. If curing compound is present, there will be no reaction between the acid
380
and the concrete. If there is no reaction, remove the compound by pressure washing the concrete
surfaces. Prepare the surfaces in accordance with the manufacturers recommendations, and
ensure that they are in a condition consistent with the manufacturers requirements.
400-15.2.6.4 Application: Apply the finish coating utilizing a method
recommended by the manufacturer. When applying the finish coating by spraying, supply heavy
duty spray equipment capable of maintaining a constant pressure necessary for proper
application. Mix and cure all coating materials in accordance with the manufacturers printed
instructions. Apply the finished coating at a rate of 50, plus or minus10 gallons per square feet.
400-15.2.6.5 Finished Product: Produce a texture of the completed finish
coat that is generally similar to that of rubbed concrete. Ensure that the completed finished
coating is tightly bonded to the structure and presents a uniform appearance and texture. If
necessary, apply additional coats to produce the desired surface texture and uniformity.
Upon failure to adhere positively to the structure without chipping,
flaking, or peeling, or to attain the desired surface appearance, remove coatings entirely from the
structure, and reapply the finish coating after surface preparation until achieving the desired
finished product. Do not allow the average thickness of the completed finish coating to exceed
1/8 inch.
400-15.2.6.6 Material Tests and Certification: Before any portion of
any shipment of finish coating is applied on the project, furnish the Engineer with a certificate
from the manufacturer attesting that the commercial product furnished conforms to the same
formula as that previously subjected to the tests specified in Section 975. In addition, submit the
following product analysis, obtained from the manufacturer, for each batch of the material used:
(a) Weight per gallon.
(b) Consistency (Krebs Units).
(c) Weight percent pigment.
(d) Weight percent vehicle solids.
(e) Infra-red spectra of vehicle solution.
400-15.2.7 Final Straightedging for Surfaces to Receive Asphalt Concrete
Surface: Test the slab surfaces of poured-in-place decks which are to be surfaced with an
asphalt concrete wearing course for trueness with a 10 foot straightedge, as specified above. As
an exception, correct only irregularities of more than 1/4 inch measured as an ordinate (either
above or below the general contour of the surface). The Engineer will not require belting or
brooming of slabs that are to be surfaced with an asphalt concrete wearing course. For curing,
meet the requirements specified for other deck slabs.
400-15.2.8 Finishing Bridge Sidewalks: Provide bridge sidewalks, that are not
finished in accordance with the requirements of Section 522, a Class 4 finish.
400-16 Curing Concrete.
400-16.1 General: Cure cast-in-place and precast (non-prestressed) concrete as required
herein for a minimum duration of 72 hours. If forms are loosened or removed before the 72 hour
curing period is complete, expand the curing to cover these surfaces by either coating with
curing compound or extending the continuous moist cure area.
Until curing has begun, retain concrete surface moisture at all times by
maintaining a surface moisture evaporation rate less than 0.1 pounds per square foot per hour.
Periodically, at the site of concrete placement prior to and during the operation, measure the
ambient air temperature, relative humidity and wind velocity with industrial grade weather
381
monitoring instruments to determine the on-site evaporation rate. If the evaporation is, or is
likely to become 0.1 pounds per square foot per hour or greater, employ measures to prevent
moisture loss such as application of evaporation retarder, application of supplemental moisture
by fogging or reduction of the concrete temperature during batching. Compute the evaporation
rate by using the nomograph in the American Concrete Insitute (ACI) manual of Concrete
Practice Part 2, Section 308R Guide to Curing Concrete, or by using an evaporation rate
calculator approved by the Engineer.
400-16.2 Methods: Except where other curing methods are specified, select from the
following options the chosen methods for curing all concrete components and indicate the
method to be used in the QC Plan.
(a) Continuous Moisture: Place burlap on the surface and keep it continuously
saturated for the curing period by means of soaker hoses or automatic sprinklers. Water flow
may be metered to cycle repetitively for five minutes on and five minutes off during the 72 hour
curing period. Do not apply moisture manually. If side forms are loosened or removed during the
curing period, extend the burlap so as to completely shield the sides of the members.
(b) Membrane Curing Compound: Apply a white Type 2 curing compound to all
surfaces at a uniform coverage as recommended by the manufacturer but not less than
0.06 gallon per square yard. Allow surfaces covered by the membrane curing compound to
remain undisturbed for the curing period. Recoat any cracks, checks or other defects in the
membrane seal which are detected during the curing period within one hour. If side forms are
loosened during the curing period, maintain surface moisture and remove the forms within one
hour and immediately coat the formed surfaces with a membrane curing compound. Bottom
surfaces shall be similarly coated after removal of or from the forms.
If curing compound is to be applied by spraying, use a compressor driven
sprayer of sufficient size to provide uniform mist. Standby equipment is required in case of
mechanical failure and hand held pump-up sprayers may be used only as standby equipment.
(c) Curing Blankets: Curing blankets may be used for curing the top surfaces of
members while the member side forms remain in place. Do not use curing blankets which have
been torn or punctured. Securely fasten all edges to provide as tight a seal as practical. Should
the system fail to maintain a moist condition on the concrete surface, discontinue use of the
blankets and continue curing using another method. Keep curing blankets in place for the
duration of the curing period.
(d) Accelerated Cure:
(1) General: Accelerated curing of the concrete can be achieved by use of
either low pressure steam curing, radiant heat curing or continuous moisture and heat curing. If
accelerated curing is completed before the 72 hour curing period has elapsed, continue curing for
the remaining part of the 72 hour curing period in accordance with one of the curing methods
listed above.
If accelerated curing is used, furnish temperature recording devices
that will provide accurate, continuous and permanent records of the time and temperature
relationship throughout the entire curing period. Provide one such recording thermometer for
each 200 feet of placement length or part thereof. Initially calibrate recording thermometers and
recalibrate at least annually.
The preheating period shall equal or exceed the time of initial set
as determined by ASTM C403 and shall not be less than 4 hours. When the ambient air
temperature is above 50F, allow the member to remain undisturbed in the ambient air for the
382
preheating period. If the ambient air temperature is below 50F, apply heat during the preheating
period to hold the air surrounding the member at a temperature of 50 to 90F.
To prevent moisture loss from exposed surfaces during the
preheating period, enclose members as soon as possible after casting or keep the surfaces wet by
fog mist or wet blankets. Use enclosures for heat curing that allow free circulation of heat about
the member with a minimum moisture loss. The use of tarpaulins or similar flexible covers may
be used provided they are kept in good repair and secured in such a manner to prevent the loss of
heat and moisture. Use enclosures that cover the entire placement.
During the application or removal of the heat, do not allow the
temperature rise or fall within the enclosure to exceed 40F/hr. Do not allow the curing
temperature throughout the enclosure to exceed 160F. Maintain the curing temperature within a
temperature range of 130 to 160F until the concrete has reached the required form removal
strength for precast and cast-in-place components or the required release strength for prestressed
concrete components.
(2) Low-Pressure Steam: The steam used shall be in a saturated condition.
Do not allow steam jets to impinge directly on the concrete, test cylinders, or forms. Cover
control cylinders to prevent moisture loss and place them in a location where the temperature is
representative of the average temperature of the enclosure.
(3) Curing with Radiant Heat: Apply radiant heat by means of pipes
circulating steam, hot oil or hot water, or by electric heating elements. Do not allow the heating
elements to come in direct contact with the concrete or the forms. Distribute sources of heat in a
manner that will prevent localized high temperatures above 160F. To prevent moisture loss
during curing, keep the exposed surfaces wet by fog mist or wet blankets.
(4) Continuous Moisture and Heat: This method consists of heating the
enclosure in combination with the continuous moisture method described above.
In addition to the curing blankets, an auxiliary cover for retention
of the heat will be required over the entire placement. Support this cover at a sufficient distance
above the placement being cured to allow circulation of the heat.
400-16.3 Silica Fume Concrete: Cure silica fume concrete a minimum of 72 hours using
continuous moisture cure. No substitution of alternative methods nor reduction in the time period
is allowed. After completion of the 72 hour curing period, apply a membrane curing compound
to all concrete surfaces. Apply curing compound according to 400-16.2.
400-16.4 Bridge Decks: Cure bridge decks for a duration of seven days. Apply a
membrane curing compound to the deck top surface in accordance with 400-16.2 using a
compressor driven sprayer. In general, apply curing compound to a concrete deck when the
surface is damp and after all pooled water has evaporated. For Short bridges, begin applying
curing compound immediately after the initially placed concrete has been floated, straightedged,
textured and a damp surface condition exists and continue applying compound as concrete
placement progresses with as little interruption as possible until the entire deck surface has been
coated with compound. For Long bridges, begin applying curing compound to the initially
placed concrete as soon as a damp surface condition exists and continue applying compound as
concrete placement progresses with as little interruption as possible until the entire deck surface
has been coated with compound. However, for both Short and Long bridges, the elapsed time
between the initial placement of deck concrete and the completed application of curing
compound must not exceed 120 minutes. The 120 minute limit may be extended by the Engineer
383
if project specific factors (cool temperatures, high humidity, retarding admixtures, etc.) are
prolonging wet surface conditions.
Prior to the first deck placement, submit to the Engineer the method that will be
used to periodically measure the rate of application of curing compound in gallons per square
foot as the deck placement progresses. Prior to the placement of each deck, submit to the
Engineer the anticipated quantity of curing compound in gallons along with the corresponding
square feet of deck to be covered to meet the coverage rate in 400-16.2. Compute the actual
quantity of curing compound applied at the conclusion of each deck placement and submit the
quantity to the Engineer. Apply the curing compound from a work platform.
Place curing blankets on all exposed surfaces which are not formed as soon as
possible with minimal effect on the surface texture. Place the curing blankets with sufficient
overlapping seams to form an effective moisture seal. Before using curing blankets, mend tears,
splits, or other damage that would make them unsuitable. Discard curing blankets that are not
repairable. Wet all curing blankets immediately after satisfactorily placing them and maintain
them in a saturated condition throughout the seven day curing period. Supply sufficient quantity
of potable water at the job site for wetting the blankets.
Where a bridge deck slab is to be subjected to walking, wheeling or other
approved construction traffic within the seven day curing period, protect the curing blankets and
the slab surface from damage by placing wooden sheeting, plywood or other approved protective
material in the travel areas.
When the ends of the curing blankets are rolled back to permit screeding of
adjacent bridge deck slabs, keep the exposed surfaces wet throughout the period of exposure.
Removal of bottom and side forms after 72 hours is acceptable upon compliance
with 400-14. Apply membrane curing compound to all surfaces stripped of forms within one
hour of loosening. Apply curing compound according to 400-16.2.
400-16.5 Construction Joints: Cure construction joint areas using either the continuous
moisture or curing blankets method.
400-16.6 Traffic Barriers, Railings, Parapets and End Post: Ensure concrete is cured
in accordance with 400-16.2(b). When construction is by the slip form method, coat all concrete
surfaces with a curing compound that meets the requirements of 925-2, either within 30 minutes
of extrusion or before the loss of water sheen, whichever occurs first. Ensure a curing compound
coating period of not less than seven days after application. Prior to each concrete placement,
submit to the Engineer the method that will be used to periodically measure the rate of
application in gallons per square foot. Also, prior to each placement, submit to the Engineer the
anticipated quantity of curing compound in gallons that will be used to meet the coverage rate
specified in 400-16.2 along with the corresponding square footage of barriers, railings, parapets
and end posts to be coated with that quantity. Compute the actual quantity of curing compound
that is applied during each concrete placement and submit the quantity to the Engineer. Applied
finish coatings, that are on the QPL and that are flagged as permitted for use as a curing
compound, may be used in lieu of a curing compound; If an applied finish coating is used in lieu
of a curing compound, have a backup system that is in full compliance with 400-16.2(b)
available at all times to ensure that an effective alternative system will be immediately available
if the applied finish coating cannot be applied within 30 minutes of extrusion or before the loss
of water sheen.
400-16.7 Removal of Membrane Curing Compounds: Provide the longest possible
curing duration; however, remove curing compound on portions of members to be bonded to
384
other concrete. Compounds may be removed by either sand or water blasting. Water blasting
requires the use of potable water and a minimum nozzle pressure of 2,900 psi.
400-17 Protection of Concrete.
400-17.1 Opening to Traffic: Close concrete bridge decks and culverts to traffic for a
period of at least 14 days after placing and for such additional times as deemed advisable. In the
operation of placing, the Contractor may wheel concrete across previously poured slabs after
they have set for 24 hours, provided plank runways are used to keep the loads over the beams.
400-17.2 Storing Materials on Bridge Slabs: Do not store heavy equipment or material,
other than light forms or tools, on concrete bridge slabs until 14 days after they have been
poured. For all stockpiles, tools, and equipment stored on bridge slabs at any time, obtain prior
approval by the Department, and the Engineer will require any such stored materials or
equipment to be dispersed in order to avoid overloading any structural part.
400-17.3 Time of Placing Superstructure: In the case of piers or bents with concrete
caps, do not place the weight of the superstructure or of beams on the caps until they have
reached the age of 10 days.
400-17.4 Alternate Procedure: As an alternate procedure, in lieu of the time delay
periods set forth in 400-17.1 and 400-17.3, test beams or cylinders may be cast from
representative concrete and cured identically with the concrete in the corresponding structural
component. Make the test beams in accordance with ASTM C31 and test them in accordance
with ASTM C78. When the test results indicate a minimum flexural strength of 550 psi for
beams or the minimum 28 day compressive strength shown in the Plans, concrete bridge decks
and culverts may be opened to traffic or the superstructure and beams may be placed on caps.
400-18 Precast Planks, Slabs, and Girders.
400-18.1 General: Where so shown in the Contract Documents, the Contractor may
construct concrete planks, slabs, girders, and other structural elements by precasting. In general,
use a method that consists of casting structural elements in a casting yard, curing as specified in
400-16, transporting them to the site of the work, installing them on previously prepared
supports and, where so shown in the Plans, joining them with poured-in-place slabs or keys.
Handle and install precast prestressed members as specified in Section 450.
400-18.2 Casting: Cast precast elements on unyielding beds or pallets. Use special care
in casting the bearing surfaces on both the elements and their foundations in order that these
surfaces shall coincide when installing the elements. Check bearing surfaces on casting beds
with a level and a straightedge prior to the casting. Similarly check corresponding surfaces on
the foundations during finishing operations.
400-18.3 Poured-in-Place Keys: Where precast elements are to be joined with pouredin-place keys, carefully align the elements prior to pouring the keys.
400-18.4 Surface Finish: Finish the surface as specified in 400-15, except that where
precast slabs and poured-in-place keys form the riding surface, give the entire surface a broomed
finish.
400-18.5 Moving, Placing, and Opening to Traffic: Reinforced precast members may
be moved from casting beds, placed in the structure, and opened to traffic at the ages shown in
the following:
Handling from casting beds to storage areas .............. 7 days
Placing in structure ................................................... 14 days
385
Opening to traffic:
Precast elements ........................................................ 14 days
Cast-in-place slabs over precast girders ................... 14 days
Cast-in-place keys joining precast slabs ..................... 7 days
As an alternate procedure, in lieu of the time delay periods set forth above, test
beams may be cast from representative concrete, and cure them identically with the concrete in
the corresponding structural component. Test the test beams in accordance with ASTM C31 and
ASTM C78. When the test results indicate a flexural strength of 550 psi, or more, any of the
operations listed above may proceed without completing the corresponding time delay period.
400-18.6 Setting Prestressed Slabs: Before permitting construction equipment on the
bridge to erect slab units, submit sketches showing axle loads and spacing and a description of
the intended method of setting slab units to the Engineer for approval. Do not use axle loads,
spacing, and methods of setting which produce stresses in the slab units greater than the
allowable stress.
400-18.7 Protection of Precast Elements: The Contractor is responsible for the safety
of precast elements during all stages of construction. The Engineer will reject any precast
elements that become cracked, broken, seriously spalled, or structurally impaired. Remove
rejected precast elements from the work at no expense to the Department.
400-18.8 Form Material: Form material used to form hollow cores may be left in place.
Ensure that the form material is neutral with respect to the generating of products harmful to the
physical and structural properties of the concrete. The Contractor is responsible for any
detrimental effects resulting from the presence of the form material within the precast element.
400-19 Cleaning and Coating Concrete Surfaces.
Water blast existing concrete surfaces as shown in the Plans to be coated. Use water blast
equipment producing a minimum working pressure of 2,900 psi with a gauge at or near the
nozzle to confirm the working pressure. After cleaning, apply a Class 5 Applied Finish Coating
as directed in the Plans.
400-20 Approach Slabs.
Construct approach slabs at the bridge ends in accordance with the applicable
requirements of Section 350 using Class II (Bridge Deck) concrete. Place the reinforcement as
specified in 350-7 and Section 415.
The approach slab may be opened to traffic, vehicular or construction equipment, 14 days
after concrete placement or after the prescribed curing period has elapsed and the concrete has
attained the required 28 day cylinder strength.
400-21Disposition of Cracked Concrete.
400-21.1 General: The disposition of cracked concrete is described in this Article and
applies to all cast-in-place concrete members, and once installed, to the precast and prestressed
concrete members that are produced in accordance with 410, 450, 521, 534, 548 and 641.
400-21.2 Investigation, Documentation and Monitoring: The Engineer will inspect
concrete surfaces as soon as surfaces are fully visible after casting, with the exception of surfaces
of precast concrete products produced in offsite plants, between 7 and 31 days after the
component has been burdened with full dead load, and a minimum of 7 days after the bridge has
been opened to full unrestricted traffic. The Engineer will measure the width, length and depth of
386
each crack and establish the precise location of the crack termination points relative to
permanent reference points on the member. The Engineer will determine if coring of the concrete
is necessary when an accurate measurement of crack depth cannot be determined by use of a
mechanical probe. The Engineer will monitor and document the growth of individual cracks at
an inspection interval determined by the Engineer to determine if cracks are active or dormant
after initial inspection. The Engineer will perform all final bridge deck crack measurements once
the deck is free of all debris and before transverse grooves are cut and after planing is complete
for decks that require planing.
Provide the access, equipment and personnel needed for the Engineer to safely
perform this work at no expense to the Department. Core cracks for use by the Engineer in
locations and to depths specified by the Engineer at no expense to the Department.
400-21.3 Classification of Cracks: The Engineer will classify cracks as either
nonstructural or structural and determine the cause. In general, nonstructural cracks are cracks
1/2 inch or less deep from the surface of the concrete; however, the Engineer may determine that
a crack greater than 1/2 inch deep is nonstructural. In general, structural cracks are cracks that
extend deeper than 1/2 inch. A crack that is fully or partially underwater at any time during its
service life will be classified as a structural crack unless the environment note on the General
Notes sheet in the Plans categorizes the substructure as slightly aggressive, in which case, the
nonstructural crack criteria may apply as determined by the Engineer.
Review and comment on the Engineers crack classification; however, the
Engineer will make the final determination.
400-21.4 Nonstructural Cracking Significance: The Engineer will determine the
cracking significance. The cracking significance will be determined on the basis of total crack
surface area as a percentage of total concrete surface area. Cracking significance will be
categorized as isolated, cccasional, moderate or severe according to the criteria in Tables 1 and
2. Cracking significance will be determined on a LOT by LOT basis. A LOT will typically be
made up of not more than 100 square feet and not less than 25 square feet of concrete surface
area for structures other than bridge decks or typically not more than 400 square feet or not less
than 100 square feet for bridge decks. A LOT will not extend beyond a single Elevation Range
as shown in Table 1 or 2.
Review and comment on the Engineers determination of cracking significance;
however, the Engineer will make the final determination.
400-21.5 Repair Method: Repair or remove and replace cracked concrete as directed by
the Engineer. Additional compensation or a time extension will not be approved for repair or
removal and replacement of cracked concrete when the Engineer determines the cause to be the
responsibility of the Contractor.
400-21.5.1 Nonstructural Cracks: Repair each crack using the method as
determined by the Engineer for each LOT in accordance with Table 1 or 2. When further
investigation is required to determine repair or rejection, either remove and replace the cracked
concrete or provide a structural evaluation signed and sealed by the Contractors Engineer of
Record that includes recommended repair methods and a determination of structural capacity and
durability to the Engineer. Upon approval by the Engineer, repair the cracked concrete. Upon
approval by the Engineer use epoxy injection in accordance with Section 411 to repair cracks in
a member inside a dry cofferdam prior to flooding of the cofferdam. Reject and Replace in
Table 1 or 2 means there is no acceptable repair method.
387
400-21.5.2 Structural Cracks: Provide a structural evaluation signed and sealed
by the Contractors Engineer of Record that includes recommended repair methods and a
determination of structural capacity and durability to the Engineer. Upon approval by the
Engineer, repair the cracked concrete. Complete all repairs to cracks in a member inside a
cofferdam prior to flooding the cofferdam.
388
Table 1
DISPOSITION OF CRACKED CONCRETE OTHER THAN BRIDGE DECKS
[see separate Key of Abbreviations and Footnotes for Tables 1 and 2]
Cracking Significance Range per LOT (1)
Occasional
Moderate
Severe
Crack Width
Isolated
(2)
0.005%
0.017%
0.029% or gtr.
Elev. Range (inch)
Less than 0.005%
to<0.017%
to<0.029%
Range
x = crack width
Environment Category
SA MA EA SA MA EA SA MA EA SA MA EA
PS
PS
PS
x 0.004
NT NT
PS NT PS
Elev.: Over
Land or
More Than
Elev.: More Than 6 ft to 12 ft AMHW
Elevation: 0 to 6 ft AMHW
(6)
0.004< x
0.008
0.008< x
0.012
0.012< x
0.016
0.016< x
0.020
0.020< x
0.024
0.024< x
0.028
x > 0.028
Crack Width
x 0.004
0.004< x
0.008
0.008< x
0.012
0.012< x
0.016
0.016< x
0.020
0.020< x
0.024
0.024< x
0.028
x > 0.028
Crack Width
x 0.004
0.004< x
0.008
NT
PS
EI
NT
PS
EI
(6)
(6)
PS
(3)
PS
(6)
(6)
(6)
(6)
EI
EI
PS
(3)
(3)
(6)
(6)
Investigate to Determine Appropriate
Repair (4, 5) or Rejection
(6)
Reject and Replace
SA
NT
MA
NT
EA
PS
SA
NT
MA
PS
EA
PS
SA
PS
MA
PS
NT
PS
EI
PS
PS
EI
PS
EI
NT
PS
EI
EI
EI
PS
EI
EI
EI
(6)
(6)
(6)
(6)
(3)
(6)
(6)
(6)
(6)
(3)
(6)
(6)
(6)
EA
PS
(6)
SA
PS
MA
EA
(6)
(3)
EI
Reject and Replace
Investigate to Determine Appropriate
Repair (4, 5) or Rejection
SA
NT
MA
NT
EA
NT
SA
NT
MA
PS
EA
PS
SA
PS
MA
PS
EA
PS
SA
PS
NT
PS
PS
PS
PS
EI
PS
EI
EI
PS
(6)
(6)
(6)
389
(6)
(6)
(6)
(3)
(6)
(6)
(6)
(3)
(6)
(3)
(6)
(6)
MA
EA
0.008< x
0.012
0.012< x
0.016
0.016< x
0.020
0.020< x
0.024
0.024< x
0.028
x > 0.028
NT
PS
EI
EI
EI
EI
PS
EI
EI
EI
EI
EI
EI
EI
EI
EI
(6)
EI
(6)
EI
Investigate to Determine Appropriate
Repair (4, 5) or Rejection
390
EI
Reject and Replace
Elevation: Over Land or More Than 12 feet
AMHW
Elevation: 12 feet or Less AMHW
Table 2
DISPOSITION OF CRACKED CONCRETE BRIDGE DECKS
[see separate Key of Abbreviations and Footnotes for Tables 1 and 2]
Cracking Significance Range per LOT (1)
Occasional
Moderate
Isolated
0.005%
0.017% to<0.029%
Crack Width
less than 0.005%
Elev.
to<0.017%
Range (inch) (2)
Range
Environment Category
x = crack width
S MA EA SA M
EA
SA
MA
EA
A
A
x 0.004
N NT
NT NT NT
NT
NT
NT
NT
T
0.004< x
N NT
EI/ NT NT EI/M EI/
EI/ EI/M
0.008
T
M
M
M
0.008< x
N NT
EI/ NT EI/ EI/M EI/
EI/
0.012
T
M
M
M
M
0.012< x
N NT
EI/ NT EI/
0.016
T
M
M
0.016< x
EI EI/
EI
EI
0.020
/M M
0.020< x
EI
EI
EI
Investigate to Determine
0.024
/M
Appropriate Repair (4, 5) or
Rejection
0.024< x
EI
EI
0.028
/M
x > 0.028
Crack Width
S MA EA SA M
EA
SA
MA
EA
A
A
x 0.004
N NT
NT NT NT
NT
NT
NT
NT
T
0.004< x
N NT
NT NT NT EI/M NT
EI/ EI/M
0.008
T
M
0.008< x
N NT
EI/ NT NT EI/M EI/
EI/
0.012
T
M
M
M
0.012< x
N NT
EI/ NT EI/
0.016
T
M
M
0.016< x
N EI/
EI
EI/
Investigate to Determine
0.020
T
M
M
Appropriate Repair (4, 5) or
0.020< x
N EI/
EI
Rejection
0.024
T
M
0.024< x
N EI/
0.028
T
M
x > 0.028
391
Severe
0.029% or
gtr.
S
A
M
A
E
A
Reject and
Replace
S
A
M
A
E
A
Reject and
Replace
Key of Abbreviations and Footnotes for Tables 1 and 2
Type Abbreviation
Abbreviation
Definition
EI
Epoxy Injection
M
Methacrylate
Repair Method
NT
No Treatment Required
PS
Penetrant Sealer
EA
Extremely Aggressive
Environment Category
MA
Moderately Aggressive
SA
Slightly Aggressive
Reference Elevation
AMHW
Above Mean High Water
Footnotes
(1) Cracking Significance Range is determined by computing the ratio of Total Cracked Surface Area (TCSA) to Total Surface Area
(TSA) per LOT in percent [(TCSA/TSA) x 100] then by identifying the Cracking Significance Range in which that value falls.
TCSA is the sum of the surface areas of the individual cracks in the LOT. The surface area of an individual crack is determined by
taking width measurements of the crack at 3 representative locations and then computing their average which is then multiplied by
the crack length.
(2) Crack Width Range is determined by computing the width of an individual crack as computed in (1) above and then identifying the
range in which that individual crack width falls.
(3) When the Engineer determines that a crack in the 0.004 inch to 0.008 inch width range cannot be injected then for Table 1 use
penetrant sealer unless the surface is horizontal, in which case, use methacrylate if the manufacturer's recommendations allow it to
be used and if it can be applied effectively as determined by the Engineer.
(4) (a) Perform epoxy injection of cracks in accordance with Section 411. Seal cracks with penetrant sealer or methacrylate as per
Section 413. (b) Use only methacrylate or penetrant sealer that is compatible, according to manufacturer's recommendations, with
previously applied materials such as curing compound or paint or remove such materials prior to application.
(5) When possible, prior to final acceptance of the project, seal cracks only after it has been determined that no additional growth will
occur.
(6) Methacrylate shall be used on horizontal surfaces in lieu of penetrant sealer if the manufacturer's recommendations allow it to be
used and if it can be applied effectively as determined by the Engineer.
400-22 Method of Measurement.
400-22.1 General: The quantities of concrete to be paid for will be the volume, in cubic
yards, of each of the various classes shown in the Plans, in place, completed and accepted. The
quantity of precast anchor beams to be paid for will be the number in place and accepted. The
quantity of bridge deck grooving to be paid for will be the area, in square yards of bridge deck
and approach slab, completed and accepted. The quantity of bridge deck grooving and planing to
be paid for will be the area, in square yards of bridge deck and approach slab, completed and
accepted.
Except for precast anchor beams, for any item of work constructed under this
Section and for which measurement for payment is not to be made by the volume of concrete,
measurement and payment for such work will be as specified in the Section under which the
work is specified in detail.
No separate payment will be made for obtaining the required concrete finish.
400-22.2 Calculation of Volume of Concrete:
400-22.2.1 Dimensions: The quantity will be computed by the Plan dimensions
of the concrete, within the neat lines shown in the Plans, except that no deduction will be made
for weep holes, deck drains, or encroachment of inlets and pipes in box culverts, and no
chamfers, scorings, fillets, or radii 1-1/2 square inches or less in cross-sectional area will be
taken into account.
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400-22.2.2 Pay Quantity: The quantity to be paid for will be the original plan
quantity, measured as provided in 400-22.2.1, except that where the Plans call for an estimated
quantity of miscellaneous concrete for contingent use, the contingent concrete will be measured
as the actual quantity in place and accepted.
400-22.2.3 Items not Included in Measurement for Payment: No
measurements or other allowances will be made for work or material for forms, falsework,
cofferdams, pumping, bracing, expansion-joint material, etc. The volume of all materials
embedded in the concrete, such as structural steel, pile heads, etc., except reinforcing steel, will
be deducted when computing the volume of concrete to be paid for. For each foot of timber pile
embedded, 0.8 cubic feet of concrete will be deducted. The cost of furnishing and placing dowel
bars shall be included in the Contract unit price for the concrete.
400-22.2.4 Deck Girders and Beam Spans: In computing the volume of
concrete in deck girders and beam spans, the thickness of the slab will be taken as the nominal
thickness shown on the drawings and the width will be taken as the horizontal distance measured
across the roadway. The volume of haunches over beams will be included in the volume to be
paid for.
400-22.2.5 Stay-in-Place Metal Forms: When using stay-in-place metal forms to
form the slab of deck girder and beam spans, the volume of concrete will be computed in
accordance with the provisions of 400-20.2.4 except that the thickness of the slab over the
projected plan area of the stay-in-place metal forms will be taken as the thickness shown on the
drawings above the top surface of the forms. The concrete required to fill the form flutes will not
be included in the volume of concrete thus computed.
400-22.3 Bridge Deck Grooving: The quantity to be paid for will be plan quantity in
square yards, computed, using the area bound by the gutter lines (at barrier rails, curbs and
median dividers) and the beginning and end of the bridge or the end of approach slabs,
whichever is applicable, constructed, in place and accepted.
400-22.4 Bridge Deck Grooving and Planing: The quantity to be paid for will be plan
quantity in square yards, computed, using the area bound by the gutter lines (at barrier rails,
curbs and median dividers) and the beginning and end of the bridge or the end of approach slabs,
whichever is applicable, constructed, in place and accepted.
400-22.5 Composite Neoprene Pads: The quantity to be paid for will be the original
plan quantity, computed using the dimensions of the pads shown in the Plans.
400-22.6 Cleaning and Coating Concrete Surfaces: The quantity to be paid for will be
the plan quantity in square feet for the areas shown in the Plans.
400-23 Basis of Payment.
400-23.1 Concrete:
400-23.1.1 General: Price and payment will be full compensation for each of the
various classes of concrete shown in the proposal.
400-23.1.2 Concrete Placed below Plan Depth: Authorized concrete placed in
seal or footings 5 feet or less below the elevation of bottom of seal or footing as shown in the
Plans will be paid for at the Contract price set forth in the proposal under the pay items for
substructure concrete.
Authorized concrete used in seal (or in the substructure where no seal is
used) at a depth greater than 5 feet below the bottom of seal or footing as shown in the Plans will
be paid for as Unforeseeable Work.
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Such payment will be full compensation for the cofferdam construction,
for excavation, and for all other expenses caused by the lowering of the footings.
400-23.1.3 Seal Concrete Required but Not Shown in Plans: When seal
concrete is required as provided in 400-8 and there is no seal concrete shown in the Plans, it will
be paid for as Unforeseeable Work.
400-23.2 Precast Anchor Beams: Price and payment will be full compensation for the
beams, including all reinforcing steel and materials necessary to complete the beams in place and
accepted.
No separate prices will be allowed for the various types of anchor beams.
400-23.3 Reinforcing Steel: Reinforcing steel will be measured and paid for as provided
in Section 415, except that no separate payment will be made for the fabric reinforcement used in
concrete jackets on steel piles or reinforcement contained in barriers, traffic separators or
parapets. Where so indicated in the Plans, the Department will not separately pay for reinforcing
steel used in incidental concrete work, but the cost of such reinforcement shall be included in the
Contract unit price for the concrete.
400-23.4 Bridge Deck Grooving: Price and payment will be full compensation for all
grinding, grooving, equipment, labor, and material required to complete the work in an
acceptable manner.
400-23.5 Bridge Deck Grooving and Planing: Price and payment will be full
compensation for all grooving, planing, equipment, labor, and material required to complete the
work in an acceptable manner.
400-23.6 Composite Neoprene Pads: Price and payment will be full compensation for
all work and materials required to complete installation of the pads.
400-23.7 Cleaning and Coating Concrete Surfaces: Price and payment will be full
compensation for all work and materials required. The cost of coating new concrete will not be
paid for separately, but will be included in the cost of the item to which it is applied.
400-23.8 General: The above prices and payments will be full compensation for all work
specified in this Section, including all forms, falsework, joints, weep holes, drains, pipes,
conduits, bearing pads, setting anchor bolts and dowels, surface finish, and cleaning up, as
shown in the Plans or as directed. Where the Plans call for water stops, include the cost of the
water stops in the Contract unit price for the concrete.
Unless payment is provided under a separate item in the proposal, the above
prices and payments will also include all clearing and grubbing; removal of existing structures;
excavation, as provided in Section 125; and expansion joint angles and bolts.
The Department will not change the rate of payment for the various classes of
concrete in which steel may be used due to the addition or reduction of reinforcing steel.
The Department will not make an allowance for cofferdams, pumping, bracing, or
other materials or equipment not becoming a part of the finished structure. The Department will
not pay for concrete placed outside the neat lines as shown in the Plans.
When using stay-in-place metal forms to form bridge decks, the forms, concrete
required to fill the form flutes, attachments, supports, shoring, accessories, and all miscellaneous
items or work required to install the forms shall be included in the Contract unit price of the
superstructure concrete.
400-23.9 Payment Items:
Payment will be made under:
Item No. 400- 0Class NS Concrete per cubic yard.
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Item No. 400- 1Item No. 400- 2Item No. 400- 3Item No. 400- 4Item No. 400- 6Item No. 400- 7Item No. 400- 9Item No. 400-143Item No. 400-147-
Class I Concrete - per cubic yard.
Class II Concrete - per cubic yard.
Class III Concrete - per cubic yard.
Class IV Concrete - per cubic yard.
Precast Anchor Beams - each.
Bridge Deck Grooving - per square yard.
Bridge Deck Grooving and Planing - per square yard.
Cleaning and Coating Concrete Surfaces - per square foot.
Composite Neoprene Pads - per cubic foot.
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SECTION 407
THREE-SIDED PRECAST CONCRETE CULVERT
407-1 Description.
Design and construct a three-sided precast concrete culvert for the three-sided concrete
culvert structure shown in the Contract Documents. Three-sided precast concrete culverts are
defined as monolithic arched segments, frame segments with vertical walls and either horizontal
or arched top slabs, or three-sided proprietary precast concrete bridge systems.
Obtain the three-sided precast culvert from a plant that is currently on the Departments
list of Producers with accepted Quality Control Programs. Producers seeking inclusion on the list
shall meet the requirements of 105-3.
At the beginning of each project, provide a notarized statement to the Engineer from a
company designated representative certifying that the plant will manufacture the products in
accordance with the requirements set forth in the Contract Documents and plants Quality
Control (QC) Plan. The QC Managers stamp on each product indicates certification that the
product was fabricated in conformance with the Contractors QC Plan, the Contract, and this
Section. Ensure that each shipment of precast concrete products to the project site is
accompanied with a Quality Control signed or stamped delivery ticket providing the description
and the list of the products.
407-2 Materials.
Ensure that the materials used for the construction of precast culverts have certification
statements from each source, showing that they meet the applicable requirements of the
following:
Portland Cement Concrete ..............................................Section 346
Reinforcing Steel ............................................................Section 415
Precast Concrete Drainage Products ...............................Section 449
Riprap ..............................................................................Section 530
Coarse Aggregate ............................................................Section 901
Fine Aggregate ................................................................Section 902
Curing Materials .............................................................Section 925
Materials for Concrete Repair .........................................Section 930
Non-Shrink Grout ...........................................................Section 934
Filter Fabric .....................................................................Section 985
407-3 Limitations on Use.
Do not use three-sided precast culverts in lieu of four-sided culverts described in
Section 410, however they may be considered as a Cost Savings Initiative Proposal (CSIP) in
accordance with Section 4. Provide the required Section 346 concrete class and concrete cover in
accordance with the Structures Design Guideline for the environmental classification shown in
the Plans for the culvert location. Do not use a three-sided precast culvert to extend the inlets of
existing multi-cell culverts due to the potential for clogging with debris.
407-4 Materials Acceptance and Testing.
407-4.1 General: Meet concrete materials, testing, inspection, and acceptance
requirements of Section 346, as modified herein:
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Precast culverts are produced using certification-acceptance criteria; therefore,
assume responsibility for performance of all quality control testing and inspections in accordance
with Section 346.
Prepare, cure, and test the test cylinders in accordance with ASTM C31 and
ASTM C39 test methods. The use of 4 inch x 8 inch test cylinders is allowed for the testing of
precast culverts, provided that it meets the requirements of 450-4.1. Follow the alternative
method of compaction, in accordance with ASTM C497, if the consistency of concrete is too
stiff for compaction by rodding or internal vibrations. Expose shipping strength test cylinders to
the same curing conditions as the precast concrete sections. 28 day test cylinders shall be cured
in accordance with Section 346.
Perform all concrete quality control testing and inspections in accordance with
346-9.2.
For training and other qualifications meet the requirements of Article105-5. Test
all QC samples for compressive strength in a laboratory meeting the requirements of Article 6-9.
407-4.2 Quality Assurance Inspection and Testing: The Engineer will perform
periodic inspections, sampling, and testing to ensure of the quality and acceptability of the
materials, methods, techniques, procedures and processes being utilized by the manufacturing
facility in the fabrication of precast concrete culverts.
407-5 Design Requirements.
Provide a design that complies with the requirements of the AASHTO LRFD Bridge
Design Specifications and the Structures Design Guidelines, current at the time of letting.
Perform a bridge load rating in accordance with the Structures Design Guidelines, for any design
with a total span equal to or greater than 20 feet, when measured between the inside face of end
supports, along the centerline of the roadway crossing. Submit design calculations, shop
drawings and loading rating for approval in accordance with Section 5. Ensure that the
Contractors Engineer of Record performs the design of the precast culvert and signs and seals
the design plans, calculations and load rating. When the channel lining design is not provided in
the Contract Documents or must be redesigned, ensure that a hydraulic analysis and scour
evaluation is completed, signed, and sealed by the Contractors Engineer of Record, and
submitted to the Engineer.
Line the channel between footings with either a cast-in-place reinforced concrete slab
with a toe wall at the inlet and outlet end of the structure or a blanket of revetment designed in
accordance with the Department Drainage Manual. Use a concrete slab with a minimum
thickness of 6 inches and with toe walls that have a minimum depth of 30 inches. Use lining
designed to withstand the hydraulic forces and extend the lining beyond the ends of the structure
a minimum of 10 feet. A riprap rubble ditch lining with a minimum thickness of 18 inches will
be permitted if the flow velocity corresponding to the Design Flood Scour Event does not exceed
five feet per second. Filter fabric must be used in conjunction with any revetment and should be
sized in accordance with Design Standards, Index No. 199. Design and construct the connection
between the revetment or concrete slab and the culvert footing, to prevent the migration of soil
through the connection.
Ensure that the bottom of spread footings are a minimum of 30 inches below the bottom
of the channel lining.
397
407-6 Other Elements of a Precast Culvert System.
Extend reinforcing from precast sections to provide adequate splice lengths or utilize a
mechanical rebar splicing system listed on the Departments Qualified Products List (QPL) for
securing reinforcing dowels for cast-in-place headwalls and wingwalls. Precast headwalls,
wingwalls and culvert footings are permitted. Precast culvert footings must span a minimum of
three culvert units and provide shear connections between adjacent units with keyed joints or
cast-in-place closure sections. Precast footings under wingwalls are not permitted.
Submit all connection details for precast elements to the Engineer for approval. All
mechanical connections must be galvanized in accordance with 962-7 or Type 316 (UNS
S31600) stainless steel, except in extremely aggressive environments only Type 316L (UNS
31603) stainless steel is permitted for welded connections and Type 316 stainless steel for nonwelded shapes and fasteners.
Unless otherwise addressed in the Plans, bedding material and compaction requirements
for wingwalls and toe walls shall be the same as required for the footing in 407-12, except that
the granular material may be placed to the inside edge of the toe wall. All requirements of
Section 400 and Section 415 apply to the fabrication of cast-in-place elements. Backfill the
locations behind the walls in accordance with the requirements of Section 125.
407-7 Fabrication.
407-7.1 Casting: Cast precast elements in unyielding beds and forms. Ensure bearing
surfaces in casting forms are level and straight, and vertical surfaces are plumb prior to casting.
Ensure surfaces within the forms against which concrete will be cast, are clean and free from rust
and hardened residual concrete. Provide full concrete cover clearance to all form wires and other
miscellaneous pieces of metal, except as permitted by Section 415. Bend all tie wires away from
the form surface to provide maximum concrete cover. Provide inserts and lifting devices in
accordance with 450-9.2.1.
407-7.2 Surface Finish: Finish the precast elements in accordance with 400-15.1.
407-7.3 Curing: Perform the curing by any method prescribed in Sections 400 and 450,
or by any other Department approved alternate curing method included in the manufacturers QC
Plan, or combinations thereof that have provided satisfactory results.
407-7.4 Fabrication Tolerances:
407-7.4.1 Internal Dimensions: Ensure the internal dimensions do not vary more
than one percent from the design dimensions, with a maximum of 3/4 inches. The haunch
dimensions shall not vary from the design dimensions more than 1/4 inches for straight haunches
or 1 inch for radial haunches.
407-7.4.2 Slab and Wall Thickness: Ensure the slab and wall thickness are not
less than that shown in the design Plans or approved shop drawings by more than five percent or
3/16 inches, whichever is greater. A thickness more than that required in the design will not be a
cause for rejection.
407-7.4.3 Length of Opposite Surfaces: Ensure the variations in laying lengths
of two opposite surfaces of the culvert segments are not more than 1/8 inch per foot of clear
span, with a maximum of 1 inch. The exception to this shall be when beveled ends, for the
purpose of laying curves, or skewed ends are specified by the Engineer.
407-7.4.4 Length of Section: Ensure the underrun in length of segments is not
more than 1/8 inch per foot of length with a maximum of 1/2 inch in any culvert segment. The
total under run in length of the in-place precast culvert must not be less than 3 inches from the
design length.
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407-7.4.5 Tongue and Groove Joints or Ends: Ensure the planes formed by the
ends of precast culvert sections do not vary perpendicular from the joint axis by more than
3/8 inches for internal spans or heights less than 15 feet, or more than 1/2 inches for internal
spans or heights of 15 feet or greater.
407-7.4.6 Position of Reinforcement: Meet the requirements of 415-5.10.2 for
the maximum variation in the position of slab steel. Meet the requirements of 415-5.8.2 for the
maximum variation of the wall steel, except that the concrete cover must not be less than
1/4 inches nor more than 1/2 inches from the design dimensions.
407-7.4.7 Area of Reinforcement: Provide the area of reinforcement as indicated
in the Plans or approved shop drawings as a minimum. If welded wire reinforcement is utilized
in lieu of mild steel reinforcement, the provisions of 415-6 shall apply. Reinforcing steel areas
greater than specified in the shop drawings will be acceptable when the reinforcing spacing is
equal or less than specified in the shop drawings.
407-7.5 Removal of Forms: Remove forms after the concrete has attained the minimum
compressive strength requirements included as part of the QC Plan, but not less than 2500 psi.
Products manufactured with dry-cast concrete, are exempt from these requirements.
407-7.6 Lifting and Removal From Casting Area: Handled all products, including
those manufactured by the dry-cast process, upon the concrete attaining sufficient compressive
strength as determined by the manufacturer and included as part of the QC Plan, but not less than
2500 psi.
407-8 Joints.
Produce the precast units with keyways at the adjoining surfaces or with butt joints
between adjacent units. In the keyways, use a non-shrink grout listed on the QPL. Design and
construct the adjoining surfaces so that when placed together, they make a continuous line of
units with a smooth interior free of appreciable irregularities within the tolerance permitted. Seal
all joints between precast units with a bituminous seal or low modulus silicone sealant listed on
the QPL, and provide an external sealing band in accordance with ASTM C877 along the outside
of the joint. Determine the minimum width of sealing bands by substituting the larger of the clear
rise or span of the precast concrete box section, for the equivalent pipe diameter in ASTM C877
Tables 1 and 2. Install external sealing band wrap in accordance with the manufacturers
instructions. Cover the external sealing band with a strip of filter fabric adhered to the precast
unit. Ensure that the filter fabric strip is a minimum of 24 inches wide and meets the
requirements of Section 985. Obtain the Engineers approval of the adhesive used. Exercise care
during backfilling to prevent damage to the filter fabric.
Construct headwalls, wingwalls, and other special features in place or as detailed on the
shop drawings. Leave sufficient steel exposed or utilize a mechanical rebar splicing system listed
on the QPL, in end units for connection of headwalls, wingwalls and other cast-in-place sections.
407-9 Handling, Storage, and Shipping.
Handle, store, and ship precast culverts in a manner that prevents chipping, cracks,
fractures, and excessive bending stress. Do not ship precast culverts before the concrete attains
the required 28 day strength.
The manufacturer is permitted to verify the shipping strength test, before 28 days, by
testing compressive strength cylinders that are cured under the conditions similar to the product
or by testing temperature match cured cylinders. The manufacturer may use the maturity method,
ASTM C1074, pulse velocity method in accordance with ASTM C597, or any other approved
399
nondestructive test method to estimate the strength of concrete for determining form removal and
handling strengths or before verification of shipping strength by test cylinders. Curing
temperature and cycle must be monitored on a minimum of one precast culvert curing cell from
each day of production when nondestructive test methods or temperature match cured cylinders
are used to determine concrete strengths.
The shipping strength test is the average compressive strength of two test cylinders. Do
not ship any products until the QC Managers stamp is affixed to the product.
407-10 Repairs and Rejection.
Evaluate cracks, spalls and other deficiencies in accordance with 450-12, except that
cracks will be classified in accordance with 400-21. Classify fractures and cracks passing
through the wall or slab, except for a single end crack that does not exceed the depth of the joint,
as structural cracks. Repair nonstructural cracks in accordance with 400-21 (substructure
requirements), and all other deficiencies in accordance with 450-13 or the plants approved
repair methods that are included as part of the QC Plan. Ensure that the original performance and
durability of the repaired precast culverts are maintained. Use materials for concrete repair that
will meet or exceed the strength requirement of the class of concrete used. Materials meeting the
requirements of Section 930 may be substituted for non-shrink grout when required by 450-13.
Precast culvert elements are subject to rejection if they fail to conform to any of the specification
requirements after repair or when damaged ends would prevent making a satisfactory joint.
407-11 Marking.
Clearly mark indelibly the following information on the interior of each precast unit by
indention, water proof paint, or other approved method: span, rise, skew angle, date of
manufacture, serial number, project number, name or trademark of manufacturer, and design
earth cover.
407-12 Construction Requirements.
Prior to constructing the footing, prepare the bearing soil in accordance with Section 455
for spread footings. If a precast concrete footing is used, prepare a 4 inch thick layer of
compacted granular bedding material to a minimum width of 12 inches outside the footing width
and meet the density requirements of 125-9.2. Provide bedding material in accordance with
Design Standards, Index No. 505 select material, with not more than 15% fines passing the
No. 200 U.S. Standard sieve, or other granular material approved by the Engineer.
Accomplish all footing construction in dry or dewatered excavations, as defined in
455-29. When coarse aggregate is approved for use as an alternate bedding or foundation backfill
material, fully wrap the coarse aggregate with a layer of Type D-4 geotextile filter fabric, as
specified in Design Standards, Index No. 199. At each end of any concrete slab channel lining,
substitute the coarse aggregate with select material within four feet of toe walls.
Form a 3 inches deep key in the top surface of the footing 4 inches wider than the wall
thickness. Ensure that footings reach a compressive strength of 3,000 psi before placing precast
units.
Place the units as shown in the shop drawings. Carefully set the structure to the true line
and grade. Set the units in a bed of mortar placed in the keyway in the top of the footing. Fill the
keyway with mortar, and float the mortar flush with the top of the footing or use shims between
the footer and culvert during setting, then inject non-shrink grout under the culvert walls.
400
Carefully place backfill against the filter fabric and joint seal to avoid damage to the
material. Use mechanical tampers or approved compacting equipment to compact all backfill and
embankment immediately adjacent to each side of the structure. Place the backfill within 4 feet
of each side of the structure in lifts of 8 inches or less (loose depth). Do not operate heavy
compaction equipment within 4 feet of the structure. Ensure that the backfill elevation
differential between both sides of the structure does not exceed 24 inches. Carry backfill in front
of wingwalls to ground lines shown in the Plans.
407-13 Shop Drawings.
Submit details of all precast culvert elements and modifications to cast-in-place elements
for approval to the Engineer prior to manufacturing in accordance with 5-1.4. These shop
drawings must include the proposed layout, full reinforcing details, lifting devices, a note
describing the casting method for the precast culverts and full details of any modifications to
cast-in-place elements. All details must be submitted as a complete package including
modifications to cast-in-place elements.
407-14 Method of Measurement.
The quantity to be paid for will be the plan quantity at the price bid for the sum of the
items shown in the Contract Documents. The length of precast culvert is measured along the
centerline of the structure, from the outside face of the headwalls at each end. No increase in
length will be permitted for multiple barrel precast culvert installations or extension of precast
culverts ends to avoid skewed end conditions.
407-15 Basis of Payment.
Price and payment will be full compensation for all work and materials specified in this
Section necessary to complete the structure, including dewatering, excavation, channel
excavation, channel lining, backfilling, footings, headwalls, wingwalls, toe walls and other
miscellaneous items.
Payment will be made under:
Item No. 407-1Precast Three-Sided Culvert per foot.
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SECTION 410
PRECAST CONCRETE BOX CULVERT
410-1 Description.
Obtain precast box culverts from a plant that is currently on the Departments list of
Producers with Accepted Quality Control Programs. Producers seeking inclusion on the list shall
meet the requirements of 105-3.
Provide precast four-sided concrete box culverts as an alternative to the structure shown
in the Contract Documents. Only monolithic segments, or two-piece segments with three-sided
bottom sections and a simple support top slab section, are permitted. Two-piece segments are
limited to installations with a minimum of two feet fill height above the top slab.
Construct headwalls, wingwalls and other special features using cast-in-place concrete.
Precast wingwalls, cut-off walls or headwalls are not permitted unless otherwise noted in the
Contract Documents.
At the beginning of each project, provide a notarized statement to the Engineer from a
company designated representative certifying that the plant will manufacture the products in
accordance with the requirements set forth in the Contract Documents and plants approved
Quality Control (QC) Plan. The QC Managers stamp on each product indicates certification that
the product was fabricated in conformance with the Contractors QC Plan, the Contract, and this
Section. Ensure that each shipment of precast concrete products to the project site is
accompanied with a QC signed or stamped delivery ticket providing the description and the list
of the products.
410-2 Materials.
Ensure that the materials used for the construction of precast box culverts have
certification statements from each source, showing that they meet the applicable requirements of
the following:
Portland Cement Concrete ................................. Section 346
Reinforcing Steel ............................................... Section 415
Precast Concrete Drainage Products .................. Section 449
Wire for Site Cage Machines .......ASTM A82, ASTM A496
...................................................................... or ASTM A615
Coarse Aggregate* ............................................. Section 901
Fine Aggregate* ................................................. Section 902
Curing Materials for Concrete ........................... Section 925
Materials For Concrete Repair ........................... Section 930
Non-Shrink Grout .............................................. Section 934
Joint Materials............................ ASTM C443, ASTM C877
..................................................................... or ASTM C990
Geotextile Fabrics .............................................. Section 985
* The gradation requirements of aggregates are not applicable when using
dry-cast concrete.
** Use products listed on the Departments Qualified Products List (QPL).
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410-3Materials Acceptance and Testing of Precast Box Culverts.
410-3.1 General: Meet the requirements of Section 346, except as modified herein:
Prepare, cure, and test the test cylinders in accordance with ASTM C31 and
ASTM C39 test methods. Follow the alternative method of compaction, in accordance with
ASTM C497, if the consistency of concrete is too stiff for compaction by rodding or internal
vibrations. Expose shipping strength test cylinders to the same curing conditions as the precast
concrete box sections.
Perform all concrete quality control testing and inspections in accordance with
346-9.2.
For training and other qualifications meet the requirements of Section 105. Test
all QC samples for compressive strength in a laboratory meeting the requirements of
Section 105.
410-3.2 Quality Assurance Inspection and Testing: The Engineer will perform
periodic inspections, sampling, and testing to ensure of the quality and acceptability of the
materials, methods, techniques, procedures and processes being utilized by the manufacturing
facility in the fabrication of precast concrete box culverts.
410-3.3 Special Requirements for Dry-Cast Concrete: Dry-cast concrete is defined as
a very low slump concrete that requires continuous and intense vibration to compact the
concrete, enabling immediate removal of the side forms without detrimental effects to the
concrete when used in a dry-cast manufacturing process.
The target slump and air content ranges of Section 346 Table 2 and the plastic
property tolerances of Section 346 Table 6 are not applicable to dry-cast concrete.
Perform absorption tests on specimens from each LOT of dry-cast production in
accordance with the test methods in ASTM C497. The absorption of each specimen must not
exceed 9.0 percent of the dry mass for Test Method A procedure or 8.5 percent for Test
Method B procedure. All specimens must be free of visible cracks and must represent the full
thickness of the product. Test specimens after 28 days of standard curing, or prior to the date of
shipping if the precast box sections are to be shipped before the completion of the 28 day curing
period.
Core three specimens for Test Method B in accordance with ASTM C42 and meet
the sampling location and size requirements of ASTM C497. Prepare or core a minimum of one
specimen for Test Method A in accordance with the test cylinder requirements of ASTM C497.
When the initial absorption specimen from a concrete box section fails to conform to this
Specification, the absorption test may be made on another specimen from the same box section
and the results of the retest may be substituted for the original test results for acceptance of the
LOT. The manufacturer may test each box section within a LOT and cull the box sections not
meeting absorption requirements marking them as deficient with waterproof paint or other
approved means. Deficient box sections must not be shipped to the project site. Reduce the
frequency of absorption tests to one test every five LOTs when the results of five consecutive
LOTs meet the specified limit.
410-4Design of Precast Concrete Box Sections.
410-4.1 General: In lieu of a cast-in-place concrete box section or if specified in the
Contract Documents, provide precast box culverts in accordance with Design Standards
Index No. 291 and the following:
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Segment lengths must be between 4 feet and 16 feet. Short-side wall lengths for
end segments of skewed culverts, may be less than 4 feet when approved by the Engineer.
Provide tongue and groove joints at the ends of segments. For two-piece box
culvert segments, provide keyed joints for the top slab-to-wall connection to prevent lateral
displacement at the top of the walls, and double-sided tongue and groove joints in the bottom
slab to minimize differential settlement between segments. Alternate methods to prevent
differential settlement may be used when included in the Contract Documents or approved by the
Engineer. Concrete cover at the joints may be reduced from the nominal cover shown in the
Contract Documents, in accordance with the Design Standards, but not less than 1 inch clear to
the ends or inside mating surfaces of the joints or 1-1/2 inches clear to the outside surface of the
joint for slightly and moderately aggressive environments, or 2 inches clear to the outside
surface for extremely aggressive environments.
Meet one of the following design options:
410-4.1.1 Equivalent to Cast-In-Place Designs: Provide precast box segments
identical to the plan details, including reinforcing steel grade, sizes and spacings, concrete cover,
concrete class, and slab and wall dimensions. Reinforcing bar sizes and spacings may be reduced
provided the equivalent area of reinforcing is provided in each layer. Haunch dimensions may be
increased with the approval of the Engineer, but not greater than 8 inches for box culverts with
internal spans less than 6 feet, or 12 inches for box culverts with larger internal spans.
410-4.1.2 Standard Precast Designs: Provide precast box segments in
accordance with Design Standards Index No. 292 with the same hydraulic opening, fill height
and reinforcing steel cover as shown in the plans, for the most critical design loading
combination. Perform a bridge load rating in accordance with the Structures Design Guidelines,
for any multiple barrel culverts with a total span equal to or greater than 20 feet, when measured
between the inside face of end supports, along the centerline of the roadway crossing.
410-4.1.3 Modified or Special Designs: Provide Modified Designs which differ
from the standard precast designs in 410-4.1.2 with modifications to the wall and slab thickness,
or haunch dimensions. Provide Special Designs for sizes, elements and loads other than those
referenced in 410-4.1.2. Redesign box culverts using the same AASHTO design specification,
live load, hydraulic opening, fill height, minimum concrete class and concrete cover as shown in
the Contract Documents. Special Designs will be required for all two-piece concrete box culvert
segments. Provide a minimum member thickness not less than 75% of the thickness of the
corresponding member of an equivalent Index No. 292 box culvert, but not less than 7 inches for
culverts with 2 inch concrete cover or 8 inches for 3 inch concrete cover. Perform a bridge load
rating in accordance with the Structures Design Guidelines, for any redesign with a total span
equal to or greater than 20 feet, when measure between the inside face of end supports, along the
centerline of the roadway crossing.
410-4.2 Design Submittals: Submit shop drawings for all design options in accordance
with 410-12. Submit design calculations, revised plans and load rating when required for
approval in accordance with Section 5 for Modified or Special Designs. Ensure that a Specialty
Engineer performs the design for Modified Designs of the box culvert and signs and seals the
calculations.
Ensure that the Contractors Engineer of Record performs any bridge load rating
and the design for any Special Designs and signs and seals the revised plans, calculations and
load rating.
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410-5 Other Elements of a Precast Box Culvert System.
Extend reinforcing from precast sections to provide adequate splice lengths or utilize a
mechanical rebar splicing system listed on the Departments Qualified Products List (QPL) for
securing reinforcing dowels for headwalls, toe walls and wingwalls.
Cast all elements of the headwalls and wingwalls (footing and stem) in-place, unless
otherwise noted in the Contract Documents. Cast all cut-off or toe walls for precast box end
segments in-place only. Extend the depth of cut-off or toe walls an additional 6 inches with the
limits of the bedding material. Bedding material and compaction requirements for wingwalls are
the same as required for precast box sections, except that the granular material may be placed to
the inside edge of the toe wall, unless otherwise specified in the Contract Documents. Bedding
material is not required for cast-in-place wingwall footings.
All requirements of Section 400 and Section 415 apply to the fabrication of these
elements. Backfill the locations behind the walls in accordance with the requirements of
Section 125.
410-6 Fabrication.
410-6.1 Casting: Cast precast elements in unyielding beds and forms. Ensure bearing
surfaces in casting forms are level and straight, and vertical surfaces are plumb prior to casting.
Ensure surfaces within the forms against which concrete will be cast, are clean and free from rust
and hardened residual concrete. Provide full concrete cover clearance to all form wires and other
miscellaneous pieces of metal, except as permitted by Section 415. Bend all tie wires away from
the form surface to provide maximum concrete cover. Provide inserts and lifting devices in
accordance with 450-9.2.1.
410-6.2 Surface Finish: Finish the precast elements in accordance with 400-15.1.
410-6.3 Curing: Perform the curing by any method prescribed in Sections 400 and 450,
or by any other Department approved alternate curing method included in the approved QC Plan,
or combinations thereof that have provided satisfactory results.
410-6.4 Fabrication Tolerances:
410-6.4.1 Internal Dimensions: Ensure the internal dimensions do not vary more
than 1% from the design dimensions, with a maximum of 3/4 inch. Ensure the haunch
dimensions do not vary more than 1/4 inch from the design dimensions.
410-6.4.2 Slab and Wall Thickness: Ensure the slab and wall thickness are not
be less than that shown in the plans or approved shop drawings by more than 5 percent or
3/16 inch, whichever is greater. A thickness more than that required in the design will not be a
cause for rejection although payment will be for plan quantity only.
410-6.4.3 Length of Opposite Surfaces: Ensure the variations in laying lengths
of two opposite surfaces of the box section are not more than 1/8 inch per foot of clear span, with
a maximum of 5/8 inches for precast boxes with a clear span of up to 7 feet and a maximum of
3/4 inches for boxes with a clear span greater than 7 feet. The exception to this is when beveled
ends, for the purpose of laying curves, or skewed ends are specified by the Engineer.
410-6.4.4 Length of Section: Ensure the under run in length of sections is not
more than 1/8 inch per foot of length with a maximum of 1/2 inches in any box section.
410-6.4.5 Tongue and Groove Joints or Ends: Ensure the planes formed by the
ends of box sections do not vary perpendicular from the joint axis by more than the following:
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1. Profiled Rubber Gasket Joints (ASTM C1677): 1/8 inch per foot of
internal span with a maximum 5/8 inches for internal spans or heights less than or equal to 7 feet,
and a maximum of 3/4 inches for internal spans greater than 7 feet.
2. Preformed Flexible Joints (ASTM C990): 1/4 inches for internal spans
or heights less than 5 feet, or more than 3/8 inches for internal spans or heights of 5 feet or
greater.
410-6.4.6 Position of Reinforcement: Meet the requirements of 415-5.10.2 for
the maximum variation in the position of slab steel. Meet the requirements of 415-5.8.2 for the
maximum variation of wall steel, except that the concrete cover must not be less than 1/4 inches
nor more than 1/2 inches from the design dimensions.
410-6.4.7 Area of Reinforcement: Provide the area of reinforcement as indicated
in the plans or approved shop drawings as a minimum. If welded wire reinforcement is utilized
in lieu of mild steel reinforcement, the provisions of 415-6 apply.
410-6.5 Removal of Forms: Remove forms after the concrete has attained the minimum
compressive strength requirements included as part of the QC Plan, but not less than the
following:
Vertically cast walls and slabs for four-sided sections
Three-sided box culvert bottom section
Horizontally cast self-supporting slabs or walls
1000 psi
2500 psi
2500 psi
Products manufactured with dry-cast concrete, are exempt from these
requirements.
410-6.6 Lifting and Removal From Casting Area: Handle all products, including those
manufactured with dry-cast concrete, after the concrete attains sufficient compressive strength as
determined by the manufacturer but not less than the following, unless otherwise approved in the
QC Plan:
Vertically cast and stored elements (walls and slabs)
Form/pallet supported elements (walls or slabs)
Self-supporting four-sided sections
Self-supporting horizontal slabs or three-sided sections
1000 psi
1000 psi
1000 psi
2500 psi
Limit the flexural tension stresses from handling to a maximum allowable stress
of three times the square root of the concrete compressive strength in psi, prior to the concrete
attaining the required 28-day strength.
410-7 Handling, Storage, and Shipping.
Handle, store, and ship precast box culverts in a manner that prevents chipping, cracks,
fractures, and excessive bending stress. Do not ship precast box culverts before the concrete
attains the required 28-day strength.
The manufacturer is permitted to verify the shipping strength test, before 28 days, by
testing compressive strength cylinders that are cured under the conditions similar to the product
or by testing temperature match cured cylinders. The manufacturer may use the maturity method,
ASTM C-1074, pulse velocity method in accordance with ASTM C-597, or any other approved
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nondestructive test method to estimate the strength of concrete for determining form removal and
handling strengths or before verification of shipping strength by test cylinders.
Curing temperature and cycle must be monitored on a minimum of one box culvert
curing cell from each day of production when nondestructive test methods or temperature match
cured cylinders are used to determine concrete strengths.
The shipping strength test is the average compressive strength of two test cylinders. Do
not ship any products until the QC Managers stamp is affixed to the product.
410-8 Repairs and Rejection.
Evaluate cracks, spalls and other deficiencies in accordance with 450-12. Classify
fractures and cracks passing through the wall or slab, except for a single end crack with a length
that does not exceed the depth of the joint, as major cracks. Walls and slab areas outside the
middle half of the internal span will be considered non-critical locations for the purpose of
evaluating cracks. Repair cracks and all other deficiencies in accordance with 450-13 or the
plants approved repair methods that are included as part of the QC Plan. Ensure that the original
performance and durability of the repaired box culverts are maintained.
Use materials for concrete repair that will meet or exceed the strength requirement of the
class of concrete used. Materials meeting the requirements of Section 930 may be substituted for
non-shrink grout when required by 450-13. Precast box culvert elements are subject to rejection
if they fail to conform to any of the Specification requirements after repair or when damaged
ends would prevent making a satisfactory joint.
410-9 Marking.
Ensure each section of Precast Box Culvert has permanently and clear marking on an
inside face by indentation, waterproof paint, or as specified in the QC Plan, showing the
manufacture date, serial number, project number, and manufacturers name or symbol. The top
of the box culvert must also be clearly indicated with waterproof paint or as specified in the QC
Plan.
410-10 Trench, Foundation, Laying, and Backfill.
410-10.1 General: Meet the requirements of Section 125 and/or Section 121, for trench
excavation, foundation construction, laying and backfilling and the following:
Lay all precast box culvert sections on a dry, slightly yielding foundation, to
ensure uniform bearing across the full width of the bottom slab. Provide dewatering devices, if
applicable, in accordance with 455-29, capable of maintaining a stable and surface-dry trench
bottom. Construct any temporary sheet piling used in cofferdams, retaining walls and to
incorporate the Contractors specific means and methods, in accordance with 125-3.
410-10.2 Bedding: Provide bedding that consists of a minimum 6 inch depth of select
material, with not more than 15% fines passing the No. 200 U.S. Standard sieve, in accordance
with Design Standards, Index No. 505 or other granular material approved by the Engineer.
Place bedding in maximum 6 inch compacted layers below the culvert to a minimum width of
12 inches outside the exterior walls of the culvert and meet the density requirements of 125-9.2.
When coarse aggregate is approved for use as an alternate bedding material, wrap the bottom and
sides of the coarse aggregate with a layer of Type D-4 geotextile filter fabric as specified in
Design Standards, Index No. 199, and substituted the coarse aggregate with select material
within 4 feet of the cut-off or toe walls at each end of the precast box culvert. Obtain the
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Engineers approval before using flowable fill for bedding material. Provide other special
bedding material, when required by the Contract Documents.
Set grade forms 12 inches outside each exterior wall of the box culvert.
Uniformly compact this material and then grade off using the forms. Set the grade forms
approximately 1/8 inches to 1/4 inches above the theoretical grade line to allow for soil
compression. Adjust this distance to yield the proper grade, but do not use in lieu of the proper
compaction of the granular bedding material. Remove the forms after placing the precast box
culvert section.
410-10.3 Placement of Precast Box Culvert Sections: Obtain the Engineers approval
of the method of controlling line and grade during culvert installation. Use a method that allows
rapid checking of the previously laid sections. Maintain line and grade on sections previously
set. The Engineer will consider sections which do not retain the plan line within 0.10 foot or
grade within 0.10 foot during laying of subsequent sections, as not having been laid to line and
grade. Take up and relay sections not to line and grade without additional compensation.
410-10.4 Placement of Multiple Barrel Culverts: For multiple barrel installations using
single-cell precast box sections, provide positive lateral support between the precast box culverts
consisting of non-shrink grout, concrete meeting the requirements of Section 347 or
non-excavatable flowable fill prior to backfilling. Provide partial height backfill or bracing to
maintain alignment, when approved by the Engineer.
410-10.5 Backfilling: Begin backfilling only after the Engineers approval. Seal
blockouts and holes provided for lifting or joint restraint by plugging using an epoxy mortar or
non-shrink grout in accordance with Sections 926 or 934 and properly cure to ensure a sound and
watertight plug, prior to backfilling.
410-10.6 Underdrain and Weep Holes: Provide a continuous underdrain in accordance
with Design Standards, Index No. 289.
410-11 Joints.
410-11.1 General: Make field joints for precast concrete box culvert sections with either
profile rubber gaskets or preformed joint sealants, unless otherwise detailed in the plans or
approved shop drawings. Joint openings at the outside face must not exceed 1-1/2 inches in the
assembled position at any location along the joint perimeter. Ensure a minimum 50% overlap of
the joint tongue and groove around the entire perimeter of the box in the assembled position.
Completely wrap the outside of each joint with geotextile filter fabric. Use fabric
meeting the physical requirements of Class D, Type 3 specified on Design Standards, Index
No. 199. Provide fabric with a minimum width of 2 feet and a length sufficient to ensure a
minimum overlap of 24 inches. The filter fabric must extend a minimum of 12 inches beyond
each side of the joint. Secure the fabric tightly against the box culvert sections with metal or
plastic strapping. Other methods which will hold the fabric securely against the wall of the
culvert until the backfill is placed and compacted, may be used when approved by the Engineer.
When specified in the plans, secure the joint by a suitable device capable of holding the sections
to line and grade as well as fully home. Remove these devices and repair locations as necessary
if intrusive into the concrete after placing and compacting sufficient backfill to secure the
sections.
410-11.2 Profile Rubber Gaskets: Install field joints in accordance with the joint
manufacturers instructions and meet the following:
1. Meet the requirements of ASTM C1677,
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2. Store all gaskets in a cool place prior to use,
3. Furnish to the Engineer written details regarding configuration of the joint and
gasket required to create a soil-tight seal. Do not apply mortar, joint compound or other filler
which would restrict the flexibility of the joint.
410-11.3 Preformed Flexible Joint Sealants: Install field joints in accordance with the
joint manufacturers instructions and meet the following:
1. Meet the requirements of ASTM C990,
2. Furnish to the Engineer a written recommendation of the size (cross-sectional
area) of joint sealant which will create a soil-tight seal. Ensure that this amount is the minimum
quantity of bitumen sealant used. Do not brush or wipe joint surfaces which are to be in contact
with the joint sealant with cement slurry. Fill minor voids with non-shrink grout,
3. Thoroughly clean and dry all joint surfaces which are to be in contact with the
sealant material. When recommended by the sealant manufacturer, apply a primer of the type
recommended to all joint surfaces which are to be in contact with the sealant material.
4. Apply sealant to form a continuous seal around each joint. The sealant must be
protected by a removable wrapper. Do not remove the paper wrapper on the exterior surface of
the preformed flexible joint sealant until immediately prior to joining the precast sections. Apply
the joint sealant only to dry surfaces. When the atmospheric temperature is below 60F, either
store the joint sealant in an area above 70F, or artificially warm the joint sealant to 70F in a
manner satisfactory to the Engineer. After assembly, ensure that there is full contact and
compression of the sealant for the entire perimeter of the joint, as evidenced by the presence of
minor bulging along any visible edges of the sealant. Neatly trim any extruded sealant flush with
the concrete surface.
410-11.4 Water-tight Joint Treatment: Provide water-tight joints when shown in the
Contract Documents. Utilize an external sealing band in accordance with ASTM C877 in
addition to the requirements of 410-11.2 or 410-11.3. Determine the minimum width of sealing
bands by substituting the larger of the clear rise or span of the precast concrete box section, for
the equivalent pipe diameter in ASTM C877 Tables 1 and 2. Install external sealing band wrap
in accordance with the manufacturers instructions prior to wrapping the joint with geotextile
filter fabric.
410-12 Shop Drawings.
Submit details of all precast box culvert elements for approval to the Engineer prior to
manufacturing in accordance with 5-1.4. These shop drawings must include the proposed layout,
lifting devices, and a note describing the casting method for the precast box culverts and details
of any modifications to cast-in-place sections or connections thereto. All details must be
submitted as a complete package including modifications to cast-in-place sections.
410-13 Method of Measurement.
The quantity to be paid for will be plan quantity for the structure shown in the Contract
Documents in accordance with 400-22 and 415-7.
410-14 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including the cost of special bedding material and its placement, additional cut-off or toe wall
depth, temporary sheet piling, graded forms, joint materials, filter fabric material, attachment of
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the filter fabric, dewatering, excavation, channel excavation and lining, backfilling, restraining
devices and any other materials or equipment necessary to make a complete and accepted
installation.
Payment will be made under pay items for concrete (culverts) and reinforcing steel
(roadway).
410
SECTION 411
EPOXY INJECTION OF CRACKS IN CONCRETE STRUCTURES
411-1 Description.
Inject epoxy into cracks in portland cement concrete.
411-2 Materials.
Meet the requirements of Section 926 and as follows:
Use Type E compound epoxy for injection.
Use Type F-1 compound epoxy for sealing crack surfaces in preparation for
injection.
Use epoxy materials listed on the Qualified Products List (QPL).
411-3 Equipment.
For the equipment used to inject the epoxy, meet the recommendations of the epoxy
injection material manufacturer and the following requirements:
(1) Use equipment that has the capacity to automatically proportion the material
components within the mix ratio tolerances set by the epoxy materials manufacturer.
(2) Use equipment that has the capacity to automatically mix the epoxy
component materials within the pump and injection apparatus. The Engineer will not allow batch
mixing.
(3) Use equipment that has the capacity to inject the epoxy resin under controlled
variable pressures up to 200 psi, with a pressure gauge mounted at or near the nozzle to indicate
the actual working pressure.
411-4 Injection Personnel Qualifications.
Employ personnel trained in performing injection work similar to that required for the
project to carry out the epoxy injection of cracks in concrete. Provide an on-site supervisor for
the epoxy injection work who is qualified by one of the following methods:
(1) Certified by the manufacturer of the epoxy injection material as having the
necessary competence to accomplish the epoxy injection work in a satisfactory and safe manner
in compliance with these Specifications.
(2) He can furnish documented evidence that he has a minimum of three years
experience of on-site supervision of similar epoxy injection work and a list of five contracts in
which similar epoxy injection was acceptably completed. Ensure that the listed experience in onsite supervision and completed contracts contains the project name and location, names of
contracting parties, the owners name, brief description of the work, and dates of completion of
the epoxy injection work.
Furnish written evidence showing personnel training and the on-site supervisors
qualification to the Department prior to beginning any epoxy injection work.
411-5 Crack Surface Preparation and Cleaning Requirements.
Clean the area surrounding the cracks of all deteriorated concrete, efflorescence and other
contaminants detrimental to the adhesion of the surface sealing epoxy compound. Clean the
interiors of the cracks with air under sufficient pressure to remove loose materials entrapped
within the crack including efflorescence.
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411-6 Sealing Cracks for Epoxy Injection.
After cleaning, drill injection port holes using a swivel drill chuck and hollow drill bits,
including a vacuum attachment which will remove dust and debris generated during drilling.
Determine the spacing of the injection port holes by the size of the crack and the depth of the
crack in the concrete substrate. Generally, space the injection ports from 4 to 8 inches apart.
Determine the actual spacing of injection ports by field trials. Drill the holes to a minimum depth
of 5/8 inch, exercising care in aligning the hole along the plane of the crack so that the hole
follows the crack for the full 5/8 inch depth.
Insert the injection ports in the drilled holes approximately 1/2 inch, allowing for a small
reservoir below the injection port.
After cleaning the cracks and drilling the injection port holes, seal the crack surface and
the injection ports with suitable epoxy.
411-7 Epoxy Injection.
Inject the epoxy in accordance with the epoxy manufacturers instructions. Determine the
actual injection procedures and pressures in field trials, based on crack widths and depth into the
substrate and sufficiency of the results.
411-8 Cleaning After Epoxy Injection.
Clean concrete surface areas of excess epoxy materials and injection ports after
completing the epoxy injection work. Clean in a manner which will not damage the concrete by
scraping, light sand blasting, grinding, use of solvents, or any other appropriate method approved
by the Engineer. Clean excess materials so that no epoxy material or injection ports extend
beyond the plane surface of the concrete.
411-9 Acceptance.
Drill three cores located in each days work as directed by the Engineer. Take drilled core
samples containing representative crack sizes. The Engineer will accept the epoxy injection work
represented by the core samples when the core samples indicate that 90% of the crack void
greater than 0.006 inch wide is filled with epoxy resin and the concrete of the core sample is
bonded through the crack into a unit.
Reinject epoxy injection work which does not satisfy the acceptance criteria, and correct
it as necessary at no expense to the Department. Install additional injection ports as required to
achieve satisfactory reinjection of epoxy resin.
After the epoxy injection work is completed and accepted, fill the core holes with an
epoxy mortar consisting of one part by volume epoxy injection resin and four parts by volume
clean, dry sand. Supply the sand in moisture proof bags. Do not use previously opened bags of
sand for making epoxy mortar. The Contractor may use one part by volume epoxy material for
sealing with one part by volume clean, dry sand in lieu of the above.
411-10 Method of Measurement.
411-10.1 Epoxy Material: The quantity to be paid will be the volume, in gallons,
authorized, injected, and accepted.
411-10.2 Inject and Seal Crack: The quantity to be paid will be the length, in feet,
authorized and accepted, measured along the approximate centerline of the sealed crack.
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411-11 Basis of Payment.
411-11.1 Epoxy Material: Price and payment will be full compensation for all work
specified in this Section, including furnishing the epoxy material, and miscellaneous related
costs, storage, handling, etc.
411-11.2 Inject and Seal Crack: Price and payment will constitute full compensation for
furnishing all labor, equipment, incidentals and materials (except epoxy), for cleaning and
sealing the crack, and all labor and equipment for injecting the crack.
411-11.3 Payment Items: Payment will be made under:
Item No. 411- 1
Epoxy Material per gallon.
Item No. 411- 2
Inject and Seal Crack per foot.
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SECTION 413
SEALING CRACKS AND CONCRETE STRUCTURE SURFACES
413-1 Description.
Seal concrete surfaces and cracks in concrete using materials, surface preparation, and
application of penetrant sealers and high molecular weight mathacrylates as specified in this
Section and in accordance with the manufacturer recommendations. Consult with the FDOT
State Materials Office in the event of conflict between the manufacturers recommendations and
this specification. Perform surface preparation and application to all areas as shown in the Plans
or as directed by the Engineer.
413-2 Penetrant Sealers.
413-2.1 Materials: Use alkylalkoxysilane penetrant sealers, with 40 percent solids and
active materials dispersed in water that meet the following:
Table 1: Physical Properties of Penetrant Sealers
Appearance
White, Milky Liquid
VOC content (EPA method 24)
Less than 350 g/l
Flash Point (ASTM 3278)
Greater than 200F SETA
Less than
Resistance to Chloride ion penetration
0.52 pounds/yd3(criteria of 1.5) at 1/2 inch level;
AASHTO T259 and T260
0.00 pounds/yd3 (criteria of 0.75) at 1 inch level
0.50% maximum/48 hours;
Water absorption test (ASTM C 642)
1.5% maximum/50 days
NCHRP 244
Series II - cube test
Water weight gain
85% reduction minimum
Absorbed chloride
87% reduction minimum
Series IV - Southern climate
Absorbed chloride
95% reduction minimum
(non - air - entrained concrete) 0 rating No
Scaling resistance test (ASTM C 672)
Scaling (100 cycles)
413-2.2 Surface Preparation for Penetrant Sealer:
413-2.2.1 General: Prepare concrete surfaces to receive a penetrant sealer in
accordance with these Specifications dependent on whether the surfaces are of recently cast
concrete (new construction) or of existing concrete.
413-2.2.2 Surface Preparation for New Construction: Remove substances such
as dust, grime, dirt, curing compounds, form oil, debris, etc. by water blasting, light sandblasting,
wire brushing, or other methods acceptable to the Engineer, all in accordance with the penetrant
sealer manufacturers recommendations. When using cleaning methods other than water blasting,
wash the cleaned surfaces with water meeting the requirements of Section 923, as a final
cleaning operation.
413-2.2.3 Surface Preparation for Existing Concrete: Remove substances such
as dust, grime, dirt, stains, mineral deposits, oil, bituminous materials, debris, and all other
414
deleterious material by using water blasting equipment of sufficient operating capacity and
pressure, all in accordance with the penetrant sealer manufacturers recommendations.
413-2.2.4 Cleaning Equipment: Use approved water blasting equipment to clean
existing concrete surfaces. Use water blasting equipment which is specifically manufactured to
clean concrete surfaces. Use equipment that has a minimum rated nozzle capacity of 6,000 psi
using the spray head proposed for use in the work.
413-2.2.5 Water for Blasting: Use water meeting the requirements of
Section 923.
413-2.2.6 Concrete Surface Cleaning Operation: During the cleaning
operation, exercise sufficient care to minimize the removal of the concrete matrix. Furnish hand
tools, power grinders, and other similar equipment to remove materials which cannot be removed
by water blasting without abrading the concrete matrix beyond acceptable limits. Wash concrete
surfaces cleaned by methods other than water blasting with water blasting equipment as the final
cleaning operation.
Limit the duration of water blasting to provide a light abraded surface. Do
not allow surface abrasion to exceed 0.016 inch. The Engineer will not require further cleaning
of stains still apparent after abrading to a depth of 0.016 inch. Avoid exposure of coarse
aggregate by water blasting.
Reclean concrete surfaces which become contaminated before applying
the penetrant sealer at no expense to the Department prior to applying the penetrant sealer.
413-2.3 Application of Penetrant Sealer Materials: Apply the penetrant sealer only to
surfaces which have been prepared in accordance with these Specifications and approved by the
Engineer. For application of the penetrant sealer, meet these Specifications and the penetrant
sealer manufacturers recommendations.
Prior to application of any penetrant sealer, cure concrete for a minimum of
21 days.
Apply penetrant sealer no later than ten days after completion of the surface
preparation and prior to any contamination of the prepared surfaces as determined by the
Engineer.
413-2.3.1 Application Equipment: Apply the penetrant sealer using any suitable
air or airless sprayer with an operating pressure of approximately 20 psi.
413-2.3.2 Application Limitations: Apply the penetrant sealer material only
when the ambient air temperature is between 50 and 90F. Apply the penetrant sealer only to
concrete surfaces which have dried a minimum of 48 hours after water last contacted the
concrete surfaces. Do not apply the penetrant sealer when winds are blowing 25 mph or more,
during rainfall, or when water spray or mist is present.
413-2.3.3 Application: Apply the penetrant sealer only to concrete surfaces that
have been prepared in accordance with the requirements and limitations set forth in these
Specifications. Determine the actual coverage rate in square feet per gallon on the basis of field
trials. Conduct a field trial to determine coverage rate at the beginning of any penetrant sealer
application operation. Conduct additional confirmation field trials at a frequency of once for
every 5,000 ft2 applied, each production day of application, or when the character of the work
changes, whichever is sooner. For each field trial, determine the optimum coverage rate for
500 ft2 of surface area. Maintain the penetrant sealer application rate between 155 and 225 ft2
covered per gallon of penetrant sealer used. Apply the penetrant sealer in a uniform manner
415
without puddling and skips. Redistribute any penetrant sealer which is applied and subsequently
puddles in low areas over the concrete surfaces by use of a squeegee.
Generally, begin the application of the penetrant at the lowest elevation
and proceed upward toward higher elevations.
Maintain operating pressures in the sprayers used for application of the
penetrant sealer material sufficiently low so that atomization or misting of the material does not
occur.
413-2.4 Control of Materials:
413-2.4.1 Packaging and Identification: Deliver the penetrant sealer to the
project in unopened, sealed containers with the manufacturers label identifying the product and
with numbered seals intact. Ensure that each container is clearly marked by the manufacturer
with the following information:
a. Manufacturers name and address.
b. Product name.
c. Date of manufacture.
d. Expiration date.
e. LOT identification number.
f. Container serial number.
413-2.4.2 Manufacturers Certification: Provide the Engineer a certification
conforming to the requirements of Section 6 from the manufacturer, confirming that the
penetrant sealer meets the requirements of this Section. Do not incorporate these materials into
the project until the Engineer has accepted and approved the certification for the material.
Submit such certification for each LOT of material delivered to the project. In each certification,
identify the serial or LOT numbers of the containers certified.
413-2.4.3 Materials Sampling for Tests: The Engineer may require samples
from each LOT or container of materials delivered to the project or from containers at the point
of use. When samples are required, furnish samples in accordance with the Engineers
instructions.
413-2.4.4 Storage of Materials: Store materials delivered to the job site in
original unopened containers within an appropriate storage facility. Use a storage facility that
provides protection from the elements, and safe and secure storage of the materials.
413-2.4.5 Unused Material in Opened Containers: Do not return unused
material in opened containers to storage for later use. Either apply such material to appropriate
areas on concrete surfaces or remove and dispose of it at offsite locations provided by the
Contractor.
413-2.5 Acceptance: The Engineer will accept penetrant sealer application when it is
determined that the Contractor has properly cleaned all surface areas to be sealed and has applied
the penetrant sealer within the required rates of application.
413-3 High Molecular Weight Methacrylate (HMWM).
413-3.1 General: Perform the surface preparation and application of a high molecular
weight methacrylate to seal cracks on horizontal and slightly sloped concrete surfaces as
approved by the Engineer. Applications on bridge decks and other riding surfaces will require
the addition of sand over the treated areas to increase the friction (skid) number measured as
described by ASTM E-274.
The rate of application (gl/ft2 of concrete) and the application method and
equipment must be approved by the Departments State Materials Office (SMO) prior to
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commencement of work based on the size, depth and the internal condition of cracks. Submit a
written sealer application plan based on the above described crack characteristics for approval by
the SMO. In addition, provide a minimum of 14 days advanced notice so that personnel from the
State Materials Office may be present at the beginning of work to evaluate the cracks and
provide final approval of the application rate. Make arrangements with the material manufacturer
to provide on-site technical assistance for the initial application and certify that the mixing ratio,
application methods, and sand broadcasting are correct and in accordance with their
recommendations.
Maintain a daily log of used resin material to be verified by the Engineer. Include
the drum or container identification number in the log as well as the date and location of use.
Retain the containers at the jobsite until the Engineer verifies its use and authorizes removal
from the site.
413-3.2 Materials: The methacrylate system must be a three component system
consisting of: a) methacrylate monomer, b) cumene hydroperoxide (CHP) initiator, and c) cobalt
promoter. Use a HMWM monomer that is approved by the Department and included on the
Departments Qualified Products List (QPL). Use initiator and promoter approved by the
monomer manufacturer. Manufacturers seeking evaluation of their products must submit an
application conforming to the requirements of Section 6 along with the following documentation:
1. Manufacturers material installation instructions showing the product can be
installed in accordance with this Section.
2. Independent laboratory test data and results showing the product has been
tested in accordance with the requirements of this Section and meets the requirements.
413-3.2.1 Properties: Use a methacrylate material that meets the following
physical and performance requirements:
Table 2: Physical Properties of Methacrylate Resin
Viscosity (Brookfield RVT)
14-20 cps at 50 rpm
Density (ASTM D1481)
8.5 - 9.0 lb/gl at 77o F
Flash Point (ASTM D93)
> 200oF (Pensky Martens CC)
Odor
Low
Bulk Cure Speed
3 Hours @ 73oF (max.)
Surface Cure
8 Hours @ 73oF (max.)
Gel Time (ASTM 2471)
60 minutes (max.)
5 Hours (max.) (at 72oF and 50%
Tack Free Time
Relative Humidity
Compressive Strength (AASHTO T106)
6,500 psi (min)
Tensile Strength (ASTM C307)
1,300 psi (min)
Shear Bond Adhesion (ASTM C882)
600 psi (min)
Wax Content
0
The monomer shall have a shelf life of no less than 12 months and shall be
no more than 8 months old at the time of application. Provide each container shipped to the job
site with the following information on a manufacturers label: manufacturers name, product
name, lot or batch number, date of production, and drum serial number. Identify the catalysts by
their generic classification and provide the date of manufacture.
417
413-3.2.2 Sand: Use uniformly graded 6-20 (or similar), clean, bagged, blast sand
for spreading over the applied polymer on bridge decks and other riding surfaces. Certify that the
sand has a maximum moisture content that does not exceed 0.25% and that the maximum
amount of dust or other material that may pass through a No. 200 sieve -200 content) is not
greater than 0.75%.
Store the sand at a location that will preserve the above described
conditions and characteristics of the sand until applied.
413-3.3 Surface Preparation:
413-3.3.1 Cleaning: On the day of application, thoroughly power sweep the area
to be treated to remove all dust, dirt or debris present. On bridge decks and other riding surfaces,
use a tractor mounted (or similar) power broom with non-metallic bristles suitable for the
intended purpose.
Use a power vacuum after sweeping when sealing cracks on grooved
bridge decks. Re-clean the deck as necessary just prior to the application as debris may be blown
back onto the work area by adjacent traffic or other means.
If present, remove oils and oil based substances from the concrete surface
using an approved solvent.
413-3.3.2 Containment: Provide adequate containment to prevent the sealer
material from flowing beyond the designated area of application. Plug any drain holes or
openings within the work area. Prevent airborne material from dispersing onto open traffic lanes
or outside the work area.
413-3.4 Application:
413-3-4.1 Equipment: Apply the material according to the manufacturers
specifications using mobile equipment capable of distributing material on large areas of decks
and riding surfaces. Apply the material by hand using adequate containers for isolated or
localized applications.
413-3.4.2 Mixing: Mix the methylmethacrylate material following the
manufacturers specified mixing proportions for the catalysts. Perform the initial mixing by
equally dividing the resin to be used into two separate containers. In all instances, mix the
initiator (CHP) at the HMWM manufacturers specified volume with 50% of the monomer resin
in one container and the cumene promoter at the HMWM manufacturers specified volume with
the other 50% in the second container. After properly blending, combine the two resins and mix
as per manufacturers instructions. For spray bar application, mix the activator/resin blend and
the promoter/resin blend through a static mixer in the feed line located ahead of the material
distribution bars where polymerization would start. Calibrate the valves to the static mixer to
ensure a one to one mixing ratio of the two blends.
413-3.4.3 Polymer Application (Mobile Distribution): Apply the material only
under weather conditions recommended by the manufacturer and when no rainfall has occurred
during the previous 48 hours and no rain is expected for the next 6 hours following completion
of the application. Unless otherwise approved by the Engineer, distribute the monomer uniformly
over the work area using a pressure nozzle or spray head distribution bar system. Provide feed to
the distribution bar(s) using positive displacement pumps moving equal amounts of the two
monomer blends from two calibrated drums.
Calibrate the equipment to mix the two monomer blends to the
recommended ratio (by volume) within plus or minus 5%. The discharge volume shall be
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calibrated to the moving speed to provide a discharge rate capability ranging from 50 to
200 square feet per gallon at a pressure ranging from 15 to 60 psi.
The typical application rate of the material is approximately 100 square
feet per gallon. Prior to application of the monomer, the State Materials Office will determine the
final production application rate based on the internal characteristics of the cracks as determined
from Contractor supplied cores that the Engineer approves as being representative of the overall
cracking conditions.
413-3.4.4 Polymer Application (Localized Distribution): Distribute the material
by hand over the work area using pails or other suitable containers adequate for the size of the
area. This only applies to localized small areas or areas where the use of mobile distribution
equipment would be considered impractical as approved by the Engineer.
Apply the material only under weather conditions recommended by the
manufacturer and on areas that have been maintained dry for a minimum of 48 hours. Ensure that
the area remains dry for the next 6 hours following completion of the application.
413-3.4.5 Sealing of Cracks: Regardless of the method used to apply the material
over the concrete surface, work the material back and forth over the cracks to maximize the
amount of material to be absorbed by the cracks. Move the material over the cracks using
brooms, squeegees or paint brushes as appropriate, based on the size of the area. Commence this
operation immediately after distributing the material on the concrete surface. Continue this
operation until no additional material is flowing inside the cracks or the material begins to
exhibit signs of polymerization.
Do not distribute material over areas larger than what the available
personnel can effectively work over the cracks within the limits of the pot life.
413-3.4.6 Sand Distribution: Apply sand over the monomer treated area within a
timely period following the application of the polymer based on the manufacturers
recommendations for the existing conditions. Use equipment that will produce a uniform
distribution of the sand over the treated area. If wheel mounted, use a sand spreader that has
pneumatic tires compatible with the treatment material such that no tire footprints are left on the
deck surface.
Use an initial application rate of 0.6 (plus or minus 0.05) pounds of sand
per square yard of treated area, and adjust the rate as necessary to produce a skid number (SN) of
no less than 25 at 24 hours and 30 at 7 days. Coordinate with the Engineer to conduct a
preliminary on-site skid test to determine the actual sand application rate prior to the beginning
of production application. If friction numbers below those specified are obtained, completely
remove all loose sand from the surface and re-apply the polymer at a rate of 150 square feet per
gallon and spread additional sand as necessary to achieve the specified skid numbers. Remove
the surface material by grinding or other approved method if satisfactory friction values are not
achieved. Friction tests will be conducted by the State Materials Office.
413-3.5 Opening Riding Surfaces to Traffic: Protect the sand covered area from
vehicular traffic until the polymer has fully cured. After curing, power vacuum to remove excess
sand from the riding surface, before opening to traffic.
413-3.6 Cure Test: Test curing on the treated area using a cotton strand or cotton ball.
Consider the material fully cured and ready for traffic when polymer does not adhere to the
cotton ball when pressed against the treated surface and then pulled away. Obtain approval from
the Engineer prior to reopening area to traffic.
419
413-4 Method of Measurement.
Prestressed, precast items designated in the Plans to be sealed with penetrant sealer, will
not be measured for separate payment. The Contractor shall include the cost of cleaning, sealing,
and applying penetrant sealer with the cost of the prestressed, precast items. For cast-in-place
surfaces to be sealed with penetrant sealer, the quantities to be paid for will be (1) the volume, in
gallons, of penetrant sealer as determined by use of the field measured area satisfactorily sealed
divided by the approved application rate based on field trials, and (2) the area, in square feet, of
cleaning and sealing concrete surfaces as determined by field measurement, completed and
accepted.
Quantities of high molecular weight methacrylate to be paid will be based on the volume
in gallons of monomer resin material (not including the promoter and initiator) actually used to
seal the cracked surfaces at the approved application rate, and the dimensions of the treated areas
in square feet.
The area of application will be computed based on the Plan dimensions of concrete
surface sealed with methacrylate. For localized application, the Engineer will determine the
method of measurement that most accurately reflects the area of application in square feet.
413-5 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including cleaning, furnishing and applying the material required to satisfactorily clean and seal
cracks and designated surface areas, testing, and miscellaneous related costs including storage,
handling, etc.
No additional compensation will be made for material, reapplication or removal due to
Contractor error, or to correct deficient friction (skid) values.
Payment will be made under:
Item No. 413-149Penetrant Sealer - per gallon
Item No. 413-151Methacrylate Monomer - per gallon
Item No. 413-154Cleaning and Sealing Concrete Surfaces - square
foot
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SECTION 415
REINFORCING STEEL
415-1 Description.
Furnish and place in concrete masonry reinforcing steel of the quality, type, size, and
quantity designated.
415-2 Materials.
Meet the following requirements:
Bar Reinforcement .................................................... 931-1.1
Fabric Reinforcement................................................ 931-1.2
415-3 Protection of Material.
Store steel reinforcement above the surface of the ground, upon platforms, skids, or other
supports, and protect it as far as practicable from mechanical injury and surface deterioration
caused by exposure to conditions producing rust. When placing steel reinforcement in the work,
ensure that the steel reinforcement is free from loose rust, scale, dirt, paint, oil, and other foreign
material.
415-4 Bending, Splicing, and Cutting.
Fabricate reinforcing bars as prescribed in the CRSI Manual of Standard Practice. Bend
the reinforcement cold to the shapes indicated in the Plans. Perform bending in the shop before
shipment, and not in the field unless shown otherwise in the Contract Documents.
Do not hot bend or straighten, weld, or thermal cut reinforcing steel unless otherwise
specified in the Contract Documents.
415-5 Placing and Fastening.
415-5.1 Bar Spacing - General: Except as otherwise specified herein, ensure that each
bar is within 1 inch of the Plan position.
415-5.2 Concrete Blocks for Spacing: Use precast concrete blocks to space and support
the reinforcing steel. Use concrete blocks with a strength equal to or greater than the concrete in
which they are to be placed and have wires cast into them for fastening to the steel. Moist-cure
the blocks for at least three days.
Provide a letter stating the class of concrete used to fabricate the concrete blocks,
and identifying the batch and load of concrete from which the concrete blocks were cast.
415-5.3 Wire for Tying: For tying reinforcing steel, use soft pliable wire, that readily
bends and twists without breaking and that provides a tie of sufficient strength to hold the
reinforcing steel in its proper position.
415-5.4 Splices: Where splices are authorized, rigidly clamp the bars or tie them in a
manner meeting the Engineers approval. Use the splice length as shown on the Plans. The
Contractor may submit additional splices the Specialty Engineer recommends for approval prior
to use.
Do not use welded splices except as specifically authorized by the Engineer and,
when authorized, meet the requirements of AWS D 1.4 Structural Welding Code - Reinforcing
Steel.
421
Use mechanical couplers or splice devices which develop at least 125% of the
specified yield strength of the bar being spliced and are listed on the Departments Qualified
Products List (QPL).
415-5.5 Footings:
415-5.5.1 Supports: In general, support the footing mat steel with concrete
blocks having dimensions not greater than 4 by 4 inches by Plan clearance. Fasten concrete
blocks to the steel using the cast-in wires. The Engineer may approve other proposed means of
support.
415-5.5.2 Tolerances: Place footing mat steel within 1/2 inch vertically from the
Plan bottom clearance and within 1 inch from the Plan side clearance.
415-5.5.3 Tying: Tie footing mat steel with a double-strand single tie at all
intersections on the periphery and at alternate intersections within the mat.
415-5.6 Dowel Bars for Columns and Walls:
415-5.6.1 Supports and Positioning: Position dowel bars projecting into
columns and walls so as to allow splicing of the column bars or vertical wall bars to the dowels
and to tie the dowel bars in their Plan position. Support the dowel bars by a rigid template
constructed across the top of the footing, and attach them to the template in such manner that
placing the concrete does not disturb their position. Set the supports prior to the pouring of the
concrete in the footings, and do not push dowel bars into the wet concrete after placing the
footing concrete.
415-5.6.2 Tolerances: Place the dowels within 1/2 inch of their Plan position and
with a side clearance tolerance not exceeding 1/4 inch.
415-5.7 Verticals and Hoops for Columns:
415-5.7.1 Spacing-off from Side Forms: Space-off column steel from the side
forms by concrete blocks of dimensions not exceeding 2 inches by 2 inches by clearance
dimension. Securely fasten each block to the reinforcing.
415-5.7.2 Tolerances and Clearance:
(a) Column Verticals: Place column verticals within 1/2 inch of their Plan
position. Ensure that the side form clearance is within 1/4 inch of the specified clearance.
(b) Column Hoops: Place every hoop within 1 inch of the Plan position for
the specific hoop, with no accumulation of such tolerance caused by the spacing between any
two hoops. Ensure that side form clearance for any hoop is within 1/2 inch of its specified
clearance.
415-5.7.3 Tying: Tie the column hoops to the column verticals at each
intersection, by a cross tie or figure 8 tie.
415-5.8 Wall Steel (Not Including Dowel Bars):
415-5.8.1 Supports: Space-off wall steel from the side forms by concrete blocks
of dimensions not greater than 2 inches by 2 inches by clearance dimensions. Fix the spacing
between wall mats by means satisfactory to the Engineer.
415-5.8.2 Tolerance: Except where it is necessary in order to clear a fixture,
place each bar within 1 inch of its specified position. In any case, ensure that the number of bars
in any affected unit is as specified, and place the remainder of the bars (not thus affected) within
the specified 1 inch tolerance.
415-5.8.3 Tying: Tie wall steel with a cross tie or figure 8 tie. On the periphery,
tie the steel at each intersection. Within the mat, tie the steel at every third intersection, except
that where the wall is of such size that it is necessary that workmen use the reinforcing as a
422
ladder, the Engineer may require tying at every other intersection, or at every intersection, as he
deems necessary.
415-5.9 Beams and Caps:
415-5.9.1 Supports: Maintain bottom clearances by approved heavy beam
bolsters. Support additional layers of main longitudinal steel from the lower layers by heavy
upper-beam bolsters, placed directly over low supports.
Begin the spacing of beam bolsters at not more than 2 feet from the end of
the beams or caps and space the additionally required bolsters at not more than 4 feet.
Use concrete blocks, having dimensions not greater than
2 inches by 2 inches by specified clearance, fastened to the steel by the cast-in wires, for spacing
the upper main longitudinal steel below the top bars. Maintain the side clearance by concrete
blocks, having dimensions not greater than 2 inches by 2 inches by required clearance, fastened
to the reinforcing steel by the cast-in wires.
415-5.9.2 Tolerances: Place the main longitudinal steel so as to provide a bottom
and top clearance within 1/4 inch of the Plan vertical dimensions for all layers. Space the steel
from side forms within 1/2 inch of the specified spacing.
Space and tie the stirrups within 1 inch of the Plan position for each
individual stirrup, and do not allow the tolerance to accumulate.
415-5.9.3 Tying: Tie all intersecting bars with a double-strand single tie.
415-5.10 Deck Slabs:
415-5.10.1 Supports:
(a) Bottom Mats: In general, support the bottom mats of steel by one row
of slab bolsters placed 6 inches from the edge of the slab and by two rows down each panel
between beams. Bottom mat slab bolsters may not have rails in contact with removable forms,
except when the environmental classification is slightly aggressive and the requirements of 4155.13.2 are satisfied. Molded plastic rails may not be in contact with removable forms. Do not use
metal chairs and bolsters on stay-in-place forms when the form bottom elevation is 12 feet or less
above mean high water and the environmental classification is extremely aggressive. Do not
allow the spacing between rows to exceed 4 feet, measured center to center.
As an exception, when deemed satisfactory by the Engineer, the
Contractor may use concrete blocks in lieu of slab bolsters. Use blocks 2 inches by 2 inches by
clearance dimensions. Space concrete blocks 4 feet on center as a maximum. If at any time,
however, the Engineer judges that the concrete blocks do not provide the proper support, he may
require using slab bolsters.
(b) Top Mats: Support the top mats of steel by either continuous high
chairs or individual high chairs. Support continuous high chairs along both sides of each beam
and approximately 6 inches back from the edge of the beam. Place the outside row of high chairs
6 inches from the edge of the slab. If using individual high chairs, space them transversely, as
specified for the continuous high chair, and do not allow the longitudinal spacing to be greater
than 4 feet.
As an alternate to the above, on prestress beam construction, the
Contractor may support the top mat of steel on the shear connectors bent to the proper elevation
with one line of high chairs centered between the beams.
(c) Truss Bars: Support truss bars at each end of the top bends by
continuous high chairs or by individual high chairs spaced longitudinally at not more than 4 feet.
423
415-5.10.2 Tolerances: Ensure that top and bottom clearances are within 1/4 inch
from those shown in the Plans.
Ensure that end and bottom clearances are within 1/4 inch from those
shown in the Plans.
Ensure that end and edge clearances are within 1/4 inch of the clearance
specified.
Place curb bars within 1/4 inch in any direction of the Plan position.
415-5.10.3 Tying: Tie all steel in each layer with a double-strand single tie at
every intersection on the periphery and at every third intersection in the interior area. If
encountering difficulty in maintaining the reinforcing steel in position during the placing of
concrete, tie additional intersections as necessary to hold the reinforcing steel secure.
415-5.11 Box Culverts:
415-5.11.1 Supports:
(a) Bottom Slabs: In the bottom slabs of box culverts, provide supports for
single-mat steel and for bottom-mat steel, including placement and spacing, as specified for
footing mat steel in 415-5.5. In addition, where the Plans call for more than one mat of steel in
the bottom slab of the culvert, support the top mat away from the bottom mat, either by upper
beam bolsters or by other means satisfactory to the Engineer.
(b) Walls: Place, space and support the steel in walls of box culverts in
accordance with the requirements of 415-5.8.
(c) Top Slabs: In the top slabs of box culverts, support the bottom mats of
steel by a row of slab bolsters 12 inches from the inside face of the walls and with additional
rows of bolsters at spacings not exceeding 4 feet, center to center. As an exception, unless the
Engineer deems the use of the slab bolsters as necessary to obtain proper support, the Contractor
may use concrete blocks as the supporting device. Use blocks of dimensions not greater than
2 inches by 2 inches by the required clearance, with spacings not exceeding 4 feet in any
direction. Fasten blocks to the reinforcing steel by the cast-in wires.
(d) Truss Bars: Support truss bars as specified in 415-5.10.1(c).
415-5.11.2 Tolerances: Use tolerances in placing the steel in box culvert slabs as
specified for deck slabs in 415-5.10.2. Use tolerances for placing steel in walls as specified in
415-5.8.2.
415-5.11.3 Tying: Tie steel in box culverts as specified for deck slabs in 4155.10.3.
415-5.12 Cleaning: Before placing any concrete, clean all mortar from the
reinforcement.
415-5.13 Bar Supports:
415-5.13.1 General: Provide reinforcing steel bar supports manufactured in
accordance with all requirements of the CRSI Manual of Standard Practice. Use bar supports of
adequate strength to withstand a 300 pound concentrated load without permanent deformation or
breakage, with the deformation being less than 5% of the support height.
Ensure that no more than 5% of the reinforcing steel bar supports exhibit
unsatisfactory performance, breakage, or permanent deformation during rebar tying and/or
concrete placement operations. If a bar support does not achieve this level of performance,
reduce the average spacing between bar supports by 15%, or remove that product from use on
the job.
424
Ensure that bar supports do not move during concrete placing operations.
To prevent movement, tie supports to the reinforcing steel.
When using bar supports on corrugated metal stay-in-place forms, use
supports specifically designed for the form being used.
For structural elements located in extremely aggressive environments, do
not use metal bar supports in contact with removable forms or floor surfaces to support
reinforcing steel.
415-5.13.2 Metal Bar Supports: For metal bar supports in contact with
removable forms for concrete to be cast, provide supports constructed with molded plastic legs
or plastic protected metal legs or bolster rails. Do not allow any portion of the bar support other
than the molded plastic leg or plastic protected portion of the metal leg or bolster rail to be closer
than 1/2 inch from the removable form surface for concrete to be cast.
Certify that all metal bar supports meet the following requirements:
(1) That they are manufactured from cold drawn steel wire in
accordance with the wire sizes and geometrical dimensions shown in the CRSI Manual of
Standard Practice, Chapter 3, Table II.
(2) That the plastic used for protection of the steel legs or bolster
rails has a thickness of 3/32 inch or greater at points of contact with the form work.
Provide plastic protection by a dipping operation, by adding premolded
plastic tips to the legs of the support or by molding plastic to the top wire of the support. Ensure
that the plastic material used for protection of steel legs does not chip, crack, deform, or peel
under ordinary job conditions. Provide molded plastic legs that have sufficient strength to carry
the weight of the supported reinforcing steel in its required position without deformation and
relaxation under job conditions.
415-5.13.3 Plastic Bar Supports and Spacers: Use non-stackable bar supports
and spacers comprised of either reinforced or non-reinforced virgin or recycled plastic. Bar
supports shall be able to meet the concentrated load requirements of 415-5.13.1 within a working
temperature range of 20 to 150F. Spacers shall be able to provide sufficient strength to support
reinforcing steel in the required position without deformation and relaxation under job
conditions. For drilled shafts, use wheel spacers with a smooth perimeter surface.
Provide protection from sunlight until placed in the form and mold in a
configuration which does not restrict concrete flow and consolidation. Do not use bolster rails in
direct contact with concrete surfaces.
All plastic bar supports and spacers shall have a maximum water
absorption of 0.5% at 7 days as per ASTM D570. Plastic bar supports and spacers made of
recycled plastic products must meet the additional requirements of Section 972.
Provide to the Engineer independent lab test data and certification that the
plastic spacers meet the requirements specified herein.
Use plastic bar supports listed on the Departments QPL. Provide each
individual bar support with an identification number unique to the particular model permanently
marked on the surface as included in the QPL. Manufacturers seeking evaluation of products for
inclusion on the QPL must submit an application in accordance with Section 6 and include
certified test reports from an independent laboratory showing that the plastic bar supports meet
all the requirements specified herein.
425
415-6 Welded Deformed Steel Wire Fabric Reinforcement.
415-6.1 General: The Contractor may substitute welded deformed steel wire fabric
reinforcement for deformed bar reinforcement when approved on shop drawings. Propose
substitutions of welded deformed steel wire fabric in a manner that provides a cross-sectional
area per foot of welded deformed steel wire fabric equal to that provided in the Plans for
deformed bar reinforcement. Orient the deformed wires of welded deformed steel wire fabric
reinforcement in the same position as bar reinforcement detailed in the Plans. The Contractor
may use smooth or deformed cross wires of welded deformed steel wire reinforcement. Use a
cross wire size that is a minimum of 35% or more of the area of the deformed wire.
Provide welded steel wire fabric reinforcement as shown in the Plans.
415-6.2 Design: When welded deformed steel wire fabric reinforcement is substituted for
deformed bar reinforcement, ensure that the development length, splices, shear reinforcement,
and distribution meet the requirements of the AASHTO LRFD Bridge Design Specifications.
415-7 Method of Measurement.
415-7.1 General: The quantity to be paid for will be the computed weight, in pounds, of
reinforcing steel entering into the completed structure or item of work and accepted. The
quantity will not include the reinforcing steel in any item of work for which the basis of payment
includes the steel reinforcement. No separate payment will be made for reinforcing steel in pipe
endwalls. No deduction will be made from reinforcing steel quantities for encroachment of inlets
and pipes in box culverts. The lengths to be used in the calculation will be the detailed lengths of
bars as shown in the Plans. The quantity to be paid for will be the original plan quantity,
determined as provided above.
415-7.2 Unit Weights of Bars: The unit weights used will be CRSI Standard Reinforcing
Steel Bar Weights.
415-7.3 Fabric Reinforcement: Where fabric reinforcement is to be paid for by weight,
the quantity to be paid for will be the product of the area, in square feet, of the fabric actually
incorporated in the structure and accepted, by the manufacturers standard weight per square
foot.
When welded deformed steel wire fabric reinforcement is substituted for
deformed bar reinforcement, the quantity to be paid for will be the quantity which would be paid
for if bar reinforcement as detailed in the Plans were utilized, based on plan quantity.
415-8 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including all welding, all clips, spacers, ties, mechanical couplers, etc., and wire or other material
used for fastening the reinforcement in place.
In case short bars are permitted for use when full length bars might reasonably be
required, the weight paid for will be only that which would be obtained if full length bars were
used, with no allowance for lap.
Payment will be made under:
Item No. 415- 1Reinforcing Steel - per pound.
426
SECTION 416
INSTALLATION OF POST-INSTALLED ANCHOR SYSTEMS AND DOWELS
FOR STRUCTURAL APPLICATIONS IN CONCRETE ELEMENTS
416-1 Description.
Prepare and install post-installed anchor systems and dowels in hardened concrete as
indicated in the Plans, as directed by the Engineer, and in accordance with the manufacturers
instructions and this Section.
Post-installed anchors and dowels in this Section are intended for use in structural
applications where designated in the Plans.
416-2 Materials.
416-2.1 Adhesive Bonded Anchors and Dowels: Use adhesive bonding material
systems which meet the requirements of Section 937 and are included on the Qualified Products
List (QPL). Use anchors and dowels installed in positions ranging from vertically downward to
horizontal.
416-2.1.1 Type HV Adhesives: Use Type HV adhesive bonding materials for all
installations other than constructing doweled pile splices. Do not use Type HV adhesives as a
substitute for Type HSHV adhesives.
416-2.1.2 Type HSHV Adhesives: Use higher strength Type HSHV adhesive
bonding materials for installation of traffic railing reinforcement and anchor bolts into existing
concrete bridge decks and approach slabs. Type HSHV adhesives may be used as a substitute for
Type HV adhesives provided the length and diameter of the anchor bolt and drilled hole remain
as designed for the Type HV adhesive.
416-2.1.3 Storage of Materials: Store materials delivered to the job site in the
original unopened containers within an appropriate facility capable of maintaining storage
conditions consistent with the manufacturers recommendations.416-3 Equipment.
Install adhesive-bonded anchor systems with equipment conforming to the
manufacturers recommendation for the type of system installed.
416-4 Preparing of Concrete Members.
416-4.1 Adhesive-Bonded Anchors and Dowels: Ensure that concrete members
receiving adhesive-bonded anchors or dowels are structurally sound and free of cracks in the
vicinity of the anchor or dowel to be installed. Unless other equipment is recommended by the
adhesive manufacturer, drill holes to the diameter required by the manufacturer, but as a
minimum, not less than 105% of the diameter including deformations, nor more than 150% of
the nominal diameter of the steel bar anchor or dowel, using a rotary hammer drill and bit.
Use a metal detector specifically designed for locating steel in concrete to avoid
conflicts with existing steel reinforcement whenever placement tolerances and edge clearances
permit. Perform core drilling through existing steel reinforcement only when approved by the
Engineer. Dry the drilled holes completely prior to cleaning and installing the anchors or dowels.
Clean and prepare drilled holes in accordance with the manufacturers
recommendations, but as a minimum, use oil free compressed air to remove loose particles from
drilling, brush inside surface to free loose particles trapped in pores, then use compressed air
again to remove the remaining loose particles. Use a non-metallic bristle brush and avoid overbrushing to prevent polishing the inside surface of the drilled hole.
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416-5 Installation Methods.
416-5.1 Adhesive-Bonded Anchors and Dowels: Remove all debris, oils, and any other
deleterious material from the anchors and dowels to avoid contamination of the adhesive
bonding material. Install anchors or dowels in accordance with the details shown in the Plans and
the manufacturers instructions, with particular attention to requirements and limitations due to
anchor position, dampness, ambient temperature, and curing.
Use adequate quantities of the adhesive bonding material to fill the drilled hole to
within 1/4 inch of the concrete surface measured after placement of the steel bar or anchor. For
horizontal and downwardly inclined installations, provide temporary supports to maintain the
anchors or dowels in the center of the drilled holes until the adhesive bonding material has cured.
416-6 Field Testing of Post-Installed Anchor Systems and Dowels.
416-6.1 General: Provide an independent testing agency to perform field testing of postinstalled anchors or dowels under the direction of a Professional Engineer registered in the State
of Florida. Submit test reports for each LOT signed and sealed by the Professional Engineer.
Perform restrained static tension tests to prevent damage to the surrounding concrete. A
restrained test is defined as a test conducted in accordance with ASTM E-488 except that the test
equipment support clearance requirements of ASTM E-488 do not apply. The opening in the
reaction base shall be approximately equal to the drilled hole diameter for the anchor to preclude
concrete or masonry failure, but allow bond failure for the adhesive-bonded anchors and dowels.
Displacement measurement for field testing is not required.
Divide the post-installed anchors or dowels into LOTs for testing and acceptance.
Each LOT must contain a maximum of 100 anchors or dowels, of the same type, manufacturer,
diameter, embedment length and adhesive bonding material system (if applicable) installed on
the same day. Randomly select four of the anchors or dowels in each LOT for testing, except if
there are three or less in the LOT, in which case, test all anchors or dowels, unless otherwise
directed by the Engineer. If three consecutive LOTs have no failing tests, sample the next three
LOTs at a 2% rate, rounded up to the nearest whole number, and if these LOTs have no failing
tests, sample at a rate of 1%, rounded up to the nearest whole number, for the remaining LOTs
unless there is a failure; however, regardless of LOT size, sample at least one anchor or dowel
per LOT. For every failed field test, perform two additional field tests on adjacent untested
anchors or dowels within the LOT. Continue additional field tests until no more test failures
occur, or all anchors or dowels within the LOT are tested. For the next LOT after a failed LOT,
randomly select four of the anchors or dowels in each LOT for testing, except if there are three
or less in the LOT, test all anchors or dowels unless otherwise directed by the Engineer then
conform to the sampling rate procedure above including rate reductions as appropriate for
subsequent LOTs.
416-6.1.1 Adhesive-Bonded Anchors: Field test installed anchors and dowels for
traffic railing applications using Type HSHV adhesives. The Engineer may also require testing
of installed anchors and dowels for other applications.
Test individual anchors and dowels by proof loading in tension to 85% of
the specified bond strength in accordance with Section 937 based on the nominal anchor or
dowel diameter and embedment depth, but not more than 90% of the yield strength of the anchor
or dowel, unless otherwise shown in the Contract Documents.
416-6.2 Removal & Replacement of Failed Test Specimens: Remove all anchors and
dowels that fail the field test, in accordance with the manufacturers recommendation and
without damage to the surrounding concrete. For adhesive-bonded anchors, redrill holes to
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remove adhesive bonding material residue and clean in accordance with 416-4. Reinstall new
anchors and dowels in accordance with 416-5. Do not reuse the failed anchors and dowels unless
approved by the Engineer. Assign reinstalled anchors into new LOTs only containing reinstalled
anchors or dowels of the same diameter, embedment length and adhesive bonding material
system, and field test in accordance with 416-6.
416-7 Acceptance.
The Engineer will base acceptance of post-installed anchor systems on determining that
the material requirements of Section 937, the installation and testing requirements of this Section
and the placement requirements of the Plans have been met.
416-8 Basis of Payment.
The work specified in this Section will not be paid for directly, but will be considered as
incidental work.
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SECTION 425
INLETS, MANHOLES, AND JUNCTION BOXES
425-1 Description.
Construct inlets, manholes, and junction boxes from reinforced concrete as shown in the
Design Standards and the Plans. Brick masonry may be used if the structure is circular and
constructed in place. Furnish and install the necessary metal frames and gratings. Construct yard
drains from concrete meeting the requirements of Section 347. Adjust structures shown in the
Plans to be adjusted or requiring adjustment for the satisfactory completion of the work.
425-2 Composition and Proportioning.
425-2.1 Concrete: For inlets, manholes, and junction boxes, use Class II or IV concrete,
as designated in the Plans and Design Standards and as specified in Section 346. For yard drains
use concrete as specified in Section 347.
425-2.2 Mortar: For brick masonry, make the mortar by mixing one part portland
cement to three parts sand. Miami Oolitic rock screenings may be substituted for the sand,
provided the screenings meet the requirements of 902-5.2.3 except for gradation requirements.
Use materials passing the No. 8 sieve that are uniformly graded from coarse to fine.
Masonry cement may be used in lieu of the above-specified mortar
provided it is delivered in packages properly identified by brand name of manufacturer, net
weight of package, and whether it is Type 1 or Type 2, and further provided that it has not been
in storage for a period greater than six months.
425-3 Materials.
425-3.1 General: Meet the following requirements:
Sand (for mortar)....................................................... 902-3.2
Portland Cement................................................. Section 921
Water .................................................................. Section 923
Reinforcing Steel ..................................... 931-1.1 and 415-3
Brick and Concrete Masonry Units ................... Section 949
Castings for Frames and Gratings ...................... Section 962
425-3.2 Gratings, Covers, and Frames: Use gratings and frames fabricated from
structural steel or cast iron as designated in the appropriate Design Standard. When Alt. G grates
are specified in the Plans, provide structural steel grates that are galvanized in accordance with
the requirements of ASTM A-123.
Use rigid frames and covers either 24 inches or 36 inches or optional three-piece
adjustable frames and covers as indicated in Design Standards, Index No. 201.
For three-piece adjustable frames, the inner frame may include replaceable
resilient seats to support the cover. In addition, the inner frame shall indicate it is adjustable, by
clearly having the word adjustable imprinted into the exposed portion of the inner frame so
adjustable is visible from the roadway after installation.
425-4 Forms.
Design and construct wood or metal forms so that they may be removed without
damaging the concrete. Build forms true to line and grade and brace them in a substantial and
unyielding manner. Obtain the Engineers approval before filling them with concrete.
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425-5 Precast Inlets, Manholes, and Junction Boxes.
Precast inlets, manholes and junction boxes, designed and fabricated in accordance with
the Plans, the Design Standards and Section 449, may be substituted for cast-in-place units.
425-6 Construction Methods.
425-6.1 Excavation: Excavate as specified in Section 125.
Where unsuitable material for foundations is encountered, excavate the unsuitable
material and backfill with suitable material prior to constructing or setting inlets, manholes and
junction boxes.
As an option to the above and with the Engineers approval, the Contractor may
carry the walls down to a depth required for a satisfactory foundation, backfill to 8 inches below
the flowline with clean sand and cast a non-reinforced 8 inch floor.
425-6.2 Placing and Curing Concrete: Place the concrete in the forms, to the depth
shown in the Plans, and thoroughly vibrate it. After the concrete has hardened sufficiently, cover
it with suitable material and keep it moist for a period of three days. Finish the traffic surface in
accordance with 522-7.2, or with a simulated broom finish approved by the Engineer.
425-6.3 Setting Manhole Castings: After curing the concrete as specified above, set the
frame of the casting in a full mortar bed composed of one part portland cement to two parts of
fine aggregate.
425-6.3.1 Standard Castings: Set manhole frames in a mortar bed and adjust to
grade using brick or concrete grade rings, with a maximum 12 inch adjustment.
425-6.3.2 Optional Adjustable Castings: When using a three-piece adjustable
frame and cover, install the frame and cover with brick or concrete grade rings to the base course
height. Make adjustments using the inner frame in accordance with the manufacturers
installation recommendations so the inner frame and cover meet the grade and slope of the
pavement surface opened to traffic.
425-6.4 Reinforcing Steel: Follow the construction methods for the steel reinforcement
as specified in Section 415.
425-6.5 Laying Brick: Saturate all brick with water before laying. Bond the brick
thoroughly into the mortar using the shovejoint method to lay the brick. Arrange headers and
stretchers so as to bond the mass thoroughly. Finish the joints properly as the work progresses
and ensure that they are not less than 1/4 inch or more than 3/4 inch in thickness. Do not use
spalls or bats except for shaping around irregular openings or when unavoidable at corners.
425-6.6 Backfilling: Backfill as specified in Section 125, meeting the specific
requirements for backfilling and compaction around inlets, manholes, and junction boxes
detailed in 125-8.1 and 125-8.2. However, for outfall lines beyond the sidewalk or future
sidewalk area, where no vehicular traffic will pass over the pipe, inlets, manholes, and junction
boxes, compact backfill as required in 125-9.2.2.
425-6.7 Adjusting Existing Structures: Cut down or extend existing manholes, catch
basins, inlets, valve boxes, etc., within the limits of the proposed work, to meet the finished
grade of the proposed pavement, or if outside of the proposed pavement area, to the finished
grade designated in the Plans for such structures. Use materials and construction methods which
meet the requirements specified above to cut down or extend the existing structures.
The Contractor may extend manholes needing to be raised using adjustable
extension rings of the type which do not require the removal of the existing manhole frame. Use
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an extension device that provides positive locking action and permits adjustment in height as
well as diameter and meets the approval of the Engineer.
When a three-piece adjustable frame and cover is installed, make adjustments
using the inner frame in accordance with the manufacturers installation recommendations so the
inner frame and cover meet the grade and slope of the pavement surface opened to traffic.
425-7 Method of Measurement.
The quantities to be paid for will be (1) the number of inlets, manholes, junction boxes,
and yard drains, completed and accepted; and (2) the number of structures of these types
(including also valve boxes) satisfactorily adjusted.
425-8 Basis of Payment.
425-8.1 New Structures: Price and payment will be full compensation for furnishing all
materials and completing all work described herein or shown in the Plans, including all clearing
and grubbing outside the limits of clearing and grubbing as shown in the Plans, all excavation
except the volume included in the measurement designated to be paid for under the items for the
grading work on the project, all backfilling around the structures, the disposal of surplus
material, and the furnishing and placing of all gratings, frames, covers, and any other necessary
fittings.
425-8.2 Adjusted Structures: When an item of payment for adjusting manholes, valve
boxes, or inlets is provided in the proposal, price and payment will be full compensation for the
number of such structures designated to be paid for under such separate items, and which are
satisfactorily adjusted, at the Contract unit prices each for adjusting inlets, adjusting manholes,
and adjusting valve boxes.
For any of such types of these structures required to be adjusted but for which no
separate item of payment is shown in the proposal for the specific type, payment will be made
under the item of adjusting miscellaneous structures.
425-8.3 Payment Items: Payment will be made under:
Item No. 425- 1Inlets - each.
Item No. 425- 2Manholes - each.
Item No. 425- 3Junction Boxes - each.
Item No. 425- 4Adjusting Inlets - each.
Item No. 425- 5Adjusting Manholes - each.
Item No. 425- 6Adjusting Valve Boxes - each.
Item No. 425- 8Adjusting Miscellaneous Structures - each.
Item No. 425- 10- Yard Drains - each.
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SECTION 430
PIPE CULVERTS
430-1 Description.
Furnish and install drainage pipe and end sections at the locations called for in the Plans.
Furnish and construct joints and connections to existing pipes, catch basins, inlets, manholes,
walls, etc., as may be required to complete the work.
Construct structural plate pipe culverts or underdrains in accordance with Sections 435
and 440.
Obtain pipe culverts from a Producer currently on the Departments list of Producers
with Accepted Quality Control Programs. Producers seeking inclusion on the list shall meet the
requirements of 105-3.
When the producers Quality Control Program is suspended, accept responsibility of
either obtaining drainage products from another producer with an accepted Quality Control
Program or await re-approval of the producers Quality Control Program. The Engineer will not
allow changes in Contract Time or completion dates as a result of the producers Quality Control
Program suspension. Accept responsibility for all delay costs or other costs associated with the
producers Quality Control Program suspension.
430-2 Materials.
430-2.1 Pipe: Meet the following requirements:
Concrete Pipe .........................................................................Section 449
Round Rubber Gaskets ..........................................................Section 942
Corrugated Steel Pipe and Pipe Arch ....................................Section 943
Corrugated Aluminum Pipe and Pipe Arch ...........................Section 945
Corrugated Polyethylene Pipe ...............................................Section 948
Polyvinyl Chloride (PVC) Pipe .............................................Section 948
430-2.2 Joint Materials: Use joint materials specified in 430-7 through 430-9 according
to type of pipe and conditions of usage.
430-2.3 Mortar: Use mortar composed of one part Portland cement and two parts of
clean, sharp sand, to which mixture the Contractor may add hydrated lime in an amount not to
exceed 15% of the cement content. Use mortar within 30 minutes after its preparation.
430-3 Type of Pipe to Be Used.
430-3.1 General: When the Plans designate a type (or types) of pipe, use only the type
(or choose from the types) designated. As an exception, when the Plans designate reinforced
concrete pipe as Class S, Class I, Class II, Class III and Class IV, the Contractor may use nonreinforced concrete pipe up to and including 36 inch in diameter.
430-3.2 Side Drain: If the Plans do not designate a type (or types) of pipe, the Contractor
may use either a minimum Class I concrete pipe, corrugated steel pipe, corrugated aluminum
pipe, corrugated polyethylene pipe or PVC pipe. If one of the metal types is chosen, use the
minimum gage specified in Section 943 for steel pipe or Section 945 for aluminum pipe.
Non-reinforced concrete pipe may also be substituted for concrete pipe in side
drains, subject to the provisions of 430-3.1.
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430-4 Laying Pipe.
430-4.1 General: Lay all pipe, true to the lines and grades given, with hubs upgrade and
tongue end fully entered into the hub. When pipe with quadrant reinforcement or circular pipe
with elliptical reinforcement is used, install the pipe in a position such that the manufacturers
marks designating top and bottom of the pipe are not more than five degrees from the
vertical plane through the longitudinal axis of the pipe. Do not allow departure from and return
to plan alignment and grade to exceed 1/16 inch per foot of nominal pipe length, with a total of
not more than 1 inch departure from theoretical line and grade. Take up and relay any pipe that is
not in true alignment or which shows any settlement after laying at no additional expense to the
Department.
Do not use concrete pipe with lift holes except round pipe which has a inside
diameter in excess of 54 inches or any elliptical pipe.
Repair lift holes, if present, by use of a hand-placed, stiff, non-shrink, 1-to-1
mortar of cement and fine sand, after first washing out the hole with water. Completely fill the
void created by the lift hole with mortar. Cover the repaired area with a 24 by 24 inches piece of
filter fabric secured to the pipe. Use a Type D-3 filter fabric meeting the requirements shown on
Design Standards, Index 199.
Secure the filter fabric to the pipe using a method that holds the fabric in place
until the backfill is placed and compacted. Use a grout mixtures, mastics, or strapping devices to
secure the fabric to the pipe.
When installing pipes in structures, construct inlet and outlet pipes of the same
size and kind as the connecting pipe shown in the Plans. Extend the pipes through the walls for a
distance beyond the outside surface sufficient for the intended connections, and construct the
concrete around them neatly to prevent leakage along their outer surface as shown on the Design
Standards, Index 201. Keep the inlet and outlet pipes flush with the inside of the wall. Resilient
connectors as specified in 942-3 may be used in lieu of a masonry seal.
Furnish and install a filter fabric jacket around all pipe joints and the joint
between the pipe and the structure in accordance with Design Standards, Index Nos. 201 and
280. Use fabric meeting the physical requirements of Type D-3 specified in the Design
Standards, Index 199. The fabric shall extend a minimum of 12 inches beyond each side of the
joint or both edges of the coupling band, if a coupling band is used. The fabric shall have a
minimum width of 24 inches, and a length sufficient to provide a minimum overlap of 24 inches.
Secure the filter fabric jacket against the outside of the pipe by metal or plastic strapping or by
other methods approved by the Engineer.
Meet the following minimum joint standards:
Pipe Application
Storm and Cross Drains
Gutter Drain
Side Drains
Minimum Standard
Water-tight
Water-tight
Soil-tight
When rubber gaskets are to be installed in the pipe joint, the gasket shall be the
sole element relied on to maintain a tight joint. Soil tight joints must be watertight to 2 psi.
Water-tight joints must be water-tight to 5 psi unless a higher pressure rating is required in the
Plans.
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430-4.2 Trench Excavation: Excavate the trench for storm and cross drains, and side
drains as specified in Section 125.
430-4.3 Foundation: Provide a suitable foundation, where the foundation material is of
inadequate supporting value, as determined by the Engineer. Remove the unsuitable material and
replace it with suitable material, as specified in 125-8. Where in the Engineers opinion, the
removal and replacement of unsuitable material is not practicable, he may direct alternates in the
design of the pipe line, as required to provide adequate support. Minor changes in the grade or
alignment will not be considered as an adequate basis for extra compensation.
Do not lay pipe on blocks or timbers, or on other unyielding material, except
where the use of such devices is called for in the Plans.
430-4.4 Backfilling: Backfill around the pipe as specified in 125-8 unless specific
backfilling procedures are described in the Contract Documents.
430-4.5 Plugging Pipe: When existing pipe culverts are to be permanently placed out of
service, fill them with flowable fill that is non-excavatable, contains a minimum 350 lbs/cy of
cementious material and meets the requirements of Section 121 and/or plug them with masonry
plugs as shown in the Plans. Install masonry plugs that are a minimum of 8 inches in thickness,
in accordance with Design Standards, Index 280.
When proposed or existing pipe culverts are to be temporarily placed out of
service, plug them with prefabricated plugs as shown in the Plans. Install prefabricated plugs in
accordance with the manufacturers recommendations. Do not fill or construct masonry plugs in
any pipe culvert intended for current or future service.
430-4.6 End Treatment: Place an end treatment at each storm and cross drain, and side
drain as shown in the Plans. Refer to the Design Standards for types of end treatment details.
As an exception to the above, when concrete mitered end sections are permitted,
the Contractor may use reinforced concrete U-endwalls, if shop drawings are submitted to the
Engineer for approval prior to use.
Provide end treatments for corrugated polyethylene pipe and PVC pipe as
specified in Section 948, or as detailed in the Plans.
430-4.7 Metal Pipe Protection: Apply a bituminous coating to the surface area of the
pipe within and 12 inches beyond the concrete or mortar seal prior to sealing, to protect
corrugated steel or aluminum pipe embedded in a concrete structure, such as an inlet, manhole,
junction box, endwall, or concrete jacket.
Ensure that the surface preparation, application methods (dry film thickness and
conditions during application), and equipment used are in accordance with the coating
manufacturers published specifications.
Obtain the Engineers approval of the coating products used.
430-4.8 Pipe Inspection: For pipes installed under the roadway, inspection is to be
conducted when backfill reaches 3 feet above the pipe crown or upon completion of placement
of the stabilized subgrade. For pipe installed within fills, including embankments confined by
walls, inspection is to be conducted when compacted embankment reaches 3 feet above the pipe
crown or the finished earthwork grade as specified in the Plans. Prior to conducting the
inspection, provide the Engineer with a video recording schedule for videoing, dewater installed
pipe, and remove all silt, debris and obstructions. Submit pipe videoing and reports to the
Department for review prior to the continuation of paving.
For pipe 48 inches or less in diameter, provide the Engineer a video DVD and
report using low barrel distortion video equipment with laser profile technology, non-contact
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video micrometer and associated software that provides:
1. Actual recorded length and width measurements of all cracks within the
pipe.
2. Actual recorded separation measurement of all pipe joints.
3. Pipe ovality report.
4. Deflection measurements and graphical diameter analysis report in
terms of x and y axis.
5. Flat analysis report.
6. Representative diameter of pipe.
7. Pipe deformation measurements, leaks, debris, or other damage or
defects.
8. Deviation in pipe line and grade, joint gaps, and joint misalignment.
9. A video record of the actual speed at which the camera is traveling
through the pipe, ensuring that the rate of travel does not exceed the limit defined in 430-4.8.1
below.
Laser profiling and measurement technology must be certified by the company
performing the work to be in compliance with the calibration criteria posted at:
http://www.dot.state.fl.us/construction/contractorissues/laser.shtm . Reports submitted in
electronic media are preferred.
The Engineer may waive this requirement for side drains and cross drains which
are short enough to inspect from each end of the pipe.
430-4.8.1 Video Report: Provide a high quality DVD in a MPEG2 format video
with a standard resolution of 720 x 480. Use a camera with lighting suitable to allow a clear
picture of the entire periphery of the pipe. Center the camera in the pipe both vertically and
horizontally and be able to pan and tilt to a 90 degree angle with the axis of the pipe and rotating
360 degrees. Use equipment to move the camera through the pipe that will not obstruct the
cameras view or interfere with proper documentation of the pipes condition.
The video image shall be clear, focused, and relatively free from roll,
static, or other image distortion qualities that would prevent the reviewer from evaluating the
condition of the pipe. The video will include identification before each section of pipe filmed.
The identification will include the project number, the structure number corresponding to the
structure number on the set of plans for the project, size of pipe, the date and time, and indicate
which pipe is being filmed if multiple pipes are connected to the structure. Notes should be taken
during the video recording process. Provide the Engineer with copies of these notes along with
the video.
Move the camera through the pipe at a speed not greater than 30 feet per
minute. Mark the video with the distance down the pipe. The distance shall have an accuracy of
one foot per 100 feet. Film the entire circumference at each joint. Stop the camera and pan when
necessary to document and measure defects. Position the camera head perpendicular to all
defects requiring measurement by the video micrometer.
430-4.8.2 Reinspection: At any time after reviewing the submitted pipe
inspection reports, the Engineer may direct additional inspections. If no defects are observed
during the reinspection, the Department will pay for the cost of the reinspections in accordance
with 4-3. If defects are observed, the reinspection and all work performed to correct the defects
will be done at no cost to the Department. Acceptance of all replacements or repairs will be
based on video documentation of the completed work prior to Final Acceptance.
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430-5 Removing Existing Pipe.
If the Plans indicate that existing pipe is to remain the property of the Department, collect
and stack along the right-of-way all existing pipe or pipe arch so indicated in the Plans to be
removed, or that does not conform to the lines and grades of the proposed work and that is not to
be re-laid, as directed by the Engineer. Take care to prevent damage to salvageable pipe during
removal and stacking operations.
430-6 Placing Pipe Under Railroad.
430-6.1 General: Construct pipe culverts under railroad tracks in accordance with the
requirements of the railroad company.
Perform all the shoring under the tracks, and sheeting and bracing of the trench,
required by the railroad company or deemed necessary by the Engineer in order to ensure safe
and uninterrupted movement of the railroad equipment, at no expense to the Department.
430-6.2 Requirements of the Railroad Company: Install pipe using methods required
by the railroad company and shown in the Contract Documents.
When the general method of installation required by the railroad company is
indicated in the Plans, do not alter such method, or any other specific details of the installation
which might be indicated in the Plans, without receiving approval or direction from the railroad,
followed by written approval from the Engineer.
430-6.3 Notification to Railroad Company: Notify the railroad company and the
Engineer at least ten days prior to the date on which pipe is to be placed under the railroad
tracks.
430-6.4 Placing Pipe by Jacking: Obtain the Engineers and the railroad companys
approval of the details of the jacking method to be used, when placing pipe through the railroad
embankment, before the work is started.
430-6.5 Use of Tunnel Liner: When the railroad company requires that a tunnel liner be
used for placing the pipe in lieu of the jacking method, the Department will pay for the tunnel
liner material separately in cases where the Contract Documents do not require the use of a
tunnel liner. For these cases the Department will reimburse the Contractor for the actual cost of
the liner, delivered at the site. The Department will base such cost on a liner having the
minimum gage acceptable to the railroad.
430-7 Specific Requirements for Concrete Pipe.
430-7.1 Sealing Joints: Seal the pipe joints with round rubber or profile gaskets meeting
the requirements of Section 449. Ensure that the gasket and the surface of the pipe joint,
including the gasket recess, are clean and free from grit, dirt and other foreign matter, at the time
the joints are made. In order to facilitate closure of the joint, application of a vegetable soap
lubricant immediately before closing of the joint will be permitted. Prelubricated gaskets may be
used in lieu of a vegetable soap lubricant when the lubricating material is certified to be inert
with respect to the rubber material.
430-7.2 Laying Requirements for Concrete Pipe with Rubber Gasket Joints: Do not
allow the gap between sections of pipe to exceed 5/8 inch for pipe diameters of 12 inches
through 18 inches, 7/8 inch for pipe diameters of 24 through 66 inches, and 1 inch for pipe
diameters 72 inches and larger. Where minor imperfections in the manufacture of the pipe create
an apparent gap in excess of the tabulated gap, the Engineer will accept the joint provided that
the imperfection does not exceed 1/3 the circumference of the pipe, and the rubber gasket is
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1/4 inch or more past the pipe joint entrance taper. Where concrete pipes are outside of these
tolerances, replace them at no expense to the Department. Do not apply mortar, joint compound,
or other filler to the gap which would restrict the flexibility of the joint.
430-7.3 Field Joints for Elliptical Concrete Pipe: Use either a preformed plastic gasket
material or an approved rubber gasket to make a field joint.
430-7.3.1 Plastic Gasket: Meet the following requirements when field joints are
made from preformed plastic gasket material:
430-7.3.1.1 General: Install field joints in accordance with the
manufacturers instructions and the following:
430-7.3.1.2 Material: Meet the requirements of 942-2.
430-7.3.1.3 Joint Design: Ensure that the pipe manufacturer furnishes the
Engineer with details regarding configuration of the joint and the amount of gasket material
required to affect a satisfactory seal. Do not brush or wipe joint surfaces which are to be in
contact with the gasket material with a cement slurry. Fill minor voids with cement slurry.
430-7.3.1.4 Primer: Apply a primer of the type recommended by the
manufacturer of the gasket material to all joint surfaces which are to be in contact with the
gasket material, prior to application of the gasket material. Thoroughly clean and dry the surface
to be primed.
430-7.3.1.5 Application of Gasket: Apply gasket material to form a
continuous gasket around the entire circumference of the leading edge of the tongue and the
groove joint, in accordance with the detail shown on the Design Standards, Index No. 280. Do
not remove the paper wrapper on the exterior surface of the gasket material until immediately
prior to joining of sections. Apply plastic gasket material only to surfaces which are dry. When
the atmospheric temperature is below 60F, either store plastic joint seal gaskets in an area above
70F, or artificially warm the gaskets to 70F in a manner satisfactory to the Engineer.
430-7.3.1.6 Installation of Pipe: Remove and reposition or replace any
displaced or contaminated gasket as directed by the Engineer. Install the pipe in a dry trench.
Carefully shape the bottom of the trench to minimize the need for realignment of sections of pipe
after they are placed in the trench. Hold to a minimum any realignment of a joint after the
gaskets come into contact. Prior to joining the pipes, fill the entire joint with gasket material and
ensure that when the pipes are joined there is evidence of squeeze-out of gasket material for the
entire internal and external circumference of the joint. Trim excess material on the interior of the
pipe to provide a smooth interior surface. If a joint is defective, remove the leading section of
pipe and reseal the joint.
430-7.3.2 Rubber Gasket: Meet the following requirements when field joints are
made with profile rubber gaskets:
430-7.3.2.1 General: Install field joints in accordance with the
manufacturers instructions and the following:
430-7.3.2.2 Material: Meet the requirements of 942-4.
430-7.3.2.3 Joint Design: Ensure that the pipe manufacturer furnishes the
Engineer with details regarding configuration of the joint and gasket required to effect a
satisfactory seal. Do not apply mortar, joint compound, or other filler which would restrict the
flexibility of the gasket joint.
430-7.4 Requirements for Concrete Radius Pipe:
430-7.4.1 Design: Construct concrete radius pipe in segments not longer than
4 feet (along the pipe centerline), except where another length is called for in the Contract
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Documents. Join each segment using round rubber gaskets. Ensure that the pipe manufacturer
submits details of the proposed joint, segment length and shape for approval by the Engineer,
prior to manufacture.
430-7.4.2 Pre-Assembly: Ensure that the manufacturer pre-assembles the entire
radius section in his yard, in the presence of the Engineer, to ensure a proper fit for all parts. At
the option of the manufacturer, the Contractor may assemble the pipe without gaskets.
Consecutively number the joints on both the interior and exterior surfaces of each joint, and
make match marks showing proper position of joints. Install the pipe at the project site in the
same order as pre-assembly.
430-8 Specific Requirements for Corrugated Metal Pipe.
430-8.1 Field Joints:
430-8.1.1 General: Make a field joint with locking bands, as specified in
Article 9 of AASHTO M 36 and AASHTO M 196M for aluminum pipe. For aluminum pipe,
fabricate bands from the same alloy as the culvert sheeting.
When existing pipe to be extended is helically fabricated, make a field
joint between the existing pipe and the new pipe using one of the following methods:
(1) Cut the new pipe to remove one of the re-rolled annular end
sections required in Sections 943 or 945, or fabricate the pipe so that the re-rolled annular
section is fabricated only on one end. Use either a spiral (helical) band with a gasket or a flat
band with gaskets as required by 430-8.1.2 (2) to join the pipe sections.
(2) The Contractor may construct a concrete jacket as shown on
the Design Standards, Index No. 280, provided that the minimum cover required by the Design
Standards, Index No. 205 can be obtained.
430-8.1.2 Side Drain, Storm and Cross Drain, and Gutter Drains: Where
corrugated metal pipe is used as side drain, storm and cross drain, or gutter drain, use a rubber
or neoprene gasket of a design shown to provide a joint as specified in 430-4.
Use a gasket of one of the following dimensions:
(1) For annular joints with 1/2 inch depth corrugation: either a
single gasket a minimum of 7 inches by 3/8 inch or two gaskets a minimum of 3 1/2 inches by
3/8 inch; and for annular joints with 1 inch depth corrugations: either a single gasket a minimum
of 7 inches by 7/8 inch or two gaskets a minimum of 3 1/2 inches by 7/8 inch.
(2) For helical joints with 1/2 inch depth corrugation: either a
single gasket a minimum of 5 inches by 1 inch or two gaskets a minimum of 3 1/2 inches by
1 inch; and for helical joints with 1 inch depth corrugations: either a single gasket a minimum of
5 inches by 1 1/2 inches or two gaskets a minimum of 3 1/2 inches by 1 1/2 inches.
(3) Such other gasket designs as may be approved by the Engineer.
If, in lieu of a single gasket spanning the joint, two gaskets are used, place
these individual gaskets approximately 2 inches from each pipe end at the joint. When two
gaskets are used, seal the overlapping area on the coupling band between the gaskets consistent
with the joint performance specified. The Contractor may tuck a strip of preformed gasket
material over the bottom lip of the band for this purpose. Use coupling bands that provide a
minimum circumferential overlap of 3 inches. As the end connections on the coupling band are
tightened, ensure that there is no local bending of the band or the connection. Use precurved
coupling bands on pipe diameters of 24 inches or less.
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Use flat gaskets meeting the requirements of ASTM D-1056, designation
2C2 or 2B3. In placing flat gaskets on pipe prior to placing the coupling band, do not stretch the
gasket more than 15% of its original circumference. Use circular gaskets meeting the
requirements of ASTM C-361. Do not stretch the circular gasket more than 20% of its original
circumference in placing the gasket on pipe. Use preformed plastic gasket material meeting the
composition requirements of 942-2.2.
Apply an approved vegetable soap lubricant, as specified for concrete pipe
in 430-7.1.1.
430-8.1.3 Alternate Joint: In lieu of the above-specified combination of locking
bands and flat gaskets, the Contractor may make field joints for these pipe installations by the
following combinations:
(a) Use the metal bands as specified in Article 9 of AASHTO M 36M that
are at least 10 1/2 inches wide and consist of a flat central section with a corrugated section near
each end, designed to match the annular corrugation in the pipe with which they are to be used.
Connect the bands in a manner approved by the Engineer, with a suitable fastening device such
as the use of two galvanized 1/2 inch diameter bolts through a galvanized bar and galvanized
strap, suitably welded to the band. Use a strap that is the same gage as the band.
Where helically corrugated pipe is to be jointed by this alternate
combination, ensure that at least the last two corrugations of each pipe section are annular, and
designed such that the band will engage each pipe end with the next-to-outside annular
corrugation.
(b) For these bands, use a rubber gasket with a circular cross-section of the
O-ring type conforming to ASTM C-361. Use gaskets having the following cross-sectional
diameter for the given size of pipe:
Non-SI Units
Pipe Size
12 inches through 36 inches (with 1/2 inch depth corrugations)
42 inches through 96 inches (with 1/2 inch depth corrugations)
36 inches through 120 inches (with 1 inch depth corrugations)
Gasket Diameter
13/16 inch
7/8 inch
1 3/8 inches
Use preformed gasket material to seal the overlapping area on the
coupling band between gaskets.
(c) Use channel band couplers in helical pipe with ends which have been
reformed and flanged specifically to receive these bands. Use channel band couplers that are of a
two piece design, are fabricated from galvanized steel stock conforming to AASHTO M 36, have
2 by 2 by 3/16 inch angles fastened to the band ends to allow for proper tightening, and meet the
following:
440
Band Thickness
0.079 inch
0.109 inch
3/4 inch wide
1 inch wide
Non SI Units
Pipe Wall Thickness
0.109 inch or lighter
0.138 inch or heavier
0.109 inch or lighter
0.138 inch or heavier
Furnish two 1/2 inch diameter connection bolts with each band, that
conform to ASTM A-307, Grade A and are electroplated in accordance with ASTM B-633.
Use a gasket with the joint that is a hydrocarbon blend of butyl rubber
meeting the chemical composition and physical properties of 942-2.2. Use a 3/8 by 3/4 inch
gasket for pipe fabricated from 0.109 inch or lighter material and a 3/8 by 1 inch gasket for pipe
fabricated from 0.138 inch and heavier material.
The Contractor may use a flange band coupler without the gasket for all
applications other than side drain, storm and cross drain, and gutter drain.
Do not use the flange band coupler to join dissimilar types of pipe.
The Contractor may join reformed flanged helical pipe to existing annular
or reformed pipe having annular ends. On non-gasketed installations, use either an annular band
or an alternate joint described in 430-8.1.3. On gasketed installations, use an annular band,
minimum of five corrugations in width, in conjunction with two O-ring gaskets as specified in
430-8.1.3. Use mastic material to seal the area of band overlap.
The minimum joint performance standards specified in 430-4.1 apply.
430-8.2 Laying and Shape Requirements for Corrugated Metal Pipe: Install pipe
using either a trench or open ditch procedure.
Check pipe shape regularly during backfilling to verify acceptability of the
construction method used. Pipe deflected 5% or more of the certified actual mean diameter of the
pipe at final inspection shall be replaced at no cost to the Department. Deflection measurements
are taken at the point of smallest diameter on the corrugations.
430-9.Specific Requirements for Corrugated Polyethylene Pipe and Polyvinyl Chloride
(PVC) Pipe.
430-9.1 Field Joints: Use gasketed joints to seal side drain, and storm and cross drain.
Use gaskets meeting the requirements of Section 449. Ensure that the pipe manufacturer
provides a joint design approved by the Engineer before use.
430-9.2 Installation Requirements Including Trenching, Foundation and Backfilling
Operations: Check structure shape regularly during backfilling to verify acceptability of the
construction method used.
Pipe deflected 5% or more of the certified actual mean diameter of the pipe at
final inspection shall be replaced at no cost to the Department.
430-10 Desilting Pipe or Concrete Box Culvert.
Desilt pipe culvert and concrete box culvert as designated in the Plans.
430-11 Method of Measurement.
430-11.1 New Pipe: The quantities of storm and cross drain pipe, storm drain trench, side
drain pipe and gutter drain pipe to be paid for will be plan quantity, in place and accepted. The
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plan quantity will be determined from the inside wall of the structure as shown on the Plans,
along the centerline of the pipe.
430-11.2 Mitered End Section: The quantity to be paid for will be the number
completed and accepted.
430-12 Basis of Payment.
430-12.1 General: Prices and payments will be full compensation for all work specified
in this Section, including all excavation except the volume included in the items for the grading
work on the project, and except for other items specified for separate payment in Section 125; all
backfilling material and compaction; disposal of surplus material; and all clearing and grubbing
outside of the required limits of clearing and grubbing as shown in the Plans.
430-12.2 Removing Existing Pipe: When existing pipe is removed and replaced with
new pipe approximately at the same location, the cost of excavating and removing the old pipe
and of its disposal will be included in the Contract unit price for clearing and grubbing.
430-12.3 Site Restoration: The cost of restoring the site, as specified in 125-11, that is
disturbed, solely for the purpose of constructing pipe culvert, will be included in the Contract
unit price for the pipe culvert, unless designated specifically to be paid for under other items.
430-12.4 Plugging Pipes: The cost of temporarily plugging a pipe culvert, either
proposed or existing, will be incidental to the contract unit price for new pipe culvert.
The cost of filling and/or plugging an existing pipe culvert that is to be
permanently placed out of service will be paid for at the contract unit price for filling and
plugging pipe, per cubic yard. Price and payment will be full compensation for flowable fill,
masonry, concrete, mortar, and all labor and materials necessary to complete the work.
When the project includes no quantities for new pipe culverts, and temporary
plugs are required for existing pipe culverts, the cost will be considered as extra work, in
accordance with 4-3.5.
430-12.5 Desilting Pipe: Desilting Pipe will be paid for at the contract unit price per foot
for each pipe desilted. Price and payment will be full compensation for furnishing all equipment,
tools and labor, disposal of silt and debris, and all incidentals necessary for satisfactorily
performing the work.
430-12.6 Desilting Concrete Box Culverts: Price and payment will be full
compensation for all work required.
430-12.7 Flared End Sections: Price and payment will be full compensation for all work
and materials required.
430-12.8 Mitered End Sections: Price and payment will be full compensation for all
pipe, grates when required, fasteners, reinforcing, connectors, anchors, concrete, sealants, jackets
and coupling bands, and all work required.
430-12.9 Railroad Requirements: Where pipe culvert is constructed under railroad
tracks, the Contract unit price for the pipe culvert will include the costs of any jacking operations
and the operation of placing the pipe by use of a tunnel liner, (except as specified for
unanticipated tunnel liner, in 430-6.5, where reimbursement is to be made for such unanticipated
liner), and all other work necessary to meet the requirements of the railroad company, excluding
the costs of watchman or flagman services provided by the railroad company, except as provided
below.
The Department will reimburse the Contractor for the actual costs of any trestle
bridge work which is performed by the railroads forces, as billed to him by the railroad, less the
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value of any salvage materials derived there from, whether such salvage materials are retained
by the railroad company or by the Contractor. When the work of shoring and bracing is to be
performed by the railroad, such fact will be stipulated in the Contract Documents and the
Contractor will be required to pay to the railroad the amount of such costs, which amount will be
reimbursed to him by the Department. The Contract unit price for the pipe culvert shall include
the costs of all other work of shoring and bracing.
430-12.10 Payment Items: Payment will be made under:
Item No. 430- 17- Pipe Culvert Optional Material - per foot.
Item No. 430- 94- Desilting Pipe per foot.
Item No. 430- 96- Polyvinyl Chloride Pipe - per foot.
Item No. 430- 98- Mitered End Section - each.
Item No. 430-200- Flared End Sections - each.
Item No. 430-610- U-Endwall - each.
Item No. 430-830- Filling and Plugging Pipe cubic yard.
Item No. 430-950- Desilting Concrete Box Culvert per cubic yard.
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SECTION 431
PIPE LINER
431-1 Description.
Rehabilitate drainage pipe by installing a pipe liner in accordance with the
requirements of this Section. The Plans will indicate the location of the pipe to be
rehabilitated, the material composition and the alternate liner types that may be used to
rehabilitate the pipe, and the method of liner installation.
431-2 Materials.
Meet the requirements of Section 948.
431-3 Pre-installation Requirements.
Prior to installing the pipe liner, inspect the host pipe and ensure that it is clean,
dry and stable. Inspect the host pipe by means of closed circuit television. The closed
circuit television inspection may be augmented by a visual inspection in which persons
enter a host pipe to inspect it, at no additional cost to the Department. Obtain written
approval from the Engineer prior to allowing persons to enter a host pipe. Furnish all
equipment necessary to inspect, remove silt and other debris, and dewater the host pipe to
the satisfaction of the Engineer. Seal cracks and joints using an approved chemical grout
of either acrylamide base gel, acrylic base gel, urethane base gel, or urethane base foam.
Place flowable fill as directed by the Engineer to maintain the stability of the host pipe.
431-4 Installation Methods.
431-4.1 General: Install the liner using one of, or a combination of, the following
methods: sliplining, inverting, pulling/pushing, spiral winding, paneling, coating, or
bursting. Seal or grout the annular space between the interior of the host pipe and the
exterior of the liner according to the liner manufacturers written instructions.
431-4.2 Sliplining: Use either polyethylene, high density polyethylene, polyvinyl
chloride, fiberglass, steel or aluminum pipe liner. Install the liner by joining discrete
lengths, panels or segments of the pipe liner in a manhole or other access point and
inserting the liner into the host pipe.
431-4.2.1 Polyethylene: Install polyethylene pipe liner in accordance with
ASTM F-585. The manufacturers written instructions may be substituted for ASTM F585 with written permission from the Engineer.
431-4.2.2 High density polyethylene: Install high density polyethylene
pipe liner in accordance with ASTM F-585. The manufacturers written instructions may
be substituted for ASTM F-585 with written permission from the Engineer.
431-4.2.3 Polyvinyl chloride: Install polyvinyl chloride pipe liner in
accordance with ASTM F-1698.
431-4.2.4 Fiberglass, steel or aluminum: Install fiberglass, steel or
aluminum pipe liner in accordance with the manufacturers written instructions.
431-4.3 Inverting: Install a resin impregnated felt tube pipe liner into the host
pipe, and cure in place, in accordance with ASTM F-1216.
431-4.4 Pulling/Pushing: Install the liner in accordance with the manufacturers
written instructions. Protect the pipe liner end using a device that uniformly distributes
the applied load around the perimeter of the liner. Continuously monitor the applied load,
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and do not stretch the liner by more than 1% of its original length. For liner lengths of
100 feet or less, the end protection device may be omitted, with written permission from
the Engineer. Do not seal the liner ends or begin grouting prior to 24 hours after liner
installation.
431-4.5 Spiral Winding: Install the pipe liner in accordance with ASTM F-1698
or ASTM F-1741.
431-4.6 Paneling: Install the pipe liner in accordance with the manufacturers
written instructions. Limit paneling to host pipes having 90 inch or greater internal
diameters. Do not place panels where a liner joint will lie along or near the crown of the
host pipe.
431-4.7 Coating: Use materials and install the pipe liner in accordance with the
manufacturers written instructions.
431-4.8 Bursting: Install the pipe liner in accordance with the manufacturers
written instructions. Limit bursting to vitrified clay or concrete crossdrain or sidedrain
pipe having no lateral connections or risers. Further limit bursting to locations where no
part of the host pipe passes within 5 feet of any buried utility or pavement base material.
431-5 Acceptance.
Inspect the complete rehabilitation by means of closed circuit television. Obtain
written approval from the Engineer prior to allowing persons to enter a host pipe. Provide
the Engineer with videos of all preliminary and final inspections.
431-6 Method of Measurement.
The quantity of pipe liner to be paid for will be the length, per foot, of pipe liner
installed and accepted, measured along the centerline of the pipe, from end to end.
The quantity of flowable fill to be paid for will be in accordance with Section 121.
The quantity of desilting pipe to be paid for will be in accordance with
Section 430.
431-7 Basis of Payment.
Price and payment for pipe liner will be full compensation for furnishing and
installing the pipe liner in accordance with the requirements of this Section, including all
materials, labor and incidentals required for sealing cracks and joints in the existing pipe,
and sealing and grouting the annular space between the liner and interior of the host pipe.
Price and payment for pipe liner will also be full compensation for all equipment,
materials and labor required for inspections, and for furnishing videos of the inspections
to the Engineer.
Price and payment for flowable fill will be in accordance with Section 121.
Price and payment for desilting pipe will be in accordance with Section 430.
Payment will be made under:
Item No. 431- 1Pipe Liner - per foot.
Item No. 431- 2Pipe Inspection - per foot.
445
SECTION 435
STRUCTURAL PLATE PIPE AND PIPE ARCH CULVERTS
435-1 Description.
Construct structural plate pipe and pipe arch culverts.
435-2 Materials.
Meet the requirements of Section 944 for steel and Section 945 for aluminum.
When the Plans call for bituminous coated pipe or pipe arch, meet the coating
requirements of 944-4.
When other types of coating material are shown in the Plans, use a coating that consists
of at least two coats of the specified material, applied at the job site. Apply the coating by brush
or by spray.
435-3 Trench, Foundation, Laying, and Backfill.
Perform this work as specified in Section 430, and as follows.
Provide a foundation for the bottom plates that is of uniform density and carefully shaped
to fit the lower plate of the pipe or pipe arch. Thoroughly tamp the backfill material against the
remaining plates.
435-4 Assembly.
Assemble the plates to form the pipe or pipe arch structure in accordance with the
diagram furnished by the manufacturer. Connect the plates by bolting tightly in all bolt holes
provided.
435-5 Method of Measurement.
The quantities to be paid for will be the plan quantity, in feet, of pipe or pipe arch,
installed in place, completed and accepted. The quantity will be measured along the centerline of
the structure from end to end of metal for full section structures, from average end to end at top
and bottom for beveled-end structures.
435-6 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including all materials, backfilling, and disposal of surplus material and all excavation except the
volume included in the items for grading work and for other items specified for payment in
Section 125.
Payment will be made under:
Item No. 435- Structural Plate Pipe Culvert - per foot.
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SECTION 436
TRENCH DRAIN
436-1 Description.
Construct Trench Drain, with one of the materials listed below, for the purpose of
collecting and removing surface run-off from paved areas. Furnish and install trench drain in
accordance with the Design Standards, at the locations shown in the Plans or as directed by the
Engineer.
436-2 Materials.
Provide preformed channels or pipe with sufficient strength to withstand construction
handling and placement of concrete backfill without deforming or deviating from line and grade.
Furnish the Engineer with certification from the manufacturer that the trench drain system meets
the requirements of this Section.
436-2.1 Channels/Pipe: Meet the following requirements:
Steel Pipe ............................................................Section 943
Aluminum Pipe ...................................................Section 945
Polyethylene ......................... Section 948 and ASTM D3350
Polymer Concrete............................................ASTM D6783
Fiberglass ........................................................ASTM D3517
436-2.2 Concrete Backfill: Use concrete that meets the requirements of Section 347.
436-2.3 Grates: Provide steel grates and supporting frames that meet the requirements of
Section 962. Ductile iron frames and grates must meet the requirements of ASTM A536. Ensure
that ductile iron grates and frames are compatible and from the same manufacturer. Frames must
be anchored into the concrete backfill with studs bolts or lugs. Grates must have at least 30%
open area and fasten securely to frames to avoid rattling, Grates must be removable for the entire
channel length and have vandal resistant locking devices. Ensure that frames have a minimum of
4 inch long studs, bolts or lugs at all four corners.
436-2.4 Clean-Out covers for Type 1 Drains: Install steel or ductile iron covers that
meet the requirements of Section 962.
436-2.5 Outlet Pipe: Connect outlet pipe to the trench drain with standard manufactured
connectors. Unless a particular type is called for in the Plans, use any of the following types of
pipe:
Concrete ..............................................................Section 449
Steel.....................................................................Section 943
Aluminum ...........................................................Section 945
Polyvinyl Chloride .................................................... 948-1.7
Polyethylene ...............................................................948.2.3
436-3 Installation.
Submit to the Engineer the proposed method of installation, noting any deviation from
the manufacturers recommendations. Place concrete backfill in the trench against undisturbed
material at the sides and bottom of the trench in a manner that will prevent floating or shifting of
the trench drain, and will prevent voids in, or segregation of the concrete. Tamp and spade to
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prevent honeycombing. Form the top surface to the lines shown in the Plans. Remove any
foreign material that falls into the trench prior to or during placement of concrete.
436-4 Method of Measurement.
The quantity to be paid for will be plan quantity, in place and accepted. The plan quantity
will be measured from the inside wall of the structure as shown in the Plans, along the centerline
of the pipe/channel.
436-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including all materials, tools, equipment, concrete backfilling, outlet pipe, connections to new or
existing structures and all incidentals necessary to complete the work.
Payment will be made under:
Item No. 436- 1Trench Drain - per foot.
448
SECTION 440
UNDERDRAINS
440-1 Description.
Construct underdrains, underdrain cleanout structures, underdrain inspection boxes and
underdrain outlet pipes. Use any one of the types of pipe listed in 440-2, unless a particular type
is specifically required. Use only perforated pipe, and do not use open joints.
440-2 Materials.
Meet the following requirements:
Concrete Pipe ..................................................... Section 449
Filter Aggregate ........................................................... 902-4
Corrugated Steel Pipe ........................................ Section 943
Corrugated Aluminum Pipe ......................................... 945-1
Polyvinyl-Chloride....................................................... 948-1
Corrugated Polyethylene Pipe ..................................... 948-2
Filter Fabric Sock......................................................... 948-3
Geotextile Fabrics .............................................. Section 985
Use bitumized-fiber pipe only when called for in the Contract Documents.
440-3 Excavating Trench.
Excavate the trench carefully, to the depth required to permit the pipe to be laid to the
grade required, and to the dimensions shown in the Plans.
440-4 Laying Pipe.
440-4.1 General: Bed the pipe firmly on the bottom of the trench, with the perforations
down and joints securely made.
440-4.2 Corrugated Steel Pipe - Protection of Coating: Handle corrugated steel pipe in
such a way that the zinc coating will not be bruised or broken. Do not use pipe showing bruises
or breakage of the zinc coating.
440-4.3 Protection of Drain Inlet: Protect the influent end of the pipe in a manner
which will prevent any soil from entering the drain.
440-4.4 Lateral Connections: Make lateral connections with prefabricated wyes, tees,
elbows, etc., as required.
440-4.5 Underdrain Inspection Box: Construct underdrain inspection boxes in
accordance with the Design Standards, Index No. 245 and the Plans.
440-4.6 Underdrain Cleanout Structures: Construct underdrain cleanout structures of
in-line wye fittings and stub for access where called for in the Plans.
440-5 Placing Filter Material and Backfilling.
440-5.1 Placing Material: After laying the pipe and obtaining the Engineers approval,
backfill the trench with filter material to the lines shown in the Plans.
440-5.2 Compaction of Filter Material and Protection of Pipe: Place and compact the
filter material around the pipe and for the full width of the trench, in layers not exceeding
6 inches in thickness. Take special care to avoid displacement or damage to the pipe.
449
440-5.3 Backfill Above Filter Material: For all types of pipe, backfill the portion of the
trench above the filter material with suitable pervious material. Place and compact the material
in layers not exceeding 4 inches in thickness.
440-6 Type V Underdrain Construction.
To prevent clogging of Type V underdrain from construction sediments, initially
excavate the associated stormwater facilities to rough grade. After the contributing drainage area
is stabilized, construct the underdrains and excavate the stormwater facilities to achieve the final
elevation.
440-7 Method of Measurement.
The quantities to be paid for will be the length, in feet, of underdrain, which includes
underdrain cleanout structures, measured in place, along the centerline and gradient of the
underdrain, completed and accepted. The quantities to be paid for will be the length, in feet, of
outlet pipe measured in place, along the centerline and gradient of the outlet pipe, completed and
accepted. The quantity of underdrain inspection boxes to be paid for will be the number
completed and accepted.
440-8 Basis of Payment.
Price and payment will be full compensation for all the work, including all materials and
all excavation except the volume included in the items for the grading work.
Payment will be made under:
Item No. 440- 1Underdrain - per foot.
Item No. 440- 70Underdrain Inspection Box - each.
Item No. 440- 73Underdrain Outlet Pipe - per foot.
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SECTION 443
FRENCH DRAINS
443-1 Description.
Construct French Drains, utilizing one of the authorized types of pipe, with coarse
aggregate, or ballast rock when specified, and filter fabric.
443-2 Materials.
443-2.1 Pipe: Unless a particular type is specified in the Plans, pipe furnished may be
any of the following types:
(1) Concrete Pipe (Bell & Spigot): Slotted or perforated concrete pipe may be
used. Meet the requirements of Section 449 for concrete pipe. Use the class of pipe specified on
the Design Standards, Index No. 205. Do not use gaskets. Fully insert the spigot in the bell, and
bring home. Conform to Design Standards, Index No. 285 for slotted pipe. Use perforated pipe
having perforations equally located 360 degrees around the pipe. Use pipe having not less than
30 round perforations, 3/8 inch each, per square foot of inside pipe surface. Extend perforations
to within 6 inches of the bell or spigot area. The Engineer will permit other perforations not less
than 5/16 inch nor more than 3/8 inch in the least dimension if they provide an opening area not
less than 3.31 in2/ft2 of pipe surface.
(2) Corrugated Aluminum Alloy Culvert Perforated Pipe: Meet the requirements
of Section 945. Use perforated pipe having perforations equally located 360 degrees around the
pipe. Locate perforations either on the inside crests or on the neutral axis of all corrugations
except that perforations are not required within 4 inches of each end of each length of pipe or in
a corrugation where seams are located.
Provide pipe having not less than 30 round perforations, 3/8 inch each, per square
foot of pipe surface. The Engineer will permit other perforations not less than 5/16 inch nor more
than 3/8 inch in the least dimension if they provide an opening area not less than 3.31 in2/ft2 of
pipe surface.
(3) Corrugated Steel Perforated Pipe: Meet the requirements of Section 943.
Space the perforations and meet the requirements as specified in (2) above.
(4) Bituminous Coated Corrugated Steel Perforated Pipe: Meet the requirements
of Section 943. Space the perforations and meet the requirements as specified in (2) above. Place
the perforations prior to the bituminous coating. The Engineer will accept the minimum opening
of not less than 3.31 in2/ft2 of pipe if 50% of the opening area is maintained after coating.
(5) Corrugated Polyethylene Pipe: Meet the requirements of 948-2.3. Space the
perforations and meet the requirements as specified in (2) above.
(6) Polyvinyl Chloride (PVC) Pipe: Meet the requirements of 948-1.7. Space the
perforations and meet the requirements as specified in (2) above.
443-2.2 Coarse Aggregate: Meet the requirements of 901-1.4 for No. 4 stone.
443-2.3 Select Fill: Use select fill meeting the requirements of either Section 911, 913,
913A or 915.
443-3 Excavating Trench.
Excavate the trench in accordance with Section 125 unless specific trench excavation
procedures are described in the Plans.
451
Carefully excavate the trench to such depths as required to permit the filter fabric, coarse
aggregate and the pipe to be placed in accordance with the details shown in the Plans.
443-4 Laying Pipe.
Lay all pipe conforming with the lines and grades specified in the Plans and in
accordance with these Specifications. Unless otherwise specified in the Plans, set the pipe with a
36 inch minimum cover and a maximum cover of 66 inches.
443-5 Placing Coarse Aggregate and Backfilling.
After placing the pipe and without disturbing the pipe, carefully place the coarse
aggregate around the pipe to a depth shown in the Plans. Fold the filter fabric over the coarse
aggregate. Backfill and compact as described below.
443-5.1 French Drains Under Pavement: Fill the area above the coarse aggregate with
select fill material meeting the requirements of this Section. Place and compact the select fill
according to the requirements for pipe as specified in Section 125. The Department will allow
use of additional coarse aggregate over the top of the pipe instead of select fill material. In this
case, the filter fabric shall be extended to wrap the additional course aggregate. The top of the
coarse aggregate shall not be higher than the bottom of the base, unless shown in the Plans. The
Department will not pay additional costs associated with substituting coarse aggregate for select
fill.
443-5.2 French Drains not Under Pavement: Fill and compact the area above the
coarse aggregate according to the requirements for pipe in Section 125, unless specific
procedures are described in the Plans as specified in Section 125.
443-6 Method of Measurement.
The quantity of french drains to be paid for under this Section will be the length in feet,
measured in place, completed and accepted as specified on Design Standards, Index No. 285 for
french drains.
443-7 Basis of Payment.
The quantities determined as provided above will be paid for at the Contract unit price
per foot for french drains. Such prices and payments will be full compensation for all the work
specified in this Section and will include all materials and all excavation, and will also include
sheeting or shoring, if required, the disposal of surplus material, pavement restoration,
backfilling and tamping, but will not include payment for items paid for elsewhere in the
specifications.
Payment shall be made under:
Item No. 443- 70French Drains - per foot.
452
SECTION 446
EDGEDRAIN (DRAINCRETE)
446-1 Description.
Construct Edgedrain (Draincrete), and Edgedrain Outlet Pipe as shown in the Plans and
Design Standards, Index No. 287. Use any one of the types of pipe listed in 446-2, unless a
particular type is specifically required within the Contract Documents. Use only perforated pipe,
and do not use open joints.
446-2 Materials.
Meet the following requirements:
Portland Cement Concrete* ............................... Section 347
Coarse Aggregate ............................................... Section 901
Portland Cement................................................. Section 921
Water .................................................................. Section 923
Polyvinyl-Chloride Pipe .................................... Section 948
Polyethylene Pipe .............................................. Section 948
Filter Fabric........................................................ Section 985
*For Draincrete, the concrete requirements of Section 347 are modified as
follows:
Use Type I or II portland cement (no fly ash or other pozzolans permitted).
Composition:
Grade of coarse aggregate (stone) ... #57, #67 or #89
Maximum Water/Cement ratio ...........................0.38
Minimum cement factor ...... 385 lb/yd3 of Draincrete
Maximum Slump Range ................... Not Applicable
Fine Aggregate .................................................. None
Admixtures ........................................................ None
Do not use materials which contain hardened lumps, crusts, or frozen matter, or are
contaminated with dissimilar material.
446-3 Control of Quality.
446-3.1 Concrete Design Mix: Submit the proposed design mix prior to production, on
the Concrete Mix Design form, for the Engineers approval. Use only draincrete design mixes
having prior approval of the Engineer. Do not change the design mix component materials
except as per 446-3.2.
The Department will verify the proposed mix design and may witness the trial
batching. Meet the unit weight requirements as determined in accordance with FM 5-530, and
the drain rate in accordance with FM 5-570. Also, provide one of the following with the design
mix submittal:
(1) Evidence from three sets of production data, either from Department
acceptance tests or independently verifiable commercial mixes, that draincrete produced in
accordance with the proposed design mix meets the requirements of this Section.
(2) Test data from a single trial batch of 0.10 yd3 minimum is required,
which demonstrates that the draincrete produced using the proposed mix, designated ingredients,
and designated water-cement ratio meets the requirements of this Section.
453
446-3.2 Batch Adjustment - Materials: Meet the theoretical yield requirements of the
approved mix design. Inform the Engineer of any adjustments to the approved mix design. Note
any batch adjustments and record the actual quantities incorporated into the mix, on the concrete
Delivery Ticket/Certification form.
446-3.3 Delivery Certification: Furnish to the Engineer a complete Delivery
Ticket/Certification form with each batch of draincrete prior to unloading at the site.
446-4 Construction.
446-4.1 Excavating Trench: Meet the requirements of Section 440.
446-4.2 Laying Pipe: Meet the requirements of Section 440.
446-4.3 Placement of Draincrete: Obtain the Engineers approval before placing the
draincrete. Deliver the draincrete to the site of placement in a freshly mixed unhardened state.
Deposit draincrete in the form or trench by a method approved by the Engineer, to ensure
uniform distribution. Do not use vibrators. Avoid displacement or damage to the pipe or filter
fabric.
446-5 Sampling and Testing.
446-5.1 General: The Engineer will take random samples of the draincrete at the point of
placement to determine the drain rate in accordance with FM 5-570 to determine the drain rate.
A minimum of two test cylinders will be made for each LOT. A LOT represents one days
production of each mix design.
446-5.2 Acceptance of Hardened Draincrete: Meet the minimum drain rate of
6 oz/second. Draincrete not meeting the drain rate requirement will be rejected.
Remove, and replace all rejected draincrete at no cost to the Department.
446-6 Method of Measurement.
The quantity of Edgedrain (Draincrete) to be paid for will be the length, in feet, measured
in place, along the centerline and gradient of the Edgedrain (Draincrete), completed and
accepted. The quantity of Edgedrain Outlet Pipe to be paid for will be the length, in feet,
measured in place along the centerline and gradient of the outlet pipe, completed and accepted.
446-7 Basis of Payment.
Price and payment will be full compensation for all work, including all materials,
excavation, equipment, labor and incidentals necessary to complete the work.
Payment will be made under:
Item No. 446- 1Edgedrain (Draincrete) - per foot.
Item No. 446- 71Edgedrain Outlet Pipe - per foot.
454
SECTION 449
PRECAST CONCRETE DRAINAGE PRODUCTS
449-1 Description.
Precast concrete drainage products hereinafter called products, may include but are not
limited to, round concrete pipe, elliptical concrete pipe, underdrains, manholes, endwalls, inlets,
junction boxes, three-sided precast concrete culverts, and precast concrete box culverts.
Ensure that all precast drainage products are designed and manufactured in accordance
with the requirements of the Contract Documents.
Obtain precast concrete pipes, box culverts, and drainage structures from a plant that is
currently on the Departments list of Producers with Accepted Quality Control Programs.
Producers seeking inclusion on the list shall meet the requirements of 105-3.
At the beginning of each project, provide a notarized statement to the Engineer from a
company designated representative certifying that the plant will manufacture the products in
accordance with the requirements set forth in the Contract Documents and plants Quality
Control (QC) Plan. The Quality Control Managers stamp on each product indicates certification
that the product was fabricated in conformance with the Contractors QC Plan, the Contract, and
this Section. Ensure that each shipment of precast concrete products to the project site is
accompanied with a QC signed or stamped delivery ticket providing the description and the list
of the products.
Accept responsibility of either obtaining products from a plant with an approved Quality
Control Program, or await re-approval of the plant, when the plants Quality Control Program is
suspended by the Department.
The Engineer will not allow changes in Contract time or completion dates as a result of
the plants loss of qualification. Accept responsibility for all delay costs or other costs associated
with the loss of the plants qualification.
449-2 Materials.
Ensure that the materials used for the construction of the precast drainage products have a
certification statement from the source, showing that they meet the applicable requirements of
the Specifications with the following modifications:
455
Reinforcing Bar...................................................Section 415
Coarse Aggregate* ..............................................Section 901
Fine Aggregate* ..................................................Section 902
Portland Cement and blended cement.................Section 921
Water ...................................................................Section 923
Admixtures ..........................................................Section 924
Pozzolans and slag ..............................................Section 929
Gasket Material ...................................................Section 942
Blended Hydraulic Cements ...................... AASHTO M 240
Welded Wire Fabric ............. ASTM A 185 or ASTM A 497
Wire for Site Cage Machines .................................................
........................ ASTM A 82, ASTM A 496 or ASTM A 615
*For concrete pipes the gradation requirements of concrete aggregates as set forth
in Sections 901 and 902 are not applicable.
449-3 Construction Requirements.
Unless otherwise stipulated within the Contract Documents, meet the following
requirements for concrete mix, product design, fabrication, transportation, and installation:
Three-Sided Precast Culverts ..........................................Section 407
Precast Concrete Box Culvert .........................................Section 410
Pipe Culverts and Storm Sewers .....................................Section 430
French Drains ..................................................................Section 443
Inlets, Manholes, and Junction Boxes
........................................................... Section 425 and ASTM C 478
Underdrains ....................................... Section 440 and ASTM C 444
Steel Reinforced Round Concrete Pipe.......................... ASTM C 76
Reinforced Elliptical Concrete Pipe............................. ASTM C 507
Non-reinforced Concrete Pipe ..................................... ASTM C 985
Meet the special requirements for the applicable pipes as described in 449-4 and 449-5.
449-4 Concrete Pipe.
449-4.1 Special Requirements for Steel Reinforced Concrete Pipe: Use pipe meeting
the requirements of ASTM C76 with the modifications as described in 449-4.2. Use Special
Designed pipe meeting the requirements of ASTM C655. Use Class S pipe meeting the
requirements of ASTM C655 and the 0.01 inch crack and ultimate D - loads given in the Design
Standards, Index No. 205. Ensure all pipes are properly marked.
449-4.2 Modifications to ASTM C 76 and ASTM C 507: The following supersedes the
provisions of ASTM C76 and ASTM C507:
(a) Ensure all materials used in concrete are certified from the source and conform
to the requirements of 449-2.
(b) Ensure all Joint Reinforcement requirements are in accordance with the
Design Standards.
(c) When membrane curing compounds are used, ensure that the requirements of
925-2 are met and the membrane curing compounds are applied in accordance with 400-16
immediately after the pipe has been removed from the form.
456
(d) Ensure the manufacturer has a suitable apparatus for testing each product in
accordance with ASTM C497 and performs all tests outlined in ASTM C497 when requested by
the Engineer.
(e) Ensure that the variation of laying lengths of two opposite sides of pipe is not
more than 1.04% of the diameter, with a maximum of 1/2 inch in any length of pipe, except
where beveled-end pipe for laying on curves is specified.
(f) Ensure that the type of wall markings is included on all precast pipes.
(g) Ensure all repairs are made in accordance with Section 449-5.4.
449-4.3 Special Requirements for Non-Reinforced Concrete Pipe: Ensure the
requirements of ASTM C985 and the ultimate D - loads given in the Design Standards,
Index 205 are met with the following exception: Modify material requirements set forth in
ASTM C985 with the material requirements set forth in 449-2. Ensure all pipes are properly
marked.
449-4.4 Special Requirements for Reinforced Elliptical Concrete Pipe: Use elliptical
concrete pipes conforming to the requirements of ASTM C507, except for the exceptions and
modifications as specified in 449-4.2. Ensure the requirements of Table I of ASTM C507 for
standard elliptical pipe, the requirements of Class HE-III and Class HE-IV of Table I of
ASTM C507 for standard elliptical pipe and special elliptical pipe, respectively are met and the
joint design requirements set forth in Article 7 of ASTM C443 are met.
449-4.5 Concrete Underdrain Pipe: Use perforated concrete pipe for underdrains
meeting the requirements of ASTM C444, with the following modifications:
(a) Strength of finished pipe: Underdrain pipe will not be required to be
reinforced, and will not be tested for strength of the finished pipe. Approval of the strength of the
finished pipe will be based on visual inspection and check.
(b) Perforations: The perforations must be molded into the pipe at the time of
fabrication, and any undue chips, fractures, incurred thereby, either in the interior of the pipe or
on the periphery, which are sufficient to significantly impair the strength or efficiency, will be
cause for rejection of the pipe.
Ensure the perforations are circular, and of the diameter called for below, with a
tolerance of plus or minus 1/16 inch. Furnish all pipe included in any single order, or for any
single installation operation, such diameter is reasonably uniform.
Internal Diameter
of Pipe
6 inches
6 inches
8 inches
8 inches
Schedule of Perforations For Concrete Underdrain Pipe
Diameter of
**Approximate
**Spacing within
Perforations
No. of Rows
distance between
Rows
*(Design)
Rows
3/8 inch
4
4 inches
5-6 inches
1/4 inch
4
4 inches
4-5 inches
3/8 inch
4
5 inches
5-6 inches
1/4 inch
4
5 inches
4-5 inches
*1/16 inch fabrication tolerance, over and under.
**Perforations to be staggered in alternate rows. The spacing between rows must be uniform.
449-4.6 Rejection of Concrete Pipe: Specific causes for rejection of concrete pipe, in
addition to any failure to meet the general requirements specified in the Contract Documents, are
as follows:
457
(a) Failure to meet the requirements listed in ASTM C76 for permissible
variations in dimensions with the modifications outlined in 449-4.1 and 449-4.2.
(b) Occurrence of defects listed in ASTM C76.
449-5 Requirements For Pipe Joints When Rubber Gaskets Are To Be Used.
449-5.1 Design of Joint: Use pipe joint of the bell-and-spigot type or the double spigot
and sleeve type, meeting the requirements called for in the Design Standards. Ensure the joint is
so proportioned that the spigot, or spigots, will readily enter the bell or sleeve of the pipe.
Ensure the joint ring forms for forming the joint surface are made of either heavy
steel, cast iron, or aluminum, and accurately machined to the dimensions of the joint. They must
be a true circular form within a tolerance of 1/32 inch. Dimensional checks of joint ring form
will indicate for each size pipe a length of spigot, or tongue, not more than 1/8 inch shorter than
the bell, or groove, depth. The pipe will be so manufactured that joint surfaces are concentric
with the inside of the pipe within a tolerance of 3/32 inch. The shape and dimensions of the joint
must be such as to provide compliance with the following requirements:
(a) The joint must be so dimensioned that when the gasket is placed on the
spigot it will not be stretched more than 20% of its original length, or the maximum stretch
length that is recommended by the manufacturer, whichever is lower.
(b) The space provided for the gasket must be a groove in the spigot end
of the pipe and such space, when the joint is made, it cannot be more than 110% of the volume of
the gasket.
(c) The joint must be designed so that when the outer surface of the spigot
and the inner surface of the bell come into contact at some point on the periphery, the diametric
deformation in the gasket at the point of contact cannot be greater than 50% of the normal gasket
diameter, and the diametric deformation in the gasket at a point opposite the contact point cannot
be less than 20% of the normal gasket diameter.
(d) When the pipes are joined, there must be parallel surfaces on both the
bell and the spigot, extending from the outside edge of the gasket toward the bell face for a
distance of not less than 3/4 inch. These parallel surfaces cannot be farther apart than 1/8 inch,
when the spigot is centered in the bell. The tapers on these surfaces cannot exceed three degrees.
(e) The inside surface of the bell at the end of the bell must be flared to
facilitate joining the pipe sections without damaging or displacing the gasket.
449-5.2 When Rubber Gaskets are Used: Ensure that the pipe joints have been tested at
the plant hydrostatically and shown to meet the requirements of Section 6.2 of the Materials
Manual, which is available at the following URL:
http://www.dot.state.fl.us/specificationsoffice/Implemented/URLinSpecs/files/section62.pdf .
449-5.3 When Profile Rubber Gaskets are Used: Ensure the joint design meets the
requirements set forth in Article 7 of ASTM C443.
449-5.4 Tolerances in Imperfections, and Permissible Repairs for Joint of Concrete
Gasketed Pipe: Ensure that all surfaces of near-contact of the jointed pipes are free from air
holes, chipped or spalled concrete, laitance, and other such defects.
Pipes showing minor manufacturing imperfections or handling injuries to the bell
or spigot may be acceptable if such defects are acceptably repaired as prescribed below.
Individual air holes (trapped air), or spalled areas with a length of up to one-half
the pipe radius, or 12 inches whichever is less, may be repaired by careful use of a hand-placed,
stiff, pre-shrunk, 1-to-1 mortar of cement and fine sand, and with no additional preparation other
than a thorough washing with water of the defect. Curing will be done either by moisture curing
458
under wet burlap or by application of an approved membrane curing compound. Such repaired
pipe which is sound, properly finished and cured, and which otherwise conforms to specification
requirements will be acceptable.
Exposed reinforcing and minor spalling in the spigot groove may be accepted if
repaired in the following manner: The spalled areas will be chipped back to solid concrete.
Exposed reinforcing will be cleaned of all laitance and scale. The entire area is to be coated with
an approved epoxy at a thickness of 5 to 10 mils. The coating must be smooth and conform to the
shape of the groove. The epoxy must be a Type F-1 as specified in Section 926.
459
SECTION 450
PRECAST PRESTRESSED CONCRETE CONSTRUCTION
450-1 Description.
Fabricate, store, transport and erect precast/prestressed concrete members prestressed by
the pretensioning method. Pretensioned precast prestressed concrete products are products
prestressed by the pretensioning method. In this method, steel components are stressed and
anchored; the concrete for the product is then cast and cured, and finally the stress in the steel
components is released from the anchorages to the concrete through bond, after the concrete has
attained its specified release strength.
A precast prestressed concrete plant, hereinafter called plant, is an independent operating
facility capable of performing all the operations necessary to fabricate precast/prestressed
concrete products.
Obtain precast/prestressed products from a plant that is currently on the Departments list
of Producers with Accepted Quality Control Programs. Producers seeking inclusion on the list
shall meet the requirements of 105-3.
When the plants Quality Control Program is suspended, accept responsibility of either
obtaining precast/prestressed products from a precast/prestressed concrete plant with an accepted
Quality Control Program, or await re-approval of the concrete plants Quality Control Program.
The Engineer will not allow changes in Contract Time or completion dates as a result of the
concrete plants Quality Control Program suspension. Accept responsibility for all delay costs or
other costs associated with the plants Quality Control Program suspension.
450-2 Quality Control Program.
450-2.1 General: Develop a Quality Control Program as specified in 105-3.
Meet the requirements of the accepted Quality Control Program, Contract
Documents, and Precast/Prestressed Concrete Institute (PCI) Manual for Quality Control for
plants and production of structural precast concrete products. The requirements of the Contract
Documents will govern, when there is a discrepancy between the PCI Manual and the Contract
Documents.
Accept responsibility for performing daily Quality Control (QC) inspections of all
phases of work ensuring all materials and workmanship incorporated into the product meet the
requirements of the Contract Documents. Also, maintain a daily activity report detailing the
results of the daily Quality Control Program activities. Ensure these daily reports and minutes of
the weekly meetings with the Engineer and the plants production personnel are maintained at
the plant. During the weekly meetings, discuss the results of the QC inspections.
Inspect the product for conformance with the product dimension tolerances shown
in Appendix B of PCI Manual MNL-116 (Manual for Quality Control for Plants and Production
of Structural Precast Concrete Products), except as modified herein. Apply the tolerances with
respect to the theoretical positions and dimensions shown in the Plans. Apply the same
tolerances for U-Beams as those specified for I-girders, excluding sweep tolerance, when
inspecting the product for conformance with dimension tolerances. For Florida U-Beam
diaphragms, the tolerance for the thickness of the intermediate and end diaphragms is plus 1 inch
and minus 1/2 inch, and the location of intermediate diaphragms, relative to design plan
positions, is plus or minus 3 inches. The tolerance of the thickness of end diaphragms shall be
plus 3 inches and minus 1/2 inch.
460
Limit sweep to 1/2 inch for U-Beams and Inverted-T Beams. The maximum
allowable sweep for I Beams is 1/8 inch per 10 foot length, but not to exceed 1.5 inch. The
maximum allowable sweep for piling is 1/8 inch per 10 feet, but not to exceed 1.0 inch.
The tolerance for beam strand sheathing is plus or minus 2 inches.
Ensure the tolerance on all miscellaneous shaping including, but not limited to,
chamfers, miters, bevels, keys, tapers, radii, holes, inserts, and block outs is within plus or minus
1/8 inch of the control dimension of the shape.
The tolerances represent the total allowable tolerance that will be accepted in the
finished product. Do not apply tolerances shown for the overall dimensions of a member to
violate the tolerances shown for positions of reinforcing and prestressing steel. Apply the
tolerances during and after the fabrication of prestressed products. Do not reduce the concrete
cover for reinforcing steel, prestressing steel or any other metallic objects specified in the Plans
more than 1/4 inch. Do not reduce the concrete cover for reinforcing steel, prestressing steel or
any other metallic objects when the cover specified in the Plans is minimum cover.
Ensure the QC inspector is present during concrete placements and performs
inspection during all fabrication of precast prestressed concrete products, including the
inspection of the operations before, during and after the placement of concrete.
Ensure the Plant QC Manager, or the QC inspectors under his/her direction,
examine all precast prestressed concrete products within five working days of detensioning to
ensure their dimensions conform to the specified tolerances and to determine if there are any
deficiencies. This process control shall be listed on the Plants Quality Control (QC) Plan.
450-2.2 Plant: Ensure each plant has an onsite QC Manager meeting the requirements of
105-8.9.
450-2.3 Product Certification: Ensure the QC inspector inspects all completed products
at the plant not less than 24 hours before shipment to verify that all Contract Documents
requirements are met. Upon verification that all Contract Document requirements have been met
and all necessary repairs have been satisfactorily completed, the product will be stamped with
the approved QC Manager stamp identified in the QC Plan.
Attach to each monthly request for payment, certification that the listed precast
prestressed products have been produced under the QC Plan and meet the Contract Document
requirements. Ensure the certification is signed by a legally responsible person of the plant and is
provided on the plants letterhead.
450-2.4 Documentation: Ensure that a system of records is maintained in each plant
which will provide all information regarding the certification and testing of prestressing steel,
reinforcing steel, concrete materials and concrete, curing materials, embedded items, tensioning,
concrete proportioning, pre-placement, placement, post-placement inspections, curing, and
disposition of products. Include in the record keeping the deficiencies found as a result of the
inspection and testing. Keep certified test reports for all materials incorporated into the
production of precast prestressed concrete products.
Ensure that the printout or manual record of the tensioning operations is
maintained and reflects the identification of the bed, type of fabricated products, the complete
Financial Project Identification Number, jack identification number, date prestressing strands
were stressed, temperature at the time of stressing, and signature of the qualified tensioning
machine operator.
Ensure the proposed method and format for documenting required information is
included in the QC Plan.
461
Maintain records until all the precast prestressed products for a project have been
fabricated then submit all the records to the Engineer. Ensure records are available at all times
for the Engineers inspection.
450-2.5 Quality Assurance Inspection and Testing: The Engineer will perform
periodic inspections, sampling, and testing to ensure of the quality and acceptability of the
materials, methods, techniques, procedures and processes being utilized by the Contractor in the
fabrication of precast prestressed concrete products.
450-3 Materials.
450-3.1 General: Meet the following requirements:
Concrete ..............................................................Section 346
Steel Strands*......................................................Section 933
Steel Bars ............................................................Section 933
Steel Accessories ................................................Section 933
Reinforcing Steel and Metal Fabric** Sections 415 and 931
Embedded Duct Enclosures ................................Section 462
Membrane Curing compounds*** ......................Section 925
Epoxy Resin Compounds....................................Section 926
Burlap ..................................................................Section 925
Curing Blanket ........................................................... 400-16
Penetrant sealer*** .............................................Section 413
Methacrylate .......................................................Section 413
Epoxy Injection of Cracks ..................................Section 411
* Do not use strands from more than one source in any individual prestressed
element, with the exception of the partially tensioned strands (dormant strands).
** The steel spirals for reinforcing in concrete piling may be manufactured from
stock meeting the requirements of any grade of reinforcing steel, as shown in
ASTM A615 for steel bars, or ASTM A82 for steel wire.
*** Use membrane curing compounds and sealers that are compatible with
coating or other materials that are applied to concrete surface.
Use inserts in accordance with the recommendations of the manufacturers and
within their certified capacities and application qualifications. Do not use aluminum inserts.
Use draped strand devices of sufficient rigidity having adequate support to retain
the position of the strand unchanged under the induced load. Do not allow the devices to induce
friction to the tendons such that the required jacking force and elongation cannot be attained.
450-3.2 Strand Chucks and Splice Chucks: For pretensioning, use strand chucks that
are capable of anchoring the strands without slippage after seating and ensure against strand
failure within the grips at loads less than 95% of ultimate strength.
Provide manufacturers certification that splice chucks used to transmit the
prestressing force from one prestressing tendon to another are capable to hold at least 95% of the
ultimate tensile strength of the prestressing strand.
Do not use wedges that become worn, cracked, deformed, or that allow dead end
seating in excess of 3/8 inch. Use components from the same manufacturer to make up chucks
and to provide proper wedge fit.
Use chucks as complete units. Clean, inspect, and lubricate the chucks between
each use. Use wedges and housing that are compatible and made for the specific type and size of
462
prestressing strand that are being used, avoid improper fit and improper seating of wedges on the
strands.
The Engineer will allow one splice per strand subject to the following:
(1) Splices are located outside the concrete products (except for precast
piling where up to two splices are permitted to be used in each pile, so long as they are not
located in the same vertical cross section, perpendicular to longitudinal axis of the pile).
(2) Strands which are being spliced have the lay or twist in the same
direction.
450-4 Material Acceptance and Testing.
450-4.1 Concrete: Perform the QC sampling and testing of concrete in accordance with
the requirements of Section 346.
450-4.2 Reinforcing Steel, Welded Wire Reinforcement and Prestressing Steel for
Pretensioning:
450-4.2.1 General: Identify all reinforcing steel, welded wire reinforcement and
prestressing steel for pretensioning by LOTs. A LOT of reinforcing steel or welded wire is a
shipment of material from the same manufacturer and heat. A LOT of prestressing steel is a
shipment of material of the same size, production grade and heat from the same manufacturer.
Acceptance of reinforcing steel, welded wire reinforcement and
prestressing steel for pretensioning is based on manufacturers certification and the Departments
verification tests. The sampling for verification testing will be performed by the Department at
each precast plant, on at least two LOTs per year, additional samples may be taken at the
manufacturing source of reinforcing steel, welded wire reinforcement and prestressing strands.
When products contain the material that has failed to meet the
requirements of 450-3, reject the unused material of the failed LOT. The Engineer may require
the evaluation of the products, which contain the failed material, in accordance with 450-14.
450-4.2.2 Reinforcing Steel and Welded Wire Reinforcement: Obtain and
maintain for each LOT a certified mill analysis, physical property test report and the
manufacturers assigned LOT number with the heat of the material represented. Verify that the
report represents the steel received and that the steel meets the Contract Documents
requirements. Reject all unidentified reinforcing steel or welded wire reinforcement received at
the plant or job site.
Provide the manufacturers certified mill analysis and three 7 foot long,
randomly selected samples from the designated LOT of reinforcing steel and three randomly
selected samples from the designated LOT of welded wire reinforcement when requested by
Engineer. Ensure each sample of welded wire reinforcement covers an area of four intersections
of transverse and longitudinal bars. Ensure the transverse wires of each piece of welded wire
reinforcement extend approximately 6 inches to both sides.
450-4.2.3 Prestressing Steel for Pretensioning: Obtain and maintain for each
LOT of material received, the manufacturers assigned LOT number, certified test values for
specified material properties together with a representative load-elongation curve and the
modulus of elasticity value based upon strand nominal area. Provide and support by records
maintained by the strand manufacturer, production tolerances applied in selection of the reported
strand modulus. Verify that documents provided represent the shipment received and meets the
Contract Documents requirements.
Reject all unidentified prestressing steel received at the plant or job site.
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Provide the manufacturers certified mill analysis and three 5 foot long
randomly selected samples from the designated LOT of material when requested by the
Engineer.
450-4.2.4 Strand Chucks and Splice Chucks: Obtain and maintain certified test
results certifying that the material meets the requirements of 450-3.
450-4.2.5 Steel Accessories: Use only steel accessories meeting the requirements
of 450-3.
450-4.2.6 Ducts: Obtain and maintain certified test results certifying that the
material meets the requirements of 450-3.
450-5 Shop Drawings.
Submit shop drawings when the Contract Documents do not contain all the detailed
information necessary to fabricate and erect the pretensioned prestressed concrete product.
Ensure the submitted shop drawings meet the requirements of 5-1 and any additional Contract
Document requirements.
Shop drawings are not required to depict supplemental reinforcing steel used to facilitate
fabrication of products.
In lieu of shop drawings, furnish one copy of the following to the Engineer:
1. A copy of the Framing Plan with product designations for all superstructure
components.
2. Strand detensioning schedule.
3. Tensioning and elongation calculations.
4. Details of supplemental steel that remains as part of the finished product.
5. Drawings, details and spacing for embedded items associated with fall
protection systems used on beams.
6. When proposing to use materials and/or methods that differ from the
requirements of the Contract Documents, submit full plan details and Specifications for the
alternate materials and methods. Ensure the alternate materials and methods meet the following
requirements:
a. The provisions of the Contract Documents.
b. The AASHTO LRFD Bridge Design Specifications, edition with
interims as referenced in Plans.
c. The recommendations of the material manufacturer.
d. Any materials change proposed by the Contractor and approved by the
Engineer.
e. Net compressive stress in the concrete due to prestressing acting alone,
after all losses, is not less than that provided by the stranding shown in the Plans.
f. Ultimate strength of the structure with the proposed changes is not less
than the ultimate strength of the original design.
g. The provisions of the Departments Structures Design Guidelines.
450-6 Forms.
450-6.1 General: Use metal side and bottom forms, unless otherwise specified in the
Contract Documents. For members with special shapes such as corner sheet piles, wood forms
are permitted. Slab units and sheet piles may be cast on concrete surfaces meeting the profile
dimensional tolerances of 450-6.3. Apply release agents in accordance with the manufacturers
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recommendations. Liquid membrane curing compounds may be used to prevent bonding of slab
products and sheet piles to the existing concrete surface, when applied in two or more coating.
Ensure the last application of liquid membrane is applied immediately before placement of the
slab or sheet pile.
For all beam members, use side forms designed to be removed without damaging
the top flange of the beam. Remove the forms horizontally away from the beam by a method that
prevents any contact of the form with the top flange after release of the form. Do not subject the
top flange to any vertical force at any time. Include the form details and method of removal in
the QC Plan.
For all Florida-I Beams, use forms that do not have more than two horizontal
joints.
Use void forms of a type for which service adequacy has been demonstrated,
having sufficient strength to provide stability during handling and placing and to withstand
hydrostatic pressures and other forces imposed upon them during concrete placement. Use form
material that is neutral with respect to the generation of products harmful to the physical and
structural properties of the concrete. Ensure that the presence of the form materials does not
cause any detrimental effect to the concrete or other materials within the member. Positively vent
all voids to the outside of the member. For end headers and inside forms, other materials capable
of resisting the pressure from concrete are permitted.
Use end headers so designed that they can be placed and maintained in correct
position between the side forms. Hold the headers in place with devices capable of being
removed or loosened after the concrete has attained its initial set allowing free form expansion
during curing methods that involve heat. Use end headers with openings conforming to the
prestressing steel pattern to permit passage of the prestressing steel. Locate the openings
accurately within 1/8 inch of planned location of prestressing steel elements.
Construct circular openings for strands a maximum of 1/4 inch larger than the
nominal strand diameter. Construct square or rectangular openings a maximum of 1/4 inch
larger, horizontally and vertically, than the nominal strand diameter. Ensure that all headers are
mortar tight.
450-6.2 Supports: Use forms of sufficient thickness, with adequate external bracing and
stiffeners, which are anchored to withstand the forces due to placement and vibration of concrete.
Ensure that joints in forms are mortar tight. Support bottom forms on concrete pallets with metal
stiffeners, wales or shims. Do not use timber elements between the bottom metal form and
concrete pallets.
450-6.3 Alignment: Make and maintain during their use, forms and centering true to the
shapes and dimensions for the product being produced. Plumb, align, and secure forms for each
product in position before each reuse.
Apply the following tolerances to form alignment and pallets or beds used in
prestressed construction:
1. Horizontal Alignment (horizontal deviation of side forms either side of
a vertical plane within the length of a product) = 1/8 inch,
2. Vertical Alignment (vertical deviation of the bed or pallet from a
horizontal plane within the length of a product) = 1/8 inch,
3. For vertical joints, Offset Between Adjacent Form Sections = 1/8 inch.
4. For horizontal joints, Offset Between Adjacent Form Sections =
1/16 inch.
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450-6.4 End Header Locations:
450-6.4.1 General: Provide a minimum of 18 inches of exposed strands from the
end header to the stressing anchorage and between adjacent ends of all products except 24 inches
square and smaller piles. Provide a minimum of 6 inches of exposed strands between adjacent
ends of 24 inches square and smaller piles.
450-6.4.2 Cold Weather: Provide a distance of at least 5 feet from the end header
to the stressing anchorage, when the ambient temperature is expected to be below 55F between
the time of tensioning and detensioning. When the ambient temperature is expected to be below
55F between the time of tensioning and detensioning and the product's exposed strands between
the stressing anchorages are not protected, maintain a 25 foot minimum free length of stressed
strands, between the end header and the stressing anchorage at each end of a bed line. When cold
weather concrete conditions as specified in 450-10.1 are in effect, protect all exposed strands
between stressing anchorages regardless of length. When the products and strands between
stressing anchorages are protected, provide protection adequate to maintain the ambient
temperature of the air around the strands at or greater than 55F until the products are
detensioned or 24 hours after placing concrete, whichever is less.
450-6.5 Surface Conditions: Use clean, rust free form surfaces against which concrete is
to be cast. Inspect forms and, if necessary, recondition them.
450-6.6 Form Ties: Ensure that no form wires or metal pieces are left within 2 inches of
the surface of the finished concrete.
450-6.7 Corners, Angles and Joints: Ensure corners and angles are chamfered, mitered,
or rounded with a radius of 3/4 inch, unless otherwise specified or shown on the Plans. Provide
smooth mortar tight joints between panel forms within the alignment tolerances.
450-6.8 Form Release Agent: Before placing concrete, treat the facing of all forms with
a form release agent in accordance with the manufacturers requirements. Ensure the application
of form release agents does not contaminate prestressing strands and/or reinforcing steel.
450-7 Protection and Placement of Prestressing Steel.
450-7.1 Protection of Prestressing Steel: Maintain and store prestressing steel above the
ground surface on platforms, skids, or other supports, to prevent contamination from below, and
protect them from mechanical injury. Do not use any packaging or wrapping material that retains
moisture at the bottom of the reel. Clean contaminated prestressing steel before use or otherwise
reject it. Handle prestressing steel carefully to prevent nicks or kinks and do not expose it to
temperatures greater than 200F at any time. Do not use arc welding equipment, including
welding electrode lines, within 2 feet of prestressing steel. Do not perform any welding on forms
that have been set in place after the prestressing steel is placed in the bed. Reject prestressing
steel that has sustained any physical damage at any time.
450-7.2 Placing Prestressing Steel: Use care during placement of prestressing steel to
avoid physical damage and contamination. Reject damaged strands. Do not use prestressing steel
containing nicks, kinks, or former chuck grip marks. Do not use steel showing evidence of scale
formation or which has become pitted. Remove and replace any damaged prestressing steel in
the bed.
450-7.3 Cleanliness of Prestressing Steel: Inspect the prestressing steel for any evidence
of contamination. Use steel that is free of deleterious materials such as grease, oil, wax, dirt,
paint (except that used for marking identification) or other similar contaminants. Remove any
contaminants detected from the steel before proceeding with fabrication activities. Rust on
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prestressing steel that can be removed by light rubbing is acceptable. Streaks or spots which may
remain after rust removal are acceptable if no pitting is present.
450-7.4 Debonded Strands: Extend the tubular debonding material (sheathing) through
the header for debonded prestressing steel. Tie and tape the debonding material at the terminus
located at the inside of the member. Seal openings between strand and sheathing for debonded
strands with 100% silicone sealant within seven calendar days of detensioning. The sealing of
openings between strand and sheathing is not required for beams with ends not be encased in
permanent concrete diaphragms per 450-11.5 and strand protection per 450-11.6. Use sheathing
that is tubular non-slit, high-density plastic with a minimum wall thickness of 0.025 inch, and an
inside diameter exceeding the maximum outside diameter of the pretensioning strand by
0.025 inch to 0.14 inch, which does not react with concrete, coating, or steel and prevents the
intrusion of water or cement paste during concrete placement.
Do not use strands debonded over the full length of a product.
450-8 Tensioning Equipment and Operations.
450-8.1 Equipment: Use a hydraulic jacking system that is adjustable to the automatic
application and sustaining of a predetermined load, together with a pressure transducer or load
cell built into the hydraulic system. Connect such pressure gage or transducer to a dial or digital
readout and printer (manual recording of the tensioning operations is permitted) which will
provide an instantaneous readout and record of the applied load in pounds. Use a jacking system
with the capacity to induce the required load. Base the use of this system on demonstrated
accuracy and repeatability of plus or minus 2% of anticipated load verified through comparison
with loads indicated by an independent load cell.
Calibrate all jacking systems before using and repeat calibration at intervals not
exceeding 12 months. Calibrate and recalibrate in accordance with the equipment manufacturers
recommendations, by qualified calibration agency or by plant personnel under the supervision of
a Specialty Engineer.
Calibrate gages, jacks and pumps as a system in the same manner they are used in
tensioning operations with the cylinder extension in the approximate position that it will be in
actual use at final jacking force. In multi-strand tensioning systems, gages may be calibrated
against a master gage of known accuracy, provided that the other units of the system are
calibrated against the same master gage. Ensure calibrations cover the load ranges that will be
used during production. Verify the accuracy setting of the automatic cutoff valves by running the
desired cutoff load. Ensure a certified calibration curve accompanies each tensioning system.
Load readings can be used directly if the calibration determines a reading is within plus or minus
2% tolerance of anticipated load. Ensure calibration of load cells or proving rings used to
calibrate jacking systems are on compression force testing equipment that has been calibrated in
accordance with ASTM E74.
When any jack or gage appears to be giving erratic results, or if the jack force and
elongation do not compare within specified limits and differences cannot be justified while work
is in progress, recalibrate the equipment. Also verify the accuracy of the equipment after internal
jacking system repairs or when gage and jacking units are switched.
Calibrate or recalibrate in accordance with ASTM E4 using equipment that is
calibrated in accordance with ASTM E74. After calibration or recalibration has been completed,
prepare a certificate and have it signed by the person in responsible charge of the verifications as
outlined in ASTM E4 and ASTM E74. Ensure that the calibration report includes, the serial
number of the equipment that is calibrated, calibration chart in a graph or tabular form,
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calibration date, temperature, full range of readings before and after calibration, National
Institute of Standards and Technologys (NISTs) traceable number of calibration device, method
of calibration, calibration agency, and laboratory or Engineer supervising the calibration.
Verify the accuracy of the jacking and recording system a minimum of once each
week during tensioning operations by either an independently calibrated load cell, or by
comparison with calculated strand elongation. When weekly verification is to be performed by
comparison with calculated strand elongation, check a minimum of ten strands and the difference
in the indicated load and the load determined from the elongation must agree within 5% of the
computed theoretical load values. If the differences are greater than 5%, suspend the tensioning
operation, evaluate the tensioning operation by qualified personnel and correct any deficiencies
before proceeding.
When weekly verification is done by load cell, perform a minimum of five spot
checks to the maximum anticipated load of strands. Use a load cell or proving ring that is
calibrated in accordance with ASTM E74 and the accuracy of the force must be traceable to
NIST. Maintain written records of readings obtained from the force recording system and
verifying standard. Ensure the weekly verification record includes the serial number of the
equipment, verification date, verification agency, NIST traceable number of calibration standard,
and name of the person making the spot checks. The load reading from the recording system
must agree within plus or minus 2% of the anticipated load indicated by the load cell or proving
ring that are calibrated annually.
450-8.2 Operations:
450-8.2.1 General: The tensioning operations consist of the application of the
final force or load which is the force required by the Plans and with the adjustments for abutment
rotation, bed shortening, anchorage header movement, live end seating, dead end seating, splice
chuck seating, friction in the jacking system and any other elements as applicable for the type of
bed and anchorage being used. Also, adjust the force required by the Plans when the temperature
differential between the ambient temperature at time of stressing and the expected concrete
temperature at time of placement is greater than 25F. Increase the force at the rate of 1% for
each 10F increment that the ambient temperature at time of stressing is below the expected
concrete temperature at time of placing. Decrease the force at the rate of 1% for each 10F that
the ambient temperature at time of stressing is above the expected concrete temperature at the
time of placing. Do not allow the stress in the prestressing steel to exceed 80% of the specified
tensile strength of the strand, after seating. During each tensioning operation, for the verification
of the live and dead end seating, check the seating of at least 4 strands or a minimum of 10% of
the total number of strands, whichever is greater. Maintain a printed or manual record of the
tensioning operation.
Compensation for temperature differential and abutment rotation are not
required for self-stressing beds. However, adjust the final load for the effects of bed shortening
due to the load from all the strands.
If the placement of concrete is delayed for more than seven calendar days
after the completion of the stressing operation, check and adjust the final strand load as necessary
before placement of concrete and maintain a printed or manual record of the stressing operation.
Accomplish tensioning by either single strand tensioning or multiple
strand tensioning, and ensure that it is symmetrical about the vertical axis of the product.
Tensioning methods, in general, consist of tensioning to the required loads indicated by the
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jacking system, or tensioning to the required load while monitoring the elongation of the
prestressing steel.
450-8.2.2 Single Straight Strand Tensioning: Apply an initial force of 5% to
25% of the final force to eliminate slack in the system. When single straight strand tensioning is
used, tension the prestressing steel until the required final force is attained. Measure and record
the force and elongation.
450-8.2.3 Multiple Straight Strand Tensioning: Apply the initial uniform
tensioning load to each individual strand before the application of full tensioning load to the
group of strands. The amount of the initial load will be influenced by the length of the casting
bed and the size of strands in the group to be tensioned. The minimum initial tensioning load will
be 5% of the required final load. Increase the magnitude of this load if deemed necessary but do
not allow it to exceed 25% of the required final load. Then tension the strands by multiple strand
tensioning to final load by pulling to elongation and checking against the jack load. Allow the
required elongation to control the tensioning. The actual jack load must agree within 5% of the
required load.
For uniform application of load to strands, the face of anchorage at final
load must be in a plane parallel to its position under initial load. Verify this by measurement of
movement on opposite sides of the anchorage and check its plumb position before and after
application of the final load. During tensioning, allow the anchorage to move without restraint.
450-8.2.4 Draped Strand Tensioning: Tension draped strands by either partial
tensioning and subsequent strains or by final tensioning in draped position.
Partial stressing and subsequent strains applies when the strands are
tensioned through a combination of applied jack loads and strand uplift. To verify the final force,
place a load cell between the tensioning anchorage and anchor chucks at the dead end on at least
two draped strands. Other methods as approved by the Engineer may be used to verify the final
force in the dead end. Bring the partially draped strand to an initial tension using a force in the
range of 5% to 25% of the required final tensioning force. After application of the initial force,
establish reference marks for measuring elongation. Apply a pre-calculated jacking force and
measure elongations on a minimum of four strands. The average measured elongation must agree
within 5% of the theoretical elongation for strand force measured by jack load, or the factors
contributing to the difference must be identified and corrected before proceeding. Allow the load
indicated by the jacking system to control the tensioning for the pre-calculated load. Obtain the
required final force by lifting or depressing the strand simultaneously at all pickup or hold down
points or in an approved sequence as shown on the shop drawings. On each different bed setup,
after lifting or depressing the strands to their final position, check the final force at the dead end
of at least two strands on the bed. If the load is below the required tensioning force by more than
5%, adjust it to the final load.
When the final stressing is performed in the draped position, apply the
tensioning load in two increments with the tendons being held in their draped positions. To
verify the final force, place a load cell between the tensioning anchorage and anchor chucks at
the dead end on at least two draped strands. Other methods as approved by the Engineer may be
used to verify the final force in the dead end. Bring each strand to an initial tension of 5% to 25%
of the final load before the application of the required final load. After application of the initial
load, establish reference marks for measuring elongation. Then tension the strands to final load
and measure the elongation. Allow the load indicated by the jacking system to control the
tensioning for the initial and final loads. The measured elongation must agree within 5% of the
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theoretical elongation for the strand force measured by jack load, or the factors contributing to
the difference must be identified and corrected before proceeding. When the jacking is
performed at one end of the bed, check the applied load on two draped strands at the other end of
the bed. If the load on the end opposite the jacking end is below the required value by more than
5%, adjust the load to the required final load.
450-8.2.5 Wire Breakage: Limit wire breakage to 2% of the total area of the
strands in any product and verify that breakage is not indicative of a more extensive distress
condition, otherwise reject all stranding. Replace individual strands with more than one wire
failure.
450-8.2.6 Position of Prestressing Steel: Position prestressing steel as shown in
the Plans within the tolerances allowed in 450-2.1. Fix the required vertical and horizontal
position of each prestressing strand at the ends of each product and at intervals within each
product not exceeding 30 feet. Use the method of fixing the prestressing steel shown in the QC
Plan. When blocks are to be used for supporting prestressing steel, use those cast from concrete
of the same mix design as used in the prestressed product. Stagger the location of blocks with an
offset of 12 inches or greater and do not stack them.
450-9 Placement of Reinforcing Steel and Other Embedded Materials.
450-9.1 Reinforcing Steel: Tie and/or support in position all reinforcing steel in each
product with other reinforcing steel in a manner that will accurately position the steel throughout
the fabrication process. Use types of ties and methods of tying recommended by the CRSI,
including lacing. Do not tie reinforcing steel to debonded prestressing steel within the limits of
the sheathing material.
Tie or lace beam stirrup bars at a minimum of three points. Tie reinforcing steel,
other than stirrup bars in beam ends, as a minimum, at every other intersection. Either tie or lace
spiral wire in piling at all four corners in the 1 inch pitch area, at the top corners and bottom
center in the 3 inch pitch area, and at the top corners in the center area. Tie the bottom center in
the pile center area as necessary to maintain concrete cover. Bend all tie wires away from the
form surface to provide maximum concrete cover.
When shown on the Plans, weld reinforcing steel in accordance with the
requirements of AWS Structural Welding Code D 1.4. Do not weld in the prestressing bed.
450-9.2 Other Embedded Materials:
450-9.2.1 Inserts and Lifting Devices:
450-9.2.1.1 Placement: Locate inserts and lifting devices in accordance
with the tolerances listed in 450-2.1.
450-9.2.1.2 Corrosion Protection: Provide corrosion protection for
embedded metal lifting devices that would remain exposed after construction.
After lifting operations using recessed metal lifting devices are
complete, backfill block-outs with a Type F epoxy compound meeting the requirements of
Section 926 for a minimum distance of 2 inches beyond the perimeter of the metal device as
measured parallel to the exposed concrete surface. If the block-out extends less than 2 inches
beyond the perimeter of the metal device, extend the epoxy compound beyond the block-out
along the concrete surface. If Type 304 or 316 stainless steel lifting devices are used, non-shrink
grout meeting the requirements of Section 934 may be used to backfill the block-out within its
limits.
After lifting operations using flush or protruding metal lifting
devices are complete, cut the lifting devices back to a minimum depth of 1 inch below the
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concrete surface and patch with a Type F epoxy compound meeting the requirements of
Section 926. For all square prestressed piling, concrete sheet piling and concrete poles, cut and
patch lifting devices before transporting from the casting yard.
450-9.2.2 Placement of Bearing Assemblies: Set bearing assemblies designed to
transmit reaction forces to the concrete in the position shown in the Plans. Place bearing plate
assemblies or shoes which are to be cast in a product within appropriate tolerances as provided in
450-2.1. Check the assemblies for position after stripping from the forms.
450-10 Concrete Operations.
450-10.1 Temperature Restrictions:
450-10.1.1 Cold Weather Concreting: When the temperature of the surrounding
air is expected to be below 40F within 24 hours after placing concrete, the temperature of the
plastic concrete as placed must be 55F or greater. Maintain the temperature of the concrete after
placement at or above 55F for the first 24 hours or until detensioning, whichever occurs first.
For piles and other members with a minimum section dimension of 12 inches or more, maintain
the temperature of the concrete after placement at or above 50F for the first 24 hours or until
detensioning, whichever occurs first. Make arrangements for heating, covering, insulating or
housing the concrete work in advance of placement and maintain the required temperature
without injury due to concentration of heat. Do not use direct fired heaters during the first
24 hours after concrete placement, unless actions are taken to prevent exposure of the concrete to
exhaust gases which contain carbon dioxide. Continuously monitor the temperature of the
concrete or the ambient air around the product until the product is detensioned. Monitor by the
use of thermocouples located in the product cross-section or temperature recording devices
located under the enclosure. Provide one thermocouple or temperature recording device for each
200 feet of bed length or part thereof. Locate the thermocouples within the products crosssection as shown in the QC Plan or as approved by the Engineer. Record the monitored
temperatures determined by each thermocouple. Review the recorded temperatures to ensure that
they are within the specified limits. Initially calibrate recording devices or thermocouples and
recalibrate them at least annually in accordance with the manufacturers recommendations.
450-10.1.2 Hot Weather Concreting: Meet the requirements of Section 346 for
temperature requirements and special measures for mixing concrete in hot weather.
Apply fog mist spray of water to prestressing strands, reinforcing steel and steel
forms just before placing the concrete when the hot weather concreting special measures are in
effect and the temperature of steel forms or reinforcing steel is greater than 120F.
450-10.2 Protection of Concrete from Weather: Have protection materials available
before the concrete placement begins to cover the products in the event of rain during the
placement of concrete. Protection materials may be tarps, curing blankets, or other impervious
material that will not puncture when placed over protruding reinforcing steel and/or form
elements. Include the method and materials for protection in the QC Plan.
450-10.3 Concrete Placement:
450-10.3.1 General: Check forms, reinforcing steel, prestressing steel, vent pipes,
anchorages and other embedded items for compliance with the Contract Documents before
placing concrete. Place concrete in accordance with 400-7, except as modified herein.
For concrete operations conducted at night, provide enough lighting to
allow visual inspection of the interior of the forms during the complete concrete placement
operation.
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Convey concrete by the use of buckets, conveyors, pumps, troughs, or
other equipment specifically designed for concrete conveyance, provided the placement method
consistently produces quality concrete with no segregation or separation of the mix. Locate the
concrete conveyance equipment within 12 inches of the top of the forms or surface of the
concrete to minimize the free fall of the concrete.
Multiple placements may be used within a bedline, provided compliance
with 450-11.1 is maintained.
450-10.3.2 Requirements for Successive Layers: Except for self-consolidating
(self-compacting) concrete, place concrete as described in 450-10.3.2.1 through 450-10.3.2.5 as
shown in the QC Plan or as approved in writing by the Engineer.
In any progressive concrete placement operation, do not allow the time
between successive placements onto previously placed concrete to exceed 20 minutes, unless the
previously placed concrete has not yet stiffened, as evidenced by the continued effective use of
vibration.
450-10.3.2.1 AASHTO Type II, Florida-I Beam 36and Double-T
Beams, Piling and Precast Slab Units (Except Voided Piling and Slabs): Place concrete in
one or more layers or lifts. If more than one layer is used for Double-T Beams, end the first layer
such that the top of the concrete is slightly below the bottom of the flange.
450-10.3.2.2 AASHTO Type III, Type IV and Florida-I Beams 45 and
54 and Voided Units (Slabs and Piling): Place concrete in a minimum of two horizontal layers.
The thickness of the first layer will be such that the top of the concrete is just above the top of
the bottom flange. In voided units, end the first layer slightly above the middle height of the
void. Fill the form by the last layer.
450-10.3.2.3 All Beams 63 Inches or Deeper: Place concrete in a
minimum of three horizontal layers. The thickness of the first layer will be such that the top of
the concrete is slightly above the top of the bottom flange. The thickness of the second layer will
be such that the top of the concrete is slightly above the bottom of the top flange. Fill the beam
forms by the last layer.
450-10.3.2.4 Pretensioned I Beams Containing Longitudinal Posttensioning Ducts: Place concrete in one continuous lift beginning in the end block zone and
progressing to the other end. Do not allow the progression of the concrete placement to proceed
until previously placed concrete has been properly consolidated, and the rate of advancement
equals the ability to fill the forms. In progression of the placement, deposit concrete within the
forms on the surface of previously placed concrete.
450-10.3.2.5 Florida U Beams: Place the concrete in Florida U Beams in
a minimum of two horizontal layers. The thickness of the first layer shall be such that the top of
the concrete is above the top of the bottom flange.
450-10.4 Vibration of Concrete: Except for self-consolidating concrete, consolidate
concrete by internal or external vibration, or combination of these methods. Design external form
vibrators for the specific use. Design forms used in conjunction with external vibration and build
them to effectively transmit vibration to the concrete mass. Mount and operate form vibrators in
compliance with the vibrator manufacturers written recommendations, a copy of which must be
on file at the prestressed concrete plant. Secure vibrators to the form mounts by positive locking
devices so that maximum vibration is transmitted into the form. Modify or replace external form
vibrator systems that are demonstrated to be ineffective. Operate vibrators at each mount location
for the time necessary for complete concrete consolidation. Do not allow progressive points of
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vibration to exceed twice the visually effective radius of vibration. Keep forms equipped with
external vibrators clean, and free of any buildup of hardened concrete.
Ensure internal vibrators are available before concrete placement is started. Use
an internal vibrator with a head of such size that proper vibration of the concrete will be secured
without causing movement of the prestressing steel or reinforcing steel. The vibrating frequency
range must be 8,000 to 15,000 impulses per minute. Have at least one standby vibrator available
on-site. Insert the vibrator in the concrete at points spaced to ensure uniform vibration of the
entire mass of the concrete. Do not allow points of insertions to be further apart than the radius
over which the vibrator is visibly effective. Allow the vibrator to sink into the concrete by its
own weight and allow it to penetrate into the underlying layers sufficiently so that the two layers
are thoroughly consolidated together. After the concrete is thoroughly consolidated, slowly
withdraw the vibrator to avoid formation of holes.
Revise the existing placement and consolidation procedure to improve the
consolidation of the concrete, if the existing placement and consolidation procedure have
produced unacceptable surface defects such as honeycombing, aggregate or mortar pockets, and
excessive air bubbles.
450-10.5 Finishing:
450-10.5.1 General: When concrete incorporating silica fume is used, screed and
finish with a continuous water fog mist maintained above the concrete. Do not apply the fog
directly toward the concrete. The Contractor may apply a monomolecular finishing aid approved
by the Engineer in accordance with the manufacturers recommendation.
450-10.5.2 Beams: Rough float the top surface of the beam and then scrub it
transversely with a coarse brush or metal tine to produce a roughened surface for bonding.
Unless otherwise specified, apply a Class 3 surface finish to the external surfaces of prestressed
beams in accordance with Section 400. Remove mortar leakage and stains to produce beams with
a uniform appearance.
450-10.5.3 Piling: Unless a Class 5 Applied Finish Coating is otherwise
specified, apply a general surface finish as specified in Section 400 to pile surfaces, except that
pointing with mortar will not be required for cosmetic chips and bug holes with a depth less than
1/4 inch and a diameter of less than 3/4 inch. All other general surface finish requirements will
apply, including the pointing of material form tie cavities with mortar. Surface finish deficiencies
that meet the definition of noncomplying prestressed products must be corrected in accordance
with 450-12. Miter or round the top corners similar to the corner radius of the pile forms.
Surfaces exposed during casting must have a steel trowel finish.
450-10.5.4 Slabs and Double-T Beams: When the Plans show the top surface of
prestress slab or Double-T Beams units to be the riding surface, apply a Class 4 floor finish in
accordance with Section 400. When the Plans show the surface to be overlaid with asphalt or
concrete, rough float the top surface and then scrub it transversely with a coarse brush to remove
all laitance and to produce a roughened surface for bonding. Unless otherwise specified, apply a
Class 3 surface finish to other exposed surfaces in accordance with Section 400.
450-10.6 Curing: Cure prestressed concrete as required for a minimum duration of
72 hours. If forms are loosened upon setting of concrete and/or removed before the 72 hour
curing period is complete, expand the curing to cover the newly exposed surfaces by either
coating with curing compound or extending the continuous moist cure area. Maintain concrete
surface moisture at all times until curing is begun. If a water sheen is not present, apply
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supplemental moisture by fog misting or prevent water sheen loss on flat work by use of an
evaporation retarder.
After the finishing operations have been completed and as soon as the concrete
has hardened sufficiently to permit the application of curing material without marring the
exposed surface, cover the exposed surfaces of all prestressed concrete products by one of the
following procedures or other alternate curing methods. Alternate curing methods and details
proposed by the Contractor must be included in the QC Plan or otherwise approved by the
Engineer. Base alternate curing methods upon a demonstrated ability to retain surface moisture
of the concrete and to control curing temperatures within acceptable limits. Discontinue use of
any alternate curing method other than those included herein upon any indication of
noncompliance with this Specification.
450-10.6.1 Continuous Moisture: Place burlap on the surface and keep it
continuously saturated for the curing period by means of soil soakers, leaking pipes, or automatic
sprinklers. Do not apply moisture manually. If side forms are removed during the curing period,
extend the burlap to completely shield the sides of the product. Water flow may be metered to
cycle repetitively for five minutes on and five minutes off during the 72 hour curing period.
When it is not practical to apply moisture or curing compound inside the voided piles, cover their
ends with wet burlap to prevent moisture loss.
450-10.6.2 Membrane Curing Compound: Apply a white Type 2 curing
compound to all surfaces in a single-coat, continuous operation, at a uniform coverage as
recommended by the manufacturer but not less than 1 gallon per 150 square feet. Apply the
curing compound on the concrete surfaces that are still damp but no free standing water. Allow
surfaces covered by the membrane curing compound to remain undisturbed for the curing period.
Recoat any cracks, checks or other defects in the membrane seal which are detected during the
curing period within one hour. If side forms are loosened during the curing period, remove them
at that time and immediately coat the formed surfaces with a clear membrane curing compound
and maintain the surface seal for the remainder of the curing period. Bottom surfaces must be
similarly coated after removal of the forms. Remove membrane curing compound to applied
surfaces of concrete products to which other concrete is to be bonded by sandblasting or waterblasting until all traces of membrane curing compound are removed.
When the curing compound is applied by spraying, use a compressor
driven sprayer of sufficient size to provide uniform spray at the nozzle. Keep all nozzles clean to
ensure a uniform application of compound. For compressor driven sprayers, provide a calibrated
reservoir which will allow the quantity of applied materials to be accurately determined.
Maintain standby equipment in case of mechanical failure. If a mechanical failure occurs, a hand
held pump-up sprayer may be used to apply curing compound to the remainder of the products
cast in the days production. Suspend additional concrete placements until the mechanical
sprayer is functioning properly.
450-10.6.3 Curing Blankets: Curing blankets may be used for curing the top
surfaces of products. Do not use curing blankets which have been torn or punctured. Securely
fasten edges to provide as tight a seal as practical. Allow curing blankets to remain in place for
the curing period. Should the system fail to maintain a moist condition on the concrete surface,
discontinue the use of curing blankets and take immediate corrective action to prevent further
loss of concrete moisture.
450-10.7 Accelerated Curing:
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450-10.7.1 General: Use low-pressure steam curing, radiant heat curing or
continuous moisture and heat curing. If accelerated curing is completed before the curing period
has elapsed, continue curing for the remaining part of the curing period in accordance with one
of the curing methods above.
If accelerated curing is used, furnish and use temperature recording
devices that will provide accurate, continuous, and permanent records of the time and
temperature relationship of the enclosure and concrete throughout the entire curing period. Place
the temperature recording sensors at a minimum of two locations, spaced approximately at or
near the third point of bed length, to measure the temperatures of the enclosure and concrete.
Initially calibrate recording thermometers and recalibrate them at least annually in accordance
with manufacturers recommendations. Place the sensors at the center of gravity of the bottom
flanges for beams. Place the sensors at the center of gravity of the cross sections normal to pile
length for solid piles, and at the midpoint of the wall thickness of the pile for voided piles.
When the ambient air temperature is equal to or higher than 50F, start the
accelerated curing by supplying or retaining moisture and the application of the heat, following
the initial set period of concrete. Determine the initial set time in accordance with ASTM C403.
During the application of heat, do not allow the temperature rise in the concrete product to
exceed 36F per hour. The maximum curing temperature of the enclosure or concrete must not
exceed 150F. Maintain the maximum curing temperature uniform throughout the enclosure,
with variation of not more than 20F from the maximum peak temperature until concrete reaches
the required release strength. Allow the concrete element to cool gradually at the maximum
cooling rate of 50F per hour and continue the cooling at this rate until the concrete temperature
is 40F or less above the ambient temperature outside the curing enclosure.
When the ambient air temperature is below 50F cure the concrete in two
stages. Start the accelerated curing of the first stage during the preset period by applying heat to
increase the temperature of concrete at the maximum rate of 10F per hour. The total temperature
gain of concrete during the initial set period cannot exceed 40F higher than the placement
temperature, or 104F, whichever is less. Upon obtaining the initial set, continue curing as stated
above for ambient temperature of 50F or higher. To prevent moisture loss on exposed surfaces
during the preheating period, cover products as soon as possible after casting or keep the exposed
surfaces wet by fog spray or wet blankets. Use enclosures for heat curing that allow free
circulation of heat about the product and that are constructed to contain the heat with a minimum
moisture loss. The use of tarpaulins or similar flexible covers may be used provided they are kept
in good repair and secured in such a manner to prevent the loss of heat and moisture. Use
enclosures that cover the entire bed from stressing abutment to stressing abutment, including all
exposed stranding.
450-10.7.2 Low-Pressure Steam: The steam must be in a saturated condition. Do
not allow steam jets to impinge directly on the concrete, test cylinders, or forms. Cover control
cylinders to prevent moisture loss and place them in a location where the temperature is
representative of the average temperature of the enclosure.
450-10.7.3 Curing with Radiant Heat: Apply radiant heat by means of pipe
circulating steam, hot oil or hot water, or by electric heating elements. To prevent moisture loss
during curing, keep the exposed surfaces wet by fog spray or wet blankets.
450-10.7.4 Continuous Moisture and Heat: This method consists of heating the
casting beds in combination with the continuous moisture method described above. Do not allow
the heating elements to come in direct contact with the concrete or the forms. The initial
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covering of burlap and the continuous application of moisture will be as described in 450-10.6.
An auxiliary cover in addition to the burlap for retention of the heat will be required over the
entire casting bed. Support this cover a sufficient distance above the product being cured to allow
circulation of the heat.
450-10.8 Curing Requirements for Silica Fume Concrete: Use either a 72 hour
continuous moisture curing or a (12-24) hour low-pressure steam curing in accordance with
450-10.7. Upon completion of the low-pressure steam curing, continue curing for the remaining
part of the 72 hour curing period by application of the curing compound, continuous moisture
curing, or use of the curing blankets.
If 72 hour continuous moisture is used, begin curing silica fume concrete
immediately after the finishing operation is complete and keep a film of water on the surface by
fogging until the curing blankets are in place. No substitution of alternative methods nor
reduction in the time period is allowed. After completion of the 72 hour curing period, apply a
membrane curing compound to all concrete surfaces. Apply curing compound according to
450-10.6.
450-10.9 Form Removal: Do not remove forms sooner than six hours after casting and
not until the concrete strength is sufficient to avoid structural damage. For AASHTO Type V,
Type VI, Florida-I Beams, and Bulb-T Beams, do not remove the forms supporting the top
flange concrete sooner than 12 hours after casting unless the release strength has been reached.
450-11 Detensioning.
450-11.1 General: The required concrete strength at which the prestressing force may be
transferred to the concrete in a product will be a minimum of 4,000 psi, unless specified
otherwise in the Plans. Verify the release strength by compressive strength cylinder tests or other
approved means, no later than 24 hours after casting and every 24 hours thereafter until release
strength is developed. In lieu of every 24 hour testing, the contractor is permitted to estimate the
strength development of concrete by the maturity method in accordance with ASTM C1074, the
pulse velocity method in accordance with ASTM C597, or any other nondestructive test method
acceptable to the Engineer, until the time of the detensioning. Before detensioning, verify the
concrete release strength by testing the compressive strength test cylinders. Make a minimum of
two compressive strength release test cylinders daily for each individual mix or for each LOT, or
fraction thereof, of given concrete mix design where the daily consumption exceeds this volume
or when non-continuous batching or dissimilar curing is used. The release strength test,
representing the LOT, is the average compressive strength of two test cylinders, which are cured
under conditions similar to the product or match-cured test specimens, which are match cured
until the time of release. For products cured using accelerated curing, release the prestressing
force immediately after terminating the accelerated curing process. After the detensioning
operation is completed, continue to 72 hour curing period using one of the methods listed in 45010.6. For products cured using methods other than accelerated curing, release the prestressing
force within a detensioning time limit, not to exceed five calendar days after the verification of
release strength by compressive strength cylinder test or other approved strength gain monitoring
system. For all products in a casting line, use the same test method for determining their release
strengths. Ensure the detensioning time limit is included in the Plants QC Plan. Cure concrete
cylinders used for detensioning strength tests in the same manner and location as the prestressed
concrete products.
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For I-girders, where side forms are loosened upon setting of concrete or removed before
the 72 hour curing period is complete, the top flange dormant strands may be released after the
concrete reaches a compressive strength of 2,000 psi.
450-11.2 Method of Stress Transfer: In all detensioning operations, keep the
prestressing forces nearly symmetrical about the vertical axis of the product and apply them in a
manner that will minimize sudden shock or loading. Remove or loosen forms, ties, inserts, or
other devices that would restrict longitudinal movement of the products along the bed. Release
hold-downs for products with draped strands in a sequence as shown in the Plans or QC Plan.
Cut dormant strands (partially tensioned strands) in top of beams before releasing any fully
tensioned strands. Release fully bonded strands next, beginning with the lowest row and moving
upwards, followed progressively by strands having the minimum length of tubular sheathing
through to those strands having the maximum length of tubular sheathing. The Contractor may
propose alternative detensioning patterns to suit the plants particular operation. Specify the
method of the stress transfer to be used either in the QC Plan or the construction submittal.
Transfer prestressing forces to the concrete by either single strand release or
multiple strand release.
450-11.3 Single Strand Detensioning: Detension the strand by using a low-oxygen
flame in accordance with a pattern and schedule provided in the approved shop drawings, or QC
Plan, or described in 450-5. Heat with a low-oxygen flame played along the strand for a
minimum of 5 inches. Heat strands in such a manner that the failure of the first wire in each
strand will occur after the torch has been applied for a minimum of five seconds. Release strands
in all prestressed products simultaneously and symmetrically about the vertical axis at both ends
of the bed and at all intermediate points between products to minimize sliding of products. As an
alternate, strands in piles, sheet piles, slabs and AASHTO Type II girders may be released
simultaneously and symmetrically about the vertical axis at both ends of the bed until all the
strands are released, then proceeding in order to intermediate points nearest the bed ends, or to
the single remaining point at the center and release strands at these points in the same manner
until all strands are released.
450-11.4 Multiple Strand Detensioning: In this method, detension all strands
simultaneously by hydraulic dejacking. The total force is taken from the header by the jack, then
released gradually. Do not allow the overstress required to loosen the anchoring devices at the
header to exceed the force in the strand by 5%. After detensioning, strands at all points may be
cut progressively from one end of the bed to the other using equipment and methods described
above.
450-11.5 Trimming Strands and Bars: Upon completion of the detensioning operation,
cut the exposed strands to required length, using an oxygen flame or mechanical cutting device.
On piles and other products requiring flush cutting of strands and bars, use only mechanical
cutting, unless specifications require strand to be burned or ground below the pile surface. Do
not use electric arc welders. Unless otherwise specified, allow all strands to protrude 2.5 inches
plus or minus 0.5 inch beyond the end of the product, except cut strands for piling back to be
flush with or below the concrete surface. For beams with ends not to be encased in permanent
concrete diaphragms, cut strands a minimum of 1/8 inch below the concrete surface.
450-11.6 Protecting Ends of Strands: For beams with ends not to be encased in
permanent concrete diaphragms, epoxy coat the exposed beam ends, including clipped and
chamfered surfaces with two layers of Type F-1 epoxy compound within seven calendar days of
detensioning and prior to development of any corrosion at the ends of strands. Prepare the
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concrete surface and apply epoxy in accordance with the manufacturers recommendations. The
finish thickness of the epoxy coating must be a minimum of 1/16 inch, forming a vertical flat
plane at the end of the beam without deviations for localized depressions resulting from
recessing of the strands or other defects.
450-12 Noncomplying Prestressed Products.
450-12.1 General: When a precast prestressed concrete product does not comply with
the requirements of this Section or is damaged, use the following provisions for evaluating and
disposing of deficiencies. However, when precast prestressed concrete products have been
installed, the disposition of concrete cracks shall be in accordance with 400-21. Apply these
provisions in all cases that clearly fall under the circumstances described. Consider situations not
covered by these specific circumstances on their individual merits. Consider and apply the
following where practical.
The QC Manager, or QC inspectors under direction of the QC Manager, will
examine all deficiencies within the time limit specified in 450-2.1 and 450-2.3, to determine the
applicable provisions and requirements of this Article and which course of action is appropriate.
If the QC Manager determines that a deficiency is a cosmetic or minor defect, appropriate repairs
may be executed immediately in accordance with 450-13. Perform and complete cosmetic and
minor defect repairs to the satisfaction of the QC Manager. If the QC Manager determines that a
deficiency is a major deficiency, requiring an engineering evaluation, submit a repair proposal to
the Engineer in accordance with 450-14. Make all repairs that require a repair proposal under the
observation of and to the satisfaction of the QC Manager.
The disposition of deficiencies and repair methods provided herein must at no
time, and under no circumstances, be used as an excuse for or applied in such a manner so as to
relieve the Contractor of his responsibility for QC. The number and type of deficiencies
evaluated under this Specification will, however, be used in evaluating the Contractors QC.
The Engineer will require a credit on any product with deficiencies that require
engineering evaluation and are attributable to the Contractor, accepted for use in the structure.
Bear the costs of repairs and any actions taken to rectify deficiencies at no expense to the
Department.
450-12.2 Surface Deficiencies: Surface deficiencies are defined below. Regardless of the
types of deficiencies, when the total surface area of all deficiencies within a single product
exceeds 2.0 % of the products length times its depth, the product will require engineering
evaluation and disposition in accordance with 450-14. Surface deficiencies include spalls, chips,
bug holes, surface porosities, and honeycombs.
450-12.2.1 Bug Hole: A bug hole is a void caused by air that is entrapped against
the form and that has an area up to 3.0 square inches and a depth up to 1.5 inches. Treat any bug
hole with a dimension exceeding either of these dimensions as a honeycomb. The Engineer will
not require the Contractor to repair any bug hole with a depth less than 0.25 inch and less than
0.75 inch in diameter, unless otherwise indicated in the Plans or Specifications. Consider all
other bug holes cosmetic and repair them in accordance with 450-13.2.
450-12.2.2 Spall: A spall is a depression resulting when a fragment is detached
from a larger mass by impact, action of weather, by pressure or by expansion within the larger
mass.
A cosmetic spall is a circular or oval depression not greater than 1.0 inch
in depth nor greater than 3.0 square inches in area, and must be repaired in accordance with
450-13.2.
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With the exception of spalls in the bearing areas and edge of the top
flange, a minor spall is defined as a spall not larger than 2.0 square feet and no deeper than one
inch plus the sum of the concrete cover and the diameter of the bar in the first layer of
reinforcing. Repair minor spalls in accordance with 450-13.4.
Spalls located at the edges of the top flange are considered minor spalls as
follows:
1. A spall on one edge of the top flange, without a coincident spall on the
other edge of the top flange, is considered a minor spall if the total longitudinal length of the
defect does not exceed 10 feet and any lateral dimensions of the spall measured perpendicular to
the longitudinal axis of the beam are not greater than 25% of the width of the top flange.
2. Coincident spalls on opposite edges of the top flange are considered
minor spalls if the total length of the defects within both spalls does not exceed 10 feet and any
lateral dimensions of the spalls at a given location measured perpendicular to the longitudinal
axis of the beam are not greater than 25% of the width of the top flange.
Spalls located in the bearing area that extend back into the concrete within
the limits above the bearing plate are considered major spalls.
A major spall is a spall that any of its dimensions exceeds the dimensions
that are described for minor spalls. A major spall requires engineering evaluation and disposition
in accordance with 450-14.
450-12.2.3 Chip: A chip is the local breaking of the corners or edges of the
concrete with the resulting void containing angular surfaces.
Cosmetic chips are chips where the sum of the two lateral dimensions
perpendicular to the length does not exceed 2.0 inches. Regardless of length, it is not necessary
to repair cosmetic chips except for visually exposed reinforcing steel, prestressing strand, insert,
or weldments surfaces, which may require repair in accordance with 450-13.5.
Minor chips are chips where the sum of the two lateral dimensions
perpendicular to the length exceeds 2.0 inches, but does not exceed 4.0 inches, and with a length
of no more than 12.0 inches. Repair minor chips in accordance with 450-13.5.
Major chips are any chips larger than minor chips. Major chips require
engineering evaluation and disposition in accordance with 450-14.
450-12.2.4 Surface Porosity: Surface porosity is considered a minor defect and is
the localized porosity of a formed surface due to medium scaling. Medium scaling is defined as
the loss of surface mortar up to 3/8 inch in depth and exposure of concrete aggregate. Repair
surface porosity in accordance with 450-13.3.
450-12.2.5 Honeycombing: Honeycombing is voids in the concrete, loss of fines
or other material from between the aggregate particles, the inclusion of air pockets between
aggregate particles, or larger volumes of lost material. Remove honeycombing in its entirety to
sound concrete before establishing the classification of the defect.
Minor honeycombing is a void no deeper than concrete cover and no
larger than 2.0 square feet in area that results after the removal of unsound material. Repair
minor honeycombing in accordance with 450-13.6.
Major honeycombing is a void deeper than concrete cover regardless of
the surface area, or shallower but with a surface area greater than 2.0 square feet that results after
the removal of unsound material. Major honeycombing requires engineering evaluation and
disposition in accordance with 450-14.
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450-12.3 Formed Surface Misshaping: Formed surface misshaping is the visual and
measurable deficiency or excess of material from the specified tolerance on any surface of a
product.
450-12.3.1 Pile Ends: Make square pile ends which are outside this Sections
tolerances by grinding in accordance with 450-13.7, or any other means of removal as approved
by the Engineer. Reshape the chamfer if more than 0.25 inch from the cast pile end is removed
and such removal affects the chamfer dimension.
450-12.3.2 Pile Chamfers: Reshape chamfers outside of this Sections tolerances
to within the tolerances in accordance with 450-13.7.
450-12.3.3 Other Surfaces: Any deficiency exceeding the plan dimensions for
size, length, squareness, designated skew, plumbness, and the like by up to twice the specified
plus (+) tolerance may be corrected by grinding to within the allowable tolerance in accordance
with 450-13.7. Any deficiency exceeding the specified minus (-) tolerance or twice the specified
plus (+) tolerance requires an engineering evaluation and disposition in accordance with 450-14.
450-12.4 Bearing Areas: Consider the bearing area to extend from the end of the product
to 3 inches beyond the edge of the bearing contact area for the full product width.
Do not allow the bearing plate or bearing area plane of precast prestressed
concrete beam and slab units to deviate from a true plane by more than 1/8 inch when tested in
all directions with a steel straightedge. In the event that a 100% true plane is not achieved, the
Engineer will accept a surface having not less than 80% of its area in a true plane provided the
deviations are evenly distributed. Remove minor convex projections by grinding with an
abrasive stone. The Engineer will accept minor depressions, provided that they amount to not
more than 20% of the bearing area, are evenly distributed over the entire bearing area, and are
not deeper than 1/8 inch.
450-12.5 Cracks: A crack is the separation of a product or portion thereof which may
appear before or after detensioning and may or may not cause separation throughout the product
thickness or depth. Identify cracks by the classifications and locations described below and
subject them to the disposition required by the identified crack. If the total surface length of all
cracks within a single product, regardless of width, located between the end zones exceeds onequarter of the products length, an engineering evaluation and disposition in accordance with
450-14 is required. Establish crack sizes subsequent to release of all pretensioning forces.
The Engineer will reject any pile that is cracked to the point that a transverse or
longitudinal crack extends through the pile, shows failure of the concrete as indicated by spalling
of concrete on the main body of the pile adjacent to the crack, or which in the opinion of the
Engineer will not withstand driving stresses. Occasional hairline surface cracking caused by
shrinkage or tensile stress in the concrete from handling will not be cause for rejection.
450-12.5.1 Classification and Treatment of Cracks: Regardless of cause and
for the purposes of Section 450, cracks in precast prestressed components, excluding piling, will
be identified according to their surface appearance in accordance with the following
classifications:
Cosmetic cracks are any cracks which are less than 0.006 inch wide and
are located in non-critical locations on the product. Based on the environmental classification of
the site where the product will be located, treat cosmetic cracks as follows:
(1) Slightly or moderately aggressive environment: Do not treat
cracks.
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(2) Extremely aggressive environment: After detensioning, apply
penetrant sealer in accordance with Section 413.
Minor cracks are any cracks which are between 0.006 and 0.012 inch
wide, inclusive, and are located in non-critical locations on products. Based on the environmental
classification of the site where the product will be located and the final elevation of the product
on the site, treat minor cracks as follows:
(1) Slightly aggressive environment: Do not treat the cracks.
(2) Moderately aggressive environment:
(a) For products that will be located at an elevation of more
than 12 feet above the existing ground level or above mean high water elevation: Do not treat
cracks.
(b) For products that will be located at an elevation within
12 feet above the existing ground level or above mean high water elevation: Apply a penetrant
sealer on the cracks after detensioning in accordance with Section 413.
(3) Extremely aggressive environment:
a. For products that will be located at an elevation of more
than 12 feet above the existing ground level or above mean high water elevation: Apply a
penetrant sealer on the cracks after detensioning in accordance with Section 413.
b. For products that will be located at an elevation within
12 feet above the existing ground level or above mean high water elevation: Inject epoxy into the
cracks after detensioning in accordance with Section 411.
Major cracks are any cracks of any width which are located in critical
locations on products or cracks in non-critical locations of the product that are greater than
0.012 inch wide. Major cracks require an engineering evaluation, including crack depth
measurement and disposition, in accordance with 450-14.
Cracks in the Riding Surface: Repair cracks in the top surface of
components which will become the riding surface (with no overlays), once in service, regardless
of the environmental classification as follows:
(1) Epoxy inject cracks wider than 0.006 inch in accordance with
Section 411, unless the Engineer approves the sealing of cracks with high molecular weight
methacrylate in accordance with Section 413.
(2) Seal cracks that are 0.006 inch wide or less by applying a
penetrant sealer in accordance with Section 413.
450-12.5.2 Locations of Cracks: Regardless of cause and for the purposes of this
Specification, cracks will be identified as occurring in either critical or non-critical locations of
the product in accordance with the following criteria and conditions:
Critical locations of cracks are any locations in which a crack would tend
to open under stresses occurring at any time during the service life of the structure, or which may
reduce the ultimate capacity or fatigue life of the product. Specifically, critical locations of
cracks are any locations in a product not defined and not included in 450-12.5.3 as non-critical.
Cracks in critical locations require engineering evaluation and disposition in accordance with
450-14.
Non-critical locations of cracks are defined by the position within a
products length, the position within a products depth, and the orientation of the crack.
450-12.5.3 Non-critical Locations of Cracks by Product Type:
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450-12.5.3.1 Piles: Surface cracks in any direction and of a length not
exceeding twice the width of the pile.
450-12.5.3.2 All Types of Simple Span Pretensioned Concrete Beams:
End zones (within a distance of three times the depth of the
product from the end):
(a) Horizontal or diagonal cracks at either or both ends in
the top flange and web of the product, not in the plane of nor intersecting any row of prestressing
strands, and extending from the end of the product for a length not to exceed the products depth.
(b) Vertical cracks extending through the top flange not to
exceed one-half of the products depth after detensioning.
Mid-span region (between end zones): Vertical cracks extending
through the top flange and web of the product.
Any Location: Horizontal crack at the interface of the web and top
flange which is not longer than the products depth.
Intermediate diaphragms of Florida U-Beams: cracks at any
location.
450-12.5.3.3 Simple Span Double-T Beams:
End zones (within a distance of twice the depth of the product from
the end): One horizontal crack at either or both ends and in the top flange of the product, not in
the plane of nor intersecting any row of prestressing strands, and extending from the end of the
product for a length not to exceed half the products depth.
Mid-span Region (between end zones): Vertical cracks extending
through the top flange and not exceeding half the web depth of the product.
Any Location: Horizontal crack at the interface of the web and top
flange which is not longer than the products depth.
450-12.5.3.4 Pretensioned I-Beams Containing Longitudinal Posttensioning Ducts:
End zones (within a distance of twice the depth of the beam from
the end): Vertical cracks in the bottom half of the beam within an end zone with no posttensioning anchorages and where the post-tensioning ducts are located in the top of the beam at
the location of a permanent substructure support. Horizontal or diagonal cracks at either or both
ends in the top flange and web of the product where no post-tensioning anchorage zone is
present.
Mid-span Region (between quarter points): Vertical cracks in the
web and top flange of the beam provided the beam is to be supported at each end in its final
position in the structure.
Any Location: Horizontal cracks not longer than the beams depth
and only at the interface of the web and top flange provided the beam is to be supported at each
end in its final position in the structure.
450-12.5.3.5 Post-Tensioned Beams for Drop-In Spans:
Pier Sections: Horizontal or diagonal cracks at either or both ends
in the top flange and web of the product.
Drop-In Sections: Same as simple span pretensioned concrete
beams.
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End Sections: At end of beam with post-tensioning anchorages:
same as Pretensioned I-Beams Containing Longitudinal Post-tensioning Ducts. At end of beam
adjacent to pier sections: same as for simple span pretensioned concrete beams.
450-12.5.3.6 Simple Span Prestressed Slab Units:
End Zones (within a distance of twice the depth of the product
from the end): One horizontal crack at either or both ends in the top half of the product, which is
not in the plane of nor intersecting any row of prestressing strands, and extending from the end
of the product for a length not to exceed half the products depth.
Any Location (after detensioning): Vertical cracks in the top half
of the products depth.
450-13 Repair Methods and Materials.
450-13.1 General: Before beginning the repair of bug holes, spalls, chips, surface
porosity, and honeycomb, remove all laitance, loose material, form oil, curing compound and
any other deleterious matter from repair area. Repair cosmetic and minor deficiencies by
methods specified herein. The Contractor is permitted to elect an alternate repair method,
provided the proposed repair method is included in the QC Plan. For each project maintain the
record of deficiencies and their repair methods. Ensure the record includes information about
product description, unit serial number, date cast, defect description including dimensions, repair
method and materials, defect discovery date, and signature of producers QC Manager indicating
concurrence with the information.
Cure repaired surfaces for the full 72 hour curing time or for the curing time as
recommended by written recommendations from the manufacturer of the repair material. Ensure
the repaired surfaces have a surface texture, finish and color which matches the appearance of
the unaffected surrounding area of the product.
450-13.1.1 Product Acceptance on the Project: Use only non-shrink grout that
is listed on the Qualified Products List (QPL).
450-13.2 Cosmetic Surface Filling: Repair areas to be filled with an approved highstrength, non-metallic, non-shrink grout meeting the requirements of Section 934. Mix, apply
and cure the grout in accordance with the manufacturers recommendations. Coating of the
prepared surface with epoxy bonding agent before grout placement is not required.
450-13.3 Surface Restoration: Maintain the surface continuously wet for a minimum of
three hours before application of repair material. Repair areas to be restored with a mortar mix
consisting by volume of one part cement, 2.5 parts sand that will pass a No. 16 sieve, and
sufficient water to produce a viscous slurry mix or repair areas to be restored with an approved
high-strength, non-metallic, non-shrink grout meeting the requirements of Section 934. Mix,
apply and cure the grout in accordance with the manufacturers recommendations. Cure areas
repaired with a mortar mix in accordance with 450-10.6. Coating of the prepared surface with
epoxy bonding agent before grout placement is not required.
450-13.4 Cutting and Filling: Carefully cut all feathered edges of the area to be repaired
back perpendicular to (or slightly undercut from) the surface to the depth of sound concrete or to
a minimum depth of 1/2 inch, whichever is deeper. Coat the prepared surface with an approved
epoxy bonding agent applied in accordance with the manufacturers recommendations. Fill the
cutout area with an approved high-strength, non-metallic, non-shrink grout mixed and applied in
accordance with the manufacturers recommendations. Firmly consolidate the grout mix in the
cutout area.
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450-13.5 Restoration of Surfaces and Edges: When reinforcing steel or prestressing
strand is exposed, remove concrete from around the items to provide a 1 inch clearance all
around. Form surfaces and edges to the original dimensions and shape of the product. Coat the
prepared surface with an approved epoxy bonding agent applied in accordance with the
manufacturers recommendations. Restore surfaces and edges with an approved high-strength,
non-metallic, non-shrink grout mixed and applied in accordance with the manufacturers
recommendations. Firmly consolidate the grout mix in the area to be repaired. Restore surfaces
and edges to the original dimensions and shape of the product.
450-13.6 Removal and Restoration of Unsound Concrete: Carefully cut the area of
unsound concrete to be repaired back perpendicular to (or slightly undercut from) the surface and
to the depth of sound concrete or to a minimum depth of 1 inch, whichever is deeper. When
reinforcing steel, prestressing strand, inserts or weldments are exposed, remove the concrete
from around the items to provide a 1 inch clearance all around. Coat the prepared surface with an
approved epoxy bonding agent applied in accordance with the manufacturers recommendations
and then filled with an approved high-strength, non-metallic, non-shrink grout mixed and applied
in accordance with the manufacturers recommendations. Firmly consolidate the grout mix in the
area to be repaired. Restore surfaces and edges to the original dimensions and shape of the
product.
450-13.7 Surface Grinding: Grind off misshaped formed surfaces with an abrasive
stone. Apply two coats of penetrant sealer in accordance with the requirements of Section 413, to
any surfaces which are not subsequently encased in concrete, immediately after grinding has
been accepted. Do not apply a penetrant sealer to any surfaces to be subsequently encased in
concrete.
450- 13.8 Treatment of Cracks: Treat cracks in accordance with 450-12.5.
450-14 Submittal of Proposal to Accept or Repair Deficiencies.
450-14.1 General: When a product has deficiencies unacceptable to the Engineer, the
Contractor may propose repairs. Deficiencies discovered in the casting yard must be repaired
before shipment. Do not ship products, which require repairs, from the casting yard to the project
site until such repairs are complete and the Engineer has determined the product to be acceptable.
Deficiencies discovered at the project site may be repaired at the site, subject to the Engineers
approval. All proposed repairs must be submitted for engineering evaluation and credit in
accordance with 450-14.2, unless the specific repair methods have been submitted and approved
in the QC Plan. The plant may use the repair method that is previously approved in the QC Plan,
without submittal of the proposal for engineering evaluation or credit. The use of the previously
approved repair method is only applicable to the same type of single deficiency that is exhibited
in a product.
450-14.2 Submittal of Repair Proposal:
The repair proposal must be completed by the Contractors Engineer of Record
and shall consist of the following:
1. A cover letter prepared on the Contractors letterhead addressed to the
Engineer describing the product.
2. Information in a format acceptable to the Engineer describing the details
of the non-compliance and the proposed repairs.
3. An engineering evaluation: A structural performance and durability
evaluation which explains why the performance and durability of the repaired deficient product
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is acceptable as compared to that of an undamaged comparable product. The evaluation must be
supported by one or more of the following types of information:
a. Written evidence of a previously approved comparable
deficiency and its repair.
b. Documented research that demonstrates the proposed repair to
be effective.
c. If applicable, engineering calculations providing support for
recommendations.
4. A proposed credit to the Contract proportionate to the products
deficiency. The credit is in addition to the cost for review and evaluation of the proposal.
5. Any other supportive information, pictures and drawings. For cracked
elements, show on a drawing the location, average width, depth, length, and termination points
of each crack along the surfaces. Provide the distance from each termination point to a fixed
reference point on the component, such as beam end or edge of flange. The description of the
proposed repair and the structural and durability evaluation of the product must be prepared by
or under the direct supervision of the Contractors Engineer of Record and must bear his/her
signature and seal.
If the proposal is accepted by the Engineer, all Department costs associated with
review of the proposal, including the cost of any and all engineering evaluation and testing
services required, will be deducted from payment to the Contractor, but not to exceed 15% of the
product value based on unit bid prices.
Include in the proposed credit consideration of the Departments added costs
which may include but are not necessarily limited to re-inspection, testing, reduced durability, or
increased maintenance cost. The Engineer will review and evaluate the Contractors proposal
and will notify the Contractor of its disposition. The Engineers review of the Contractors
proposal does not amend or delete code requirements, unless such changes are specifically
brought to the Engineers attention and accepted by the Engineer. The Engineers acceptance of
a proposal does not relieve the Contractor of his responsibility to provide products that are
structurally adequate to resist the loads specified in the Contract drawings and that maintain the
intended aesthetic, durability and maintenance aspects of the product. The Engineer will not
accept repaired products unless repairs are made as proposed or described, the resulting repairs
are sound in all aspects, and the repairs are aesthetically acceptable. Replace a rejected product
with a product meeting the requirements of the Contract Documents at no additional expense to
the Department.
450-15 Repairs Before Approval.
If repairs to precast products are initiated in advance of the Engineers approval, the
affected product will only be considered for acceptability and use when the following conditions
have been satisfied:
1. Before beginning the repairs, prepare and deliver to the Engineer a repair
proposal in accordance with the requirements of 450-14.
2. All repair materials must meet the requirements of Section 930 and be selected
from the QPL or otherwise be subsequently evaluated, tested by the Contractor as required by the
Department, and approved by the Department for the specific use made of the material.
3. Repairs have been performed under the observation of the QC Manager.
Accept responsibility for actions taken, and perform these actions at your own risk. It is
intended that repairs be made only after the proposed methods have been accepted to ensure that
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the proposal will not be modified or rejected, and the work will be accepted if the repair proves
to be adequate.
450-16 Handling, Storage, Shipping and Erection.
450-16.1 Handling: All products which are pretensioned may only be handled after
transfer of the prestressing force. For products that are prestressed by a combination of
pretensioning and post-tensioning do not handle before sufficient prestress has been applied to
sustain all forces and bending moments due to handling. Exercise care in handling to prevent
damage to products. Lift and move products so as to minimize stresses due to sudden changes in
momentum. Calculate pick up and dunnage points. Pick up products only at points designated as
pickup points as shown on the Contract Plans or shop drawings. Maintain all beams in an upright
position at all times.
Evaluate the temporary stresses and stability of beams during their handling. The
temporary stresses induced into the products during handling must be within the acceptable
stresses at release listed in the Departments Structures Design Guidelines. Take appropriate
action to increase the stability of products during handling when the factor of safety against
lateral buckling instability is below 2.0. Include the expected fabrication tolerance for sweep in
the analysis. The analysis procedure provided by the Precast/Prestressed Concrete Institute or
similar procedures may be used for the stability evaluation.
Verify lifting devices for capacity in lifting and handling products, taking into
account various positions during handling. Keep multiple component lifting devices matched to
avoid non-compatible use. When a product has multiple lifting devices, use lifting equipment
capable of distributing the load at each device uniformly to maintain the stability of the product.
When the lifting devices are grouped in multiples at one location, align them for equal lifting.
Take appropriate steps to prevent the occurrence of cracking. When cracking
occurs during handling and transportation, revise handling and transporting equipment and
procedures as necessary to prevent cracking for subsequent products.
450-16.2 Storage: Store precast prestressed beams, Double-T Beams and slab units on
only two points of support located within 18 inches of the end of the product or as calculated.
Support skewed beams, Double-T Beams or slab units within 18 inches of the end of the full
product section or as calculated. Support other products on an adequate number of supports so as
to keep stresses in the products within the allowable stresses at release listed in the Department's
Structures Design Guidelines. Locate multiple supports (more than two) within 1/2 inch of a
horizontal plane through the top surface of the supports. Adequately brace beams as necessary to
maintain stability.
All supports must be level and on adequate foundation material that will prevent
shifting or differential settlement which may cause twisting or rotation of products. Immediately
pick up products in storage that have rotated or twisted and adjust the supports to provide level
and uniform support for the product.
Support prestressed products that are stacked by dunnage placed across the full
width of each bearing point and aligned vertically over lower supports. Do not use stored
products as a storage area for either shorter or longer products or heavy equipment.
Where feasible, base the selection of storage sites, storage conditions and
orientation upon consideration of minimizing the thermal and time-dependent creep and
shrinkage effects on the camber and/or sweep of the precast pretensioned products.
Continuous application of water during the initial 72 hour moist curing period
may be interrupted for a maximum of one hour to allow relocation of precast prestressed
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concrete elements within the manufacturing facility. Keep the moist burlap in place during
relocation of the element.
Measure and record the sweep and camber of beams monthly. Keep the
measurement records on file for review at any time by the Engineer, and upon request, transmit a
copy of these measurements to the Engineer. If the camber exceeds by 1 inch the design camber
shown in the Plans, take appropriate actions in accordance with 400-7.13.1 to accommodate the
product in the structure.
If the sweep exceeds the tolerance specified, take immediate measures to bring
the sweep of the product back to within tolerance.
Notify the Engineer immediately when the sweep or camber exceeds the specified
tolerances. Special storage conditions for the purpose of removing excessive sweep will not be
restricted by requirements of this Subarticle nor contained in 450-2.1. If the sweep of the product
exceeds the tolerance specified and cannot be removed, the disposition of the product will be in
accordance with 450-12.1 and 450-14.
450-16.3 Shipping: Do not ship precast prestressed concrete products to the project site
prior to the completion of the 72 hour curing period and attainment of the required 28-day
strength. The contractor is permitted to verify the shipping strength test, before 28 days, by
testing compressive strength cylinders that are cured under the conditions similar to the product
or by testing temperature match cured cylinders. The use of maturity method, ASTM C1074,
pulse velocity method in accordance with ASTM C597, or any other nondestructive test method
acceptable to Engineer, is permitted to estimate the strength before its verification by test
cylinders. The shipping strength test is the average compressive strength of two test cylinders.
Do not ship products until accepted and stamped by the QC Manager or the inspectors under the
direct observation of the QC Manager. At the beginning of each project, provide a notarized
statement to the Engineer from a responsible company representative certifying that the plant
will manufacture the products in accordance with the requirements set forth in the Contract
Documents and plants QC Plan. The QC Managers stamp on each product indicates
certification that the product was fabricated in conformance with the Contractors QC Plan, the
Contract, and this Section. Ensure that each shipment of prestressed concrete products to the
project site is accompanied with a signed or stamped delivery ticket providing the description
and the list of the products.
Evaluate the temporary stresses and stability of all products during shipping and
locate supports, generally within 18 inches from the beam end, in such a manner as to maintain
stresses within acceptable levels. Include impact loadings in the evaluation.
450-16.4 Erection: Erect precast prestressed products without damage. Meet the
handling and storage requirements of 450-16.1 and 450-16.2 for field operations. Before casting
diaphragms and the deck slab, do not allow the horizontal alignment of prestressed concrete
beams to deviate from a straight line connecting similar points of beam ends by more than the
sweep tolerances specified in 450-2.1. Adequately brace beams as necessary to maintain
stability.
450-17 Measurement and Payment.
450-17.1 General: The work specified in this Section will be measured and paid for as
shown below for the particular item involved. Precast prestressed concrete members are
acceptable to the Department for full payment when all requirements of the Contract Documents
have been met. No partial payments will be made for precast prestressed concrete members until
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the 28-day strength requirement, along with other applicable Specification requirements, have
been met.
450-17.2 Prestressed Concrete Piling: Payment will be made at the Contract unit price
per foot for the particular type of piling, measured and paid for as specified in Section 455,
including the provisions for cutoffs and splices.
450-17.3 Prestressed Concrete Beams: Payment will be made at the Contract unit price
per foot for Prestressed Beams, complete in place and accepted. Final pay lengths will be plan
quantity based on casting lengths, as detailed on the Plans, subject to the provisions of 9-3.2.
450-17.4 Prestressed Concrete Slab Units: Payment will be made at the Contract unit
price per foot for the units, complete in place and accepted. Final pay lengths will be plan
quantity based on casting lengths, as detailed in the Plans, subject to the provisions of 9-3.2.
450-18 Basis of Payment.
Price and payment will be full compensation for all work and materials specified in this
Section, including steel reinforcement, pretensioning steel, embedded ducts, hardware, inserts
and other materials as required, to fabricate, transport and place the product into its permanent
position in the structure.
Payment for the items will be made under the following:
Item No. 450- 1Prestressed Beams - per foot.
Item No. 450- 2
Prestressed Beams: Florida-I Beams per foot.
Item No. 450- 3Prestressed Slab Units - per foot.
Item No. 450- 4Prestressed Beam U-beams - per foot.
Item No. 450- 88Prestressed Slab Units Transversely Post-Tensioned square foot.
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SECTION 451
PRESTRESSED SOIL ANCHORS
451-1 Description.
Construct prestressed soil anchors consisting of a high strength steel tendon anchored to
the retaining wall on one end and to the soil on the other end through a bulb of pressure injected
portland cement concrete grout. Test each anchor by prestressing to the load indicated in the
Contract Documents before locking off to the retaining wall.
Select the prestressed soil anchor type and the installation method, and determine the
bond length and anchor diameter. Assume responsibility for installing prestressed soil anchors
that develop the load-carrying capacity indicated in the Plans in accordance with 451-7.
Provide corrosion protection for permanent prestressed soil anchors. The Engineer will
not require corrosion protection for temporary prestressed soil anchors. Protect anchor tendons
from corrosion as shown in the Plans in accordance with 451-8.
451-2 Definitions.
(a) Anchorage Devices: The anchor head wedges or nuts which grip the prestressing
steel.
(b) Bearing Plate: The steel plate which distributes the prestressed soil anchor force to
the structure.
(c) Bond Length: The length of the prestressed soil anchor which is bonded to the ground
and transmits the tensile force to the soil or rock. For a compression prestressed soil anchor, the
bond length will be different from the tendon bond length.
(d) Factored Design Load: The maximum anticipated load that will be applied to the
prestressed soil anchor during its service life after completing stressing and testing. The factored
design load includes appropriate load factors to ensure that the overall structure has adequate
strength for its intended use.
(e) Fine-grained Soils: Soils with at least 50% of the material smaller than the No. 200
sieve size.
(f) Tendon: The complete anchor assembly, excluding grout, consisting of anchorage and
prestressing steel with sheathing and coating when required.
(g) Coupling: The means by which the prestressing force may be transmitted from one
partial-length of prestressing tendon to another.
(h) Sheathing: Enclosure around the prestressing steel to avoid temporary or permanent
bond between the prestressing steel and the surrounding grout or to provide corrosion protection.
(i) Coating: Material used to protect against corrosion or lubricate the prestressing steel.
(j) Anchor Grout: Portland cement grout that is injected into the anchor hole to provide
anchorage at the bond length of the tendon.
(k) Proof Load: Temporary loading of an anchor to its factored design load for testing
purposes.
(l) Transfer (Lock-Off) Load: Prestressing force in an anchor after proof loading
immediately after the force has been transferred from the jack to the stressing anchorage.
(m) Stressing Anchorage: That portion of assembly not within the earth fill.
(n) Alignment Load: A small load maintained on an anchor during testing sufficient to
keep the testing equipment positioned.
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(o) Performance Test: Incremental test loading and unloading of a prestressed anchor
recording the movement of the tendon at each increment.
(p) Proof Test: Incremental loading of a prestressed anchor recording the movement of
the tendon at each increment.
(q) Creep Test: A test to determine the movement of the tendon at constant load during a
certain period of time.
(r) Lift-Off Reading: A check made to determine that the actual transfer load is within
10% of the desired transfer load. This check is made immediately after transferring the load to
the stressing anchorage.
(s) Residual Movement: The non-elastic (non-recoverable) movement of an anchor
measured during soil anchor testing.
(t) Elastic Movement: The recoverable movement of an anchor measured during soil
anchor testing.
(u) Prestressed Soil Anchor: A system, referred to as a tieback or a ground anchor, used
to transfer tensile loads to soil or rock. A prestressed soil anchor includes all prestressing steel,
anchorage devices, bearing plates, grout, coatings, corrosion protection, sheathings and couplers
if used.
(v) Minimum Specified Ultimate Tensile Strength: The minimum breaking strength of
the prestressing steel as defined by the specified standard.
(w) Tendon Bond Length: The length of the tendon which is bonded to the anchor grout.
(x) Total Anchor Length: The unbonded length plus the tendon bond length.
(y) Unbonded Length (Stressing Length): The length of the tendon which is not bonded
to the grout and free to elongate during stressing. The grout surrounding the unbonded length is a
void filler and provides corrosion protection.
(z) Service Load: The load anticipated to be applied to the prestressed soil anchor during
its service life after completing stressing and testing in order to limit deflection. The service load
does not include load factors.
451-3 Qualifications.
The Contractor or subcontractor performing the work described in this Section shall have
installed prestressed soil anchors for a minimum of five years. At the preconstruction conference,
the Contractor shall submit a list containing at least five projects, completed within the last five
years, where the Contractor has installed prestressed soil anchors. Include a brief description of
each project and a reference for each project listed. As a minimum, include with the reference an
individual's name and current phone number.
Prior to the start of work, the Contractor shall submit a list identifying his engineer, drill
operators, and on-site supervisors who will be assigned to the project. Include in the list a
summary of each individuals experience.
Assign a Specialty Engineer to supervise the work with at least five years of experience
in the design and construction of permanently-anchored structures. Do not use manufacturers'
representatives in order to meet the requirements of this Section. Provide drill operators and onsite supervisors that have a minimum of one year experience installing permanent prestressed
soil anchors with the Contractors organization.
The Engineer will approve or reject the Contractors qualifications and staff within
15 working days after receipt of the submission. Do not start work on any prestressed soil anchor
wall system or order materials until receiving approval of the qualifications. The Engineer may
490
suspend the prestressed soil anchor work if the Contractor or subcontractor substitutes
unqualified personnel for approved personnel during construction. If work is suspended due to
the substitution of unqualified personnel, the Contractor is fully liable for additional costs
resulting from the suspension of work and the Department will not allow any adjustment in
Contract Time resulting from the suspension of work.
451-4 Materials.
451-4.1 General: Meet the following requirements:
Concrete ............................................................. Section 346
Prestressed Construction .................................... Section 450
Structural Steel and Miscellaneous Metals ........ Section 460
451-4.2 Prestressing Steel: Use prestressed soil anchor tendons fabricated from single or
multiple elements of one of the following prestressing steels, unless otherwise shown in the
Plans:
(a) Steel bars meeting the requirements of AASHTO M275.
(b) 7-wire, low-relaxation strands meeting the requirements of AASHTO M203.
(c) Compact 7-wire, low-relaxation strands meeting the requirements of
ASTM A779.
451-4.3 Anchorage Covers (include for temporary anchors only when shown in the
Plans): Use exposed anchorage covers fabricated from steel or ductile cast iron with a minimum
thickness of 0.10 inches. Ensure that the cover is securely attached to the anchorage device or
bearing plate. If the cover is to be grease filled, ensure the cover forms a permanent watertight
enclosure for the anchorage device.
451-4.4 Anchorage Devices: Use anchorage devices capable of developing 95% of the
minimum specified ultimate tensile strength of the prestressing steel tendon. Use anchorage
devices that meet the static strength requirements of Section 3.1.6(1) and Section 3.1.8(1) of the
Post Tensioning Institute Guide Specification for Post-tensioning Materials. Use couplers for
tendon sections capable of developing 95% of the minimum specified ultimate tensile strength.
451-4.5 Cement Grout: Use grout for anchorage consisting of a pumpable mixture of
Type I, II, or III portland cement meeting the requirements of AASHTO M85, sand, water, and
admixtures. The Contractor may use admixtures which control bleed, improve flowability,
reduce water content, and retard set in the grout subject to the approval of the Engineer. The
Contractor may only add expansive admixtures to the grout used for filling sealed
encapsulations, trumpets, and anchorage covers. Do not use accelerators. Use admixtures
compatible with the prestressing steels and mixed in accordance with the manufacturer's
recommendations.
Do not perform strength testing as system performance will be measured by
proof-testing each anchor. The Department may require grout cube testing if the Contractor uses
admixtures or irregularities occur in anchor testing. Use grout that attains a minimum cube
strength of 3,400 psi within seven days.
451-4.6 Bearing Plate: Use bearing plates fabricated from steel meeting the
requirements of AASHTO M270 or ASTM A709.
451-4.7 Bondbreaker: Use bondbreaker fabricated from a smooth plastic tube or pipe
having the following properties:
(a) Resistant to chemical attack from aggressive environments, grout, or grease
(b) Resistant to aging by ultra-violet light
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(c) Fabricated from material non-detrimental to the tendon
(d) Capable of withstanding abrasion, impact, and bending during handling and
installation
(e) Enable the tendon to elongate during testing and stressing
(f) Allow the tendon to remain unbonded after lock-off.
451-4.8 Centralizers: Use centralizers fabricated from plastic, steel, or material that is
nondetrimental to the prestressing steel. Do not use wood. Ensure that the centralizer is able to
support the tendon in the drill hole, and position the tendon so a minimum of 0.5 inches of grout
cover is provided over the tendon bond length. In addition, locate the upper centralizer a
maximum of 5 feet from the top of the tendon bond length, and locate the lower centralizer a
maximum of 12 inches from the bottom of the tendon bond length. The Engineer will not require
centralizers on pressure injected tendons if the Contractor installs the anchor in coarse grained
soils using grouting pressures greater than 150 psi. The Engineer will not require centralizers if
the Contractor installs the anchors and grouts them through a hollow stem auger and maintains
the hole full of stiff grout (slump less than 9 inches) during extraction of the auger.
451-4.9 Corrosion Inhibiting Grease (include for temporary anchors only when
shown in the Plans): For corrosion inhibiting grease, meet the requirements of Section 3.2.5 of
the Post Tensioning Institute Specification for Unbonded Single Strand Tendons.
451-4.10 Heat Shrinkable Tubes: Use heat shrinkable tubes fabricated from a radiation
cross-linked polyolefin tube internally coated with an adhesive sealant. Prior to shrinking, ensure
that the tube has a nominal wall thickness of 24 mils. Ensure that the adhesive sealant inside the
tube has a nominal thickness of 20 mils.
451-4.11 Sheath (include for temporary anchors only when shown in the Plans): Use
a sheath as part of the corrosion protection system for the unbonded length portion of the tendon
fabricated from one of the following:
(a) A polyethylene tube pulled or pushed over the prestressing steel. Use
polyethylene Type II, III, or IV as defined by ASTM D1248 or approved equal, with a minimum
wall thickness of 60 mils, plus or minus 10 mils.
(b) A hot-melt extruded polypropylene tube. Use polypropylene cell classification
PP 210 B5554211 as defined by ASTM D4101 or approved equal, with a minimum wall
thickness of 60 mils, plus or minus 10 mils.
(c) A hot-melt extruded polyethylene tube. Use polyethylene high density
Type III as defined by ASTM D3350 and ASTM D1248 (or approved equal), with a minimum
wall thickness of 60 mils, plus or minus 10 mils.
(d) Steel tubing meeting the requirements of ASTM A500, with a minimum wall
thickness of 0.20 inches.
(e) Steel pipe meeting the requirements of ASTM A53, Schedule 40 minimum.
(f) Plastic pipe meeting the requirements of ASTM D1785, Schedule 40
minimum.
(g) A corrugated tube meeting the requirement of the tendon bond length
encapsulation.
451-4.12 Spacers: Use spacers to separate elements of a multi-element tendon and which
permit grout to flow freely up the drill hole. Use spacers fabricated from plastic, steel, or
material which is nondetrimental to the prestressing steel. Do not use wood. The Contractor may
use a combination centralizer-spacer.
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451-4.13 Tendon Bond Length Encapsulations (include for temporary anchors only
when shown in the Plans): When the Contract drawings require the tendon bond length to be
encapsulated to provide additional corrosion protection, use encapsulation fabricated from one of
the following:
(a) High density corrugated polyethylene tubing meeting the requirements of
AASHTO M252, with a minimum wall thickness of 30 mils
(b) Deformed steel tubing or pipes with a minimum wall thickness of 25 mils
(c) Corrugated, PVC tubes manufactured from rigid PVC compounds meeting the
requirements of ASTM D1784, Class 13464-B.
451-4.14 Trumpet (include for temporary anchors only when shown in the Plans):
Use a trumpet to provide a transition from the anchorage to the unbonded length corrosion
protection fabricated from a steel pipe or tube meeting the requirements of ASTM A53 for pipe
or ASTM A500 for tubing. Use a trumpet that has a minimum wall thickness of 0.125 inches for
diameters up to 4 inches and 0.20 inches for larger diameters.
451-4.15 Water: Use potable water for mixing grout.
451-4.16 Grout Tube: Use a grout tube fabricated from a high density polyethylene
tube, or a PVC pipe, or a steel pipe with a 0.5 inches minimum inside diameter.
451-5 Tendon Fabrication.
Provide tendons that are either shop or field fabricated. Fabricate the tendon as shown on
the approved shop drawings.
Ensure that tendons are free of dirt, rust, or any other deleterious substance. Degrease the
bond length.
Handle and protect tendons, prior to installation, in a manner to avoid corrosion and
physical damage. The Engineer will consider damage such as abrasion kinks, welds and weld
splatters, cuts, and nicks which impair the proper performance of the tendon cause for rejection.
Sheath tendons in the stressing length to prevent contact of the anchor tendon with the
drill hole wall. The Contractor may use sheathing that consists of tubes surrounding individual
tendon elements or a single tube surrounding the elements altogether.
The Contractor may use sheathing material of either steel, plastic, or any other material
nondetrimental to the high strength prestressing steel. The Contractor may use tape to prevent
grout from entering under the sheath on individually sheathed elements.
Select the type of tendon to be used. Unless otherwise shown in the Plans, size the tendon
so the factored design load does not exceed 80% of the minimum specified ultimate tensile
strength of the tendon. Increase the tendon size by the sacrificial steel thickness shown in the
Plans. In addition, size the tendon so the maximum test load does not exceed 90% of the
minimum yield strength of the tendon.
Assume responsibility for determining the bond length necessary to develop the design
load indicated in the Plans or the shop drawings. Use a minimum bond length of 10 feet in rock
and 15 feet in soil. Ensure that the minimum tendon bond length is 10 feet.
451-6 Installation.
451-6.1 General:
451-6.1.1 Drilling: Core drilling, rotary drilling, percussion drilling, auger
drilling, or driven casing may be used. At the ground surface, locate the drill hole within
12 inches of the location shown in the Plans or the approved shop drawings. Locate the drill hole
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so that the longitudinal axis of the drill hole and the longitudinal axis of the tendon are parallel.
In particular, do not drill the prestressed soil anchor hole in a location that requires the tendon to
be bent in order to connect the bearing plate to the supported structure. At the point of entry,
install the prestressed soil anchor within plus or minus 3 degrees of the inclination from
horizontal shown in the Plans or the approved shop drawings. At the point of entry, make the
horizontal angle formed by the prestressed soil anchor and the structure to within plus or minus
3 degrees of a line drawn perpendicular to the plane of the structure unless otherwise shown in
the Plans or approved shop drawings. Do not allow the prestressed soil anchors to extend beyond
the right-of-way or easement limits shown in the Plans.
451-6.1.2 Tendon Insertion: Insert the tendon into the drill hole to the desired
depth. When the tendon cannot be completely inserted, remove the tendon from the drill hole,
and then clean or redrill the hole to permit insertion. Do not drive or force partially inserted
tendons into the hole.
451-6.1.3 Installation of Trumpet and Anchorage: When corrosion protection
is required, extend that portion of the corrosion protection surrounding the unbonded length of
the tendon, up beyond the bottom seal of the trumpet or 12 inches into the trumpet if no trumpet
seal is provided. If the protection does not extend beyond the seal or sufficiently far enough into
the trumpet, extend the corrosion protection, or lengthen the trumpet.
When required, ensure that the corrosion protection surrounding the
unbonded length of the tendon does not contact the bearing plate or the anchor head during
testing and stressing. If the protection is too long, trim the corrosion protection to prevent
contact.
Place the bearing plate and anchor head so the axis of the tendon is
perpendicular to the bearing plate within plus or minus 3 degrees and the axis of the tendon
passes through the center of the bearing plate.
If using grout protected tendons, electrically isolate the bearing plate,
anchor head, and trumpet from the surrounding concrete, soldier pile, or any metallic element
embedded in the structure.
Completely fill the trumpet with corrosion inhibiting grease or grout.
Trumpet grease may be placed any time during construction. Place trumpet grout after the
prestressed soil anchor has been tested and stressed. Demonstrate to the Engineer that the
procedures selected for placement of either grease or grout will produce a completely filled
trumpet.
For permanent soil anchors, cover all anchorages permanently exposed to
the atmosphere with a corrosion inhibiting grease-filled or grout-filled cover. Demonstrate to the
Engineer that the procedures selected for placement of either grease or grout will produce a
completely filled cover. If the Plans require restressable anchorages, use corrosion inhibiting
grease to fill the anchorage cover.
451-6.2 Anchor Grouting: Provide grouting equipment that produces a grout free of
lumps and undispersed cement. Use a positive displacement grout pump equipped with a
pressure gauge to monitor grout pressures. Ensure that the pressure gauge is capable of
measuring pressures of at least 150 psi or twice the actual grout pressures used, whichever is
greater. Size the grouting equipment to enable the grout to be pumped in one continuous
operation. Ensure that the mixer is capable of continuously agitating the grout.
Inject the grout from the lowest point of the drill hole. Grout may be pumped
through grout tubes, casing, hollow-stem-augers, or drill rods. The grout may be placed before or
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after insertion of the tendon. Record the quantity of the grout and the grout pressures. Control the
grout pressures and grout takes to prevent excessive heave or fracturing.
Except where indicated below, the grout may be placed above the top of the bond
length at the same time as the bond length grout but may not be placed under pressure. Ensure
that the grout at the top of the drill hole does not contact the back of the structure or the bottom
of the trumpet.
If the prestressed soil anchor is installed in a fine-grained soil using drill holes
larger than 6 inches in diameter, place the grout above the top of the bond length after testing
and stressing the prestressed soil anchor. The Engineer will allow the entire drill hole to be
grouted at the same time if it can be demonstrated that the particular prestressed soil anchor
system does not derive a significant portion of its load-carrying capacity from the soil above the
bond length portion of the prestressed soil anchor.
If using grout protected tendons for prestressed soil anchors anchored in rock, use
pressure grouting techniques. For pressure grouting, seal the drill hole, and inject grout until a
50 psi grout pressure (measured at the top of the drill hole) can be maintained on the grout for
five minutes.
Upon completion of grouting, the grout tube may remain in the hole, but it must
be filled with grout.
After grouting, do not load the tendon for at least three days.
Record the following data concerning the grouting operation:
(a) Type of mixer
(b) Water/cement ratio
(c) Types of additives (if any)
(d) Grout pressure
(e) Type of cement
(f) Strength test samples (if any)
(g) Volume of first and second stage grout
451-7 Prestressed Soil Anchor Testing and Stressing.
451-7.1 General: Test each prestressed soil anchor. Perform performance tests as
follows:
(a) on the first two soil anchors installed on the project prior to the grouting of
any additional soil anchors. The purpose of these initial tests is to verify the Contractors
installation procedures and the performance of the bond length.
(b) as shown on the Plans
(c) on 10% of the prestressed soil anchors or a minimum of three, whichever is
greater
Perform creep testing as follows:
(a) as shown in the Plans
(b) on 5% of the prestressed soil anchors
The Engineer will select the prestressed soil anchors to be performance tested and
those to be creep tested and, at his discretion, may increase or decrease the number of tests.
Perform proof tests on all prestressed soil anchors, not subjected to a performance
test or a creep test. Record the results of each test on forms approved by the Engineer, such as
the testing forms provided in the appendix of the AASHTO/AGC/ARTBA Joint Committee Task
Force 27 Report. Submit a separate form for each test. Submit the test results to the Engineer on
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a weekly basis within one week of testing. Do not apply a load greater than 10% of the factored
design load to the prestressed soil anchor prior to testing. For the maximum test load, do not
exceed 90% of the minimum yield strength of the tendon. Simultaneously apply the test load to
the entire tendon. Do not perform stressing of single elements of multi-element tendons.
Provide testing equipment that consists of:
(a) a dial gauge or vernier scale capable of measuring to 0.001 inch to
measure the ground anchor movement. Use a movement-measuring device that has a minimum
travel equal to the theoretical elastic elongation of the total anchor length at the maximum test
load and that has adequate travel so the prestressed soil anchor movement can be measured
without resetting the device.
(b) a hydraulic jack and pump to apply the test load. Use the jack, with a
minimum ram travel of not less than the theoretical elastic elongation of the total anchor length
at the maximum test load, and a calibrated pressure gauge, graduated in 100 psi increments or
less, or calibrated load cell with readout box, to measure the applied load. Ensure that the jack
and pressure gauge are calibrated by an independent firm as a unit, and that the calibration is
performed within 45 working days of the date submitted. When load cells will be used for
performance and proof tests, ensure that the load cell is calibrated by an independent firm and
that the calibration is performed within 45 working days of the date submitted. Obtain the
Engineers approval of the calibration before testing commences. In case of disagreement
between the load cell and pressure gage, use the load cell measurement.
(c) Keep a calibrated reference pressure gauge at the site in possession of
the Engineer. Ensure that the reference gauge is calibrated with the test jack and pressure gauge.
(d) Provide an electrical resistance load cell and readout to be used when
performing a creep test. Ensure that the load cell is calibrated by an independent firm and that
the calibration is performed within 45 working days of the date submitted.
(e) Place the stressing equipment over the prestressed soil anchor tendon
in such a manner that the jack, bearing plates, load cells and stressing anchorage are axially
aligned with the tendon and the tendon is centered within the equipment.
451-7.2 Criteria for Performing a Performance Test and a Proof Test: Raise the load
from one increment to another immediately after recording the prestressed soil anchor
movement. Measure and record the prestressed soil anchor movement to the nearest 0.001 inch
with respect to an independent fixed reference point at the alignment load and at each increment
of load. Monitor the load with a pressure gauge or load cell. At load increments other than the
maximum test load, hold the load just long enough to obtain the movement reading.
Hold the maximum test load in a proof test for at least 10 minutes. Pump the jack
as necessary in order to maintain a constant load. Start the load-hold period as soon as the
maximum test load is applied, and measure and record the prestressed soil anchor movement,
with respect to an independent fixed reference, at 1, 2, 3, 4, 5, 6, and 10 minutes. If the
prestressed soil anchor movement between 1 minute and 10 minutes exceeds 0.04 inches, hold
the maximum test load for an additional 50 minutes. If extending the load-hold, record the
prestressed soil anchor movements at 15 minutes, 20, 25, 30, 40, 50 and 60 minutes.
451-7.2.1 Performance Test: Place the reference pressure gauge in series with
the pressure gauge during each performance test. If the load determined by the reference
pressure gauge and the load determined by the pressure gauge differ by more than 10%,
recalibrate the jack, pressure gauge, and reference pressure gauge at no expense to the
Department.
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Perform the performance test by incrementally loading and unloading the
prestressed soil anchor in accordance with the following schedule:
Performance Test Schedule
Load
AL
0.20 DL*
AL
0.20 DL
0.40 DL*
AL
0.20 DL
0.40 DL
0.60 DL*
AL
0.20 DL
0.40 DL
0.60 DL
0.80 DL*
Load
AL
0.20 DL
0.40 DL
0.60 DL
0.80 DL
0.90 DL*
AL
0.20 DL
0.40 DL
0.60 DL
0.80 DL
0.90 DL
1.00 DL*
Reduce to lock-off load
AL - is the alignment load.
DL - is the prestressed soil anchor factored design load.
Plot the prestressed soil anchor movement versus load for each load
increment marked with an asterisk (*) in the performance test schedule, and plot the residual
movement of the tendon at each alignment load versus the highest previously applied load.
451-7.2.2 Proof Test: Perform the proof test by incrementally loading the
prestressed soil anchor in accordance with the following schedule:
Proof Test Schedule
Load
AL
0.20 DL
0.40 DL
0.60 DL
Load
0.80 DL
0.90 DL
1.00 DL
Reduce to lock-off load
Compare the proof test results to the performance test results. If there is
any significant variation from the performance test results, perform a performance test on the
next anchor.
Plot the prestressed soil anchor movement versus load for each load
increment in the proof test.
451-7.3 Criteria for Performing a Creep Test: Perform the creep test by incrementally
loading and unloading the prestressed soil anchor in accordance with the performance test
schedule given above. At the end of each loading cycle, hold the load constant for the
observation period indicated in the creep test schedule below. Use the following times for
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reading and recording the prestressed soil anchor movement during each observation period: 1,
2, 3, 4, 5, 6, 10, 15, 20, 25, 30, 40, 50, 60, 75, 90, 100, 120, 150, 180, 210, 240, 270, and
300 minutes as appropriate. Start each load-hold period as soon as applying the test load. In a
creep test, use the pressure gauge and reference pressure gauge or load cell to measure the
applied load, and use the load cell to monitor small changes in load during a constant load-hold
period. Pump the jack as necessary in order to maintain a constant load.
Plot the prestressed soil anchor movement and the residual movement measured
in a creep test as described for the performance test above, and plot the creep movement for each
load-hold as a function of the logarithm of time.
Load
AL
0.20 DL
0.40 DL
0.60 DL
0.80 DL
0.90 DL
1.00 DL
Creep Test Schedule
Observation Period (minutes.)
10
30
30
40
60
300
451-7.4 Lock-Off: Upon satisfactory completion of all testing, reduce the load to the
lock-off load, and transfer the load to the anchorage device. Use a lock-off load that is 80% of
the prestressed soil anchor service load. The Contractor may completely unload the prestressed
soil anchor prior to lock-off. After transferring the load and prior to removing the jack, take a
lift-off reading. Use a lift-off reading that is within 10% of the specified lock-off load. If the load
is not within 10% of the specified lock-off load, reset the anchorage, and take another lift-off
reading. Repeat this process until obtaining the desired lock-off load.
451-7.5 Cutting of Tendon Protrusions: After an anchor has been accepted by the
Engineer, saw cut the portion of the anchor tendon extending beyond the anchorage. Take care
not to damage the tendon or the tendon anchorage.
451-7.6 Prestressed Soil Anchor Load Test Acceptance Criteria: The Engineer will
accept a performance or proof-tested prestressed soil anchor with a 10 minute load hold if the:
(a) prestressed soil anchor carries the maximum test load with less than
0.04 inches of movement between 1 minute and 10 minutes; and
(b) total movement at the maximum test load exceeds 80% of the theoretical
elastic elongation of the unbonded length.
The Engineer will accept a performance or proof-tested prestressed soil
anchor with a 60 minute load hold if the:
(a) prestressed soil anchor carries the maximum test load with a creep rate that
does not exceed 0.08 inches/log cycle of time; and
(b) total movement at the maximum test load exceeds 80% of the theoretical
elastic elongation of the unbonded length.
The Engineer will accept a creep tested prestressed soil anchor if the:
(a) prestressed soil anchor carries the maximum test load with a creep rate that
does not exceed 0.08 inches/log cycle of time; and
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(b) total movement at the maximum test load exceeds 80% of the theoretical
elastic elongation of the unbonded length.
If the total movement of the prestressed soil anchors at the maximum test
load does not exceed 80% of the theoretical elastic elongation of the unbonded length, replace
the prestressed soil anchor at no cost to the Department.
Incorporate prestressed soil anchors which have a creep rate greater than
0.08 inches/log cycle of time in the finished work at a load equal to one-half its failure load. The
failure load is the load carried by the prestressed soil anchor after the load has been allowed to
stabilize for 10 minutes.
When a prestressed soil anchor does not satisfy the load test acceptance
criteria, the Contractor may modify the design and/or the construction procedures. These
modifications may include, but are not limited to, installing replacement prestressed soil anchors,
reducing the factored design load by increasing the number of prestressed soil anchors,
modifying the installation methods, increasing the bond length or changing the prestressed soil
anchor type. Obtain the Engineers approval prior to making any modification which requires
changes to the structure. Perform any modifications at no additional cost to the Department. The
Department will not allow additional Contract Time for modifications. The Engineer will not
allow retesting of the failed prestressed soil anchor.
451-8 Corrosion Protection (include for temporary anchors only when shown in the Plans).
451-8.1 General: Protect prestressed soil anchors against corrosion using materials and
procedures described herein. The following materials may be used independently or in various
combinations:
(a) Portland cement grout
(b) Plastic pipe or tubing
(c) Steel pipe or tubing
(d) Greases specially compounded for post-tensioning
(e) Bitumens
(f) Heat shrinkable polyethylene tubing
Use corrosion protection materials with properties that are not detrimental to the
prestressing steel and that prevent the intrusion of corrosive environments. Use coating materials
that also have the following properties:
(a) Free from cracks and not brittle or fluid over the entire anticipated
range of temperature
(b) Chemically stable for the life of the tendon
(c) Nonreactive with the surrounding materials such as concrete, tendons,
or sheathing
(d) Corrosion-inhibiting
(e) Impervious to moisture
When acidic water can enter the bore hole during the period subsequent to the
drilling and flushing operation and prior to tendon insertion and grouting, introduce chemical
additives for neutralizing purposes. Maintain a minimum pH of 9.0 when the prestressing steel is
in contact with this water. During prolonged periods, monitor the pH at regular intervals, and add
additional neutralization as required. Concentrated sodium hydroxide and calcium hydroxide
have proven effective for this purpose.
451-8.2 Protection Systems:
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451-8.2.1 Bond Length:
(a) When the Plans require grout protected prestressed soil anchor
tendons, meet the following requirements:
1. Provide corrosion protection of the tendon bond length by the
cement grout cover.
2. Use spacers along the tendon bond length of multi-element
tendons to separate each of the individual elements of the tendon so the prestressing steel will
bond to the grout. Position spacers so their center to center spacing does not exceed 10 feet. In
addition, locate the upper spacer a maximum of 5 feet from the top of the tendon bond length,
and locate the lower spacer a maximum of 5 feet from the bottom of the tendon bond length.
3. Use centralizers to ensure a minimum of 0.5 inches of grout
cover over the tendon bond length. Position centralizers so their center to center spacing does not
exceed 10 feet. In addition, locate the upper centralizer a maximum of 5 feet from the top of the
tendon bond length, and locate the lower centralizer a maximum of 12 inches from the bottom of
the tendon bond length.
4. The Engineer will not require centralizers on pressure-injected
prestressed soil anchor tendons if the prestressed soil anchor is installed in coarse-grained soils
using grouting pressures greater than 150 psi.
5. The Engineer will not require centralizers on hollow-stemaugured prestressed soil anchor tendons if the prestressed soil anchor is grouted through the
auger and the hole is maintained full of a stiff grout, (9 inches slump or less) during extraction of
the auger.
(b) When the Plans require the tendon bond length to be encapsulated:
1. Protect the tendon bond length portion of the tendon against
corrosion by encapsulating the tendon in a grout-filled corrugated plastic or deformed steel tube.
Grout the tendon inside the encapsulation prior to inserting the tendon in the drill hole or after
the tendon has been placed in the drill hole. Mix expansive admixtures with the encapsulation
grout if the tendon is grouted inside the encapsulation prior to inserting it in the drill hole.
Centralize the tendon within the tendon bond length encapsulation with a minimum of
0.10 inches of grout cover. Use spacers along the tendon bond length of multi-element tendons to
separate the elements of the tendon so the prestressing steel will bond to the encapsulation grout.
2. Use centralizers to provide a minimum of 0.5 inches of grout
cover over the tendon bond length encapsulation. Position centralizers so their center to center
spacing does not exceed 10 feet. In addition, locate the upper centralizer a maximum of 5 feet
from the top of the tendon bond length, and locate the lower centralizer a maximum of 12 inches
from the bottom of the tendon bond length.
3. The Engineer will not require centralizers on encapsulated,
pressure-injected prestressed soil anchor tendons if the prestressed soil anchor is installed in
coarse-grained soils using grouting pressures greater than 150 psi.
4. The Engineer will not require centralizers on encapsulated,
hollow-stem-augured prestressed soil anchor tendons if the prestressed soil anchor is grouted
through the auger and the hole is maintained full of a stiff grout (9 inches slump or less) during
extraction of the auger.
451-8.2.2 Unbonded Length: For the minimum unbonded length of the tendon,
use 15 feet or as indicated in the Plans or the approved shop drawings, whichever is greater.
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If grouting the entire drill hole (tendon bond length and unbonded length)
in one operation, provide the corrosion protection of the unbonded length by a sheath completely
filled with corrosion inhibiting grease or grout, or a heat shrinkable tube internally coated with
an elastic adhesive. If using grease under the sheath, make provisions to prevent the grease from
escaping at the ends of the sheath. With grease, completely coat the tendon, fill the void between
the tendon and the sheath, and fill the interstices between the wires of the 7-wire strands. Ensure
that the shop drawings show how to provide a transition between the bond length and the
unbonded length corrosion protection. If the sheath is grout filled, provide a separate
bondbreaker that prevents the tendon from bonding to the grout surrounding the unbonded
length.
If providing grease-filled sheath corrosion protection and the drill hole
above the bond length is grouted after locking off the prestressed soil anchor, grout the tendon
inside a second sheath.
451-8.2.3 Anchorage and Trumpet: Use non-restressable anchorage devices
except where indicated in the Plans. Provide restressable anchorages on those prestressed soil
anchors designated as restressable in the Plans. Ensure that the post-tensioning supplier provides
a restressable anchorage compatible with the post-tensioning system provided along with written
recommendations concerning the restressing of the tendons.
If using strand tendons, provide written recommendations from the posttensioning supplier for seating the wedges. Include with the recommendations the minimum load
required to properly seat the wedges in the anchor head.
Size the bearing plates so that:
(a) the bending stresses in the plate do not exceed the yield
strength of the steel when applying a load equal to 95% of the minimum specified ultimate
tensile strength of the tendon; and
(b) the average bearing stress on the concrete does not exceed that
recommended in Section 3.1.7 of the Post Tensioning Institute Guide Specification for PostTensioning Materials.
Weld the trumpet to the bearing plate. Provide a trumpet that has an inside
diameter equal to or larger than the hole in the bearing plate. Ensure that the trumpet is long
enough to accommodate movements of the structure during testing and stressing. For strand
tendons with encapsulation over the unbonded length, provide a trumpet that is long enough to
enable the tendon to make a transition from the diameter of the tendon in the unbonded length to
the diameter of the tendon at the anchor head without damaging the encapsulation. Ensure that
trumpets filled with corrosion-inhibiting grease have a permanent Buna-N synthetic rubber or
approved equal seal provided between the trumpet and the unbonded length corrosion protection.
Ensure that trumpets filled with grout have a temporary seal provided between the trumpet and
the unbonded length corrosion protection or that the trumpet overlaps the unbonded length
corrosion protection by a minimum of 12 inches and fits tightly over the unbonded length
corrosion protection.
451-9 Submittals.
Prepare and submit Shop drawings and a design submission describing the prestressed
soil anchor system or systems intended for use to the Engineer for review and approval
30 working days prior to the commencement of the prestressed soil anchor work. Include the
following in the shop drawings and design submission:
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(a) A prestressed soil anchor schedule providing the following:
1. Prestressed soil anchor number
2. Prestressed soil anchor factored design load
3. Type and size of tendon
4. Minimum total anchor length
5. Minimum bond length
6. Minimum tendon bond length
7. Minimum unbonded length
(b) A drawing of the prestressed soil anchor tendon and the corrosion protection
system. Include details for the following:
1. Spacers and their location
2. Centralizers and their location
3. Unbonded length corrosion protection system
4. Bond length corrosion protection system
5. Anchorage and trumpet
6. Anchorage corrosion protection system
(c) Certificates of Compliance for the following materials, if used, stating that the
material or assemblies to be provided will fully comply with the requirements of the Contract.
1. Prestressing steel, strand or bar
2. Portland cement
3. Prestressing hardware
4. Bearing plates
5. Corrosion protection system
The Engineer will approve or reject the shop drawings and design submission within
30 working days after receipt of the submission.
Submit to the Engineer for review and approval or rejection mill test reports for the
prestressing steel and the bearing plate steel. The Engineer may require the Contractor to provide
samples of any prestressed soil anchor material intended for use on the project. The Engineer
will approve or reject the prestressing steel and bearing plate steel within five working days after
receipt of the test reports. Do not incorporate the prestressing steel and bearing plates in the work
without the Engineers approval.
Submit to the Engineer for review and approval or rejection calibration data for each test
jack, pressure gauge, and reference pressure gauge to be used. The Engineer will approve or
reject the calibration data within five working days after receipt of the data. Do not commence
testing until the Engineer has approved the jack, pressure gauge, and reference pressure gauge
calibrations.
Submit to the Engineer within 20 calendar days after completion of the prestressed soil
anchor work a report containing:
(a) prestressing steel manufacturers mill test reports for the tendons incorporated
in the installation
(b) grouting records indicating the cement type, quantity injected, and the grout
pressures
(c) prestressed soil anchors test results and graphs.
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451-10 Tendon Storage and Handling.
Handle and store tendons in a manner to avoid damage or corrosion. The Engineer will
consider damage to the prestressing steel as a result of abrasions, cuts, nicks, welds and weld
splatter cause for rejection. Protect the prestressing steel if performing welding in the vicinity.
Do not ground welding leads to the prestressing steel. Protect prestressing steel from dirt, rust, or
deleterious substances.
The Engineer will allow a light coating of rust on the steel. If heavy corrosion or pitting
is noted, the Engineer will reject the affected tendons.
Use care in handling and storing the tendons at the site. Prior to inserting a tendon in the
drill hole, examine the tendon for damage to the encapsulation and the sheathing. If, in the
opinion of the Engineer, the encapsulation is damaged, repair the encapsulation in accordance
with the tendon suppliers recommendations. If, in the opinion of the Engineer, the smooth
sheathing has been damaged, repair it with ultra high molecular weight polyethylene tape. Spiral
wind the tape around the tendon to completely seal the damaged area at a pitch that ensures a
double thickness at all points.
451-11 Method of Measurement.
Unless otherwise shown in the Plans, the quantity to be paid for will be the number of
prestressed soil anchors, based on the maximum anchor spacing shown in the Plans, installed and
accepted. For prestressed soil anchors that do not meet the acceptance criteria, the original
prestressed soil anchor and any required additional work or prestressed soil anchors will be, in
sum, considered to be one prestressed soil anchor for payment purposes.
451-12 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including furnishing the materials necessary to complete the anchors in place and accepted. The
quantity of performance and creep tests to be paid for will be the number of tests performed on
accepted anchors.
The cost of proof testing will be included in Item No. 451-70.
No payment will be made for tests performed on unaccepted anchors.
Payment will be made under:
Item No. 451- 70Prestressed Soil Anchors - each.
Item No. 451- 70-1 Prestressed Soil Anchor (Performance Tests) - each.
Item No. 451- 70-2 Prestressed Soil Anchors (Creep Tests) - each.
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SECTION 452
PRECAST SEGMENTAL BRIDGE CONSTRUCTION
452-1 Description.
Fabricate, store, transport and erect precast structural concrete superstructure and/or
substructure segments on a prepared foundation, to the established lines and grades, in
accordance with the design, dimensions and details shown on the Plans and in accordance with
this Section.
Reinforcing steel, embedded items and all appurtenant items are included.
Base the bid on the design shown in the Plans.
The work in this Section does not include longitudinally post-tensioned beams upon
which a concrete slab is cast-in-place.
452-2 Qualification Requirements for Supervisory Personnel.
Meet the requirements of Section 105.
452-3 Definitions.
The following definitions apply to segmental bridge construction:
452-3.1 Segment: A modular section of the superstructure and/or substructure
consisting of a certain cross-section shape and length as detailed in the Plans.
452-3.2 Match Cast: A precast concrete fabrication process whereby a segment
is cast against the preceding segment producing a matching interface which permits the
re-establishment of the cast geometry at erection time. Match casting is accomplished by either
the short line or long line casting method.
452-3.3 Short Line Casting: Casting segments one at a time in a casting cell
between a bulkhead at one end and a previously cast segment at the other. The first segment is
cast between the bulkhead and another, temporary bulkhead.
452-3.4 Long Line Casting: Casting segments on a casting bed of sufficient
length to permit the cumulative casting of segments for the entire length of a span or cantilever
between field closure pours without repositioning the segments on the casting bed. With this
method, the first segment is cast between bulkheads and successive segments are cast between a
movable bulkhead on one end and the previously cast segment on the other.
452-3.5 Casting Cell: A special formwork arrangement usually consisting of a
fixed vertical bulkhead of the cross section shape at one end and adjustable soffit, side and core
forms all designed and assembled into a machine for making a single superstructure segment. A
casting cell for a substructure pier shaft segment consists of exterior and interior side forms and a
soffit form of the cross section shape.
452-3.6 Wet Joint System: Where segments are made in a casting cell between
two bulkheads and are not match cast. The segments are then erected in the superstructure with a
narrow cast-in-place joint between each segment. (During erection, all the segments of a span or
multiple spans are supported by falsework, truss or other technique until the joints have gained
strength and the longitudinal post-tensioning installed to make them self supporting.)
452-3.7 Span By Span (Erection): Placing a specified number of segments on a
temporary support system, aligned and post-tensioned longitudinally forming a completed span
of the superstructure.
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452-3.8 Balanced Cantilever (Erection): The segments are sequentially erected
alternately on either side of the pier in cantilever to a point where a closure is cast-in-place.
452-3.9 Progressive Cantilever: (Erection): The segments are erected
progressively in cantilever, in one direction, from one pier to the next, using temporary
intermediate piers, or other systems as required to support the advancing cantilever between
piers.
452-3.10 Casting Curve: The curve of casting geometry that has to be followed
in the casting cell or bed for achieving the theoretical bridge profile and alignment after all the
final structural and time dependent (creep and shrinkage) deformations have taken place. The
casting curve is a combination of the theoretical bridge geometrical profile grade, alignment and
the camber.
452-3.11 Camber: The amount by which the concrete profile at casting time must
differ from the theoretical geometric profile grade to compensate for all structural dead load,
post-tensioning, all long term and time dependent deformations (creep and shrinkage) including
all the intermediate erection stages and effects. (The opposite of deflections).
452-3.12 Erection Elevation: The elevation at which a segment is set in the
structure at the time it is erected. (This is profile grade corrected by the amount of deflection
calculated to occur from that stage onwards.)
452-4 Shop Drawings, Calculations And Manuals.
452-4.1 General: Use methods and procedures providing adequate safety to the general
public from construction/erection activities and/or falsework placed over or adjacent to traveled
roadways, navigational or recreational waterways or any existing commercial, industrial or other
facility.
452-4.2 Information Required: Submit detailed shop drawings, calculations, manuals
and other information, including, but not limited to, the following:
452-4.2.1 Segment Shop Drawings:
(1) A schedule of materials for segment fabrication including concrete,
reinforcing steel, prestressing steel, grout, and other similar items.
(2) Each segment number and the direction of erection.
(3) Segment dimensions including widths, lengths, thicknesses, tapers,
fillets, radii, working points, post-tensioning, clearances, rebar dimensions and spacing,
embedded items, holes, anchorages positions, and other similar items.
(4) Post-tensioning requirements as outlined in Section 462. Check posttensioning for consistency with pre-approved post-tensioning hardware and provide part numbers
for Department pre-approved systems on the shop drawings. Substitution of parts or materials is
not allowed.
(5) The volume of concrete, weight of reinforcement and weight of posttensioning in each precast segment and the total weight for reinforcement and post-tensioning for
both the superstructure and substructure summarized and tabulated on the shop drawings.
(6) Details and calculations for any localized strengthening for
concentrated supports and loads or reactions from any special erection equipment placed in
locations not already allowed for in the Plans.
(7) Details and supporting calculations for any modifications to segment
geometry, cross section dimensions, or segment length including any required changes to
reinforcing and post-tensioning.
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(8) Details of permanent and temporary embedded items including inserts,
blockouts, temporary openings, holes, and other similar items; and any localized required
strengthening and the materials and methods to fill and finish the holes.
452-4.2.2 Casting Yard:
(1) Procedures for segment fabrication including layout of the casting
yard, set up and operation of the casting cells, movable rain and sun shades, geometry control
stations, the storage and handling of rebar cages. the preparation of as built geometry data,
placing and finishing concrete, curing of concrete, form stripping, bond breaking, and other
similar items.
(2) Calculations and details for lifting, storage and stacking of segments.
Additional strengthening of the segments to accommodate stacking will be at no expense to the
Department.
(3) Equipment for segments fabrication, including details of the forms and
casting cells for the manufacture of the segments, surveying the segment, lifting and
transportation of the segment in the yard, and other similar items.
(4) Segment storage including layout of the storage area, method of
supporting the segments, single or double stacking, placing erection marks and segment
identification, and other similar items.
(5) Segment transportation from the casting yard to the site.
452-4.2.3 Erection Manual: Meet the requirements in 452-8.
452-4.2.4 Manual for Geometry Control and Casting Curves: Meet the
requirements in 452-6.3.
452-5 Materials.
452-5.1 General: Use materials which conform to this Section and the requirements
prescribed in Division III, Materials, for the particular kind and type of material specified.
452-5.2 Concrete: Use concrete as specified in Section 346 except as specifically
modified herein. Use No. 67 coarse aggregate in the concrete for segments.
Screenings are not allowed as a substitute for silica sand for use in concrete for
Precast Superstructure Segments.
452-5.3 Reinforcing Steel: Use ASTM A615, Grade 60 reinforcing steel which meets
the requirements of Section 415. When welding reinforcing steel, meet the requirements of the
American Welding Societys Structural Welding Code D1.4. The Engineer may allow shop
prepared welded reinforcing grillages. Field welding of reinforcing steel is not allowed.
452-5.4 Post-Tensioning Systems: Use post-tensioning hardware components meeting
the requirements of Section 462. Components are not interchangeable and must comply with the
details of the approved shop drawings.
452-6 Casting Requirements.
452-6.1 General: Ensure that all materials, details, and procedures are as specified
herein, as noted in the Plans, or as directed by the Engineer.
Do not begin casting segments until the Engineer approves the relevant shop
drawings, calculations, casting manuals, concrete forms and concreting operations and the posttensioning system components and layout if different from that on the Contract Plans. (Approval
of post-tensioning stressing elongations and forces for field erection operations is not required at
this stage but is required prior to erection.)
506
To use wet joints to join cantilevers or for corrective measures, obtain the
Engineers written approval.
Give each segment an erection mark indicating its location, orientation and order
in the erection sequence. Match mark abutting edges of adjacent segments. Show erection marks
on the erection plans or in the erection manual.
452-6.2 Forms: Take responsibility for the design and engineering of the forms as well
as their construction. Form all exposed formed surfaces of each element of the structure with the
same material to produce similar concrete surface textures, color, and appearance. Obtain the
Engineers approval of forms prior to initiating casting operations. Build the details shown on the
Contract Plans or as amended by approved shop drawings into the forms.
Repair worn, damaged, or otherwise unacceptable forms and obtain the
Engineers approval before casting any segment.
Where sections of forms are joined, ensure that offsets in flat surfaces do not
exceed 1/16 inches and that offsets with corners and bends do not exceed 1/8 inches.
Ensure that all joints in the forms and contact points with bulkheads and existing
segments have good fitting seals to prevent loss of fine material and cement grout.
Check and inspect forms on a regular weekly basis to ensure proper alignment
and geometric accuracy. Do not use forms which fail to meet the specified casting tolerances
until such corrections are made to produce segments within the specified tolerances.
Use a small blockout at all locations where an external tendon enters or exits the
face of the concrete at deviation blocks and diaphragms except at anchorage locations. The
blockout will be approximately 2 inches larger in diameter or overall dimensions than the tendon
duct and have a depth equal to at least the minimum prescribed concrete cover dimension shown
in the Plans.
452-6.3 Casting Control (Geometry): Before commencing the casting operation, submit
the proposed method of geometry control for all segment casting operations to the Engineer for
approval. This submittal must be in the form of a Casting Manual and include but not
necessarily be limited to:
(1) All measuring equipment, procedures and the location of control points to be
established on each segment.
(2) The location and values of all permanent benchmarks and reference points in
the precasting yard.
(3) A geometry control procedure for the vertical and horizontal alignment control
for the precasting of segments; including survey controls and procedures, observations, checks,
computational and/or graphical methods and correction techniques.
(4) The casting curves which include the theoretical geometric horizontal
alignment, profile grade and superelevation appropriately combined with the camber.
Ensure that the casting manual covers all geometry control operations
necessary and is compatible with the chosen methods of casting and erection, including erection
survey, elevation and alignment control. Prepare the manual in accordance with submittal
requirements of this Section.
Do not begin casting without the Engineers approval of the geometry
control method.
In the precasting yard, use instruments for the geometry control which are
mounted on a permanent platform of sufficient height to sight on all control points. In addition,
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establish and maintain permanent benchmarks and reference points throughout the casting
operations.
During casting, make all corrections required in the geometry of the
segments from the control points established on each segment.
With a match cast system, after casting and before bond breaking to
separate the segments, check the position of the new cast and match cast segments again. If
positions are not as desired, make corrections in the next segment. In general, and unless
otherwise approved by the Engineer, make observations on the geometry control reference
hardware cast into the segments (i.e. elevation bolts, alignment offsets and lengths) to a precision
of plus or minus 0.001 foot.
During casting operations, produce and maintain on a daily basis a
graphical plot of the vertical and horizontal as cast alignments along each vertical and
horizontal control line to an exaggerated scale in order to clearly highlight variations. Depict
these against both the theoretical geometric vertical and horizontal alignment casting curves on a
continuous layout of an entire unit of the bridge between expansion joints. Maintain this plot in
good condition so that it may be used and referenced during erection.
Keep all geometry control hardware cast into any segments, such as
elevation bolts and alignment hairpins, in place during erection for reference and checking
purposes. Remove the hardware after completion of erection of the unit in the bridge between
expansion joints.
Use experienced personnel to operate the instruments and supervise the
casting operation. Prior to the commencement of casting, obtain the Engineers approval of the
experience and/or qualifications of the supervisory and instrument operating personnel,
particularly with regard to the observational precision required.
452-6.4 Preparation For Match Casting: When match casting is used, take great care in
positioning of the match cast (previously cast) segment in relation to the segment to be cast.
Ensure that the match cast segment is not twisted.
Ensure that all materials to be embedded in the concrete of the new cast segment
are properly positioned and supported in order to maintain their position and withstand concrete
placement and consolidation without damage. Make provisions for all projections, recesses,
notches, openings, blockouts and the like in accordance with the Plans and approved shop
drawings.
Cover the abutting surface of the match cast segment with a thin film of a bond
breaker consisting of flax soap and talc, or other material approved by the Engineer. Use a soap
and talc mixture consisting of five parts flax soap to one part talc. The Engineer will base
acceptance of a material other than soap and talc prior to casting any segments by demonstration
on a large specimen consisting of a precast piece and a new cast piece with a contact facial area
of at least 4 square feet.
452-6.5 Embedded Items:
452-6.5.1 General: Embedded items must be in accordance with specifications
for prestressed and post-tensioned construction and the requirements herein.
452-6.5.2 Embedded Post-Tensioning Ducts: Ensure that embedded ducts for
post-tensioning tendons and bars are positioned accurately to their required alignment. Properly
fabricate and identify all ducts so that proper positioning is assured and can be verified after
casting.
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Utilize positive methods to ensure that ducts will not be displaced or
damaged during concrete placement and consolidation. Adequately secure all embedded posttensioning ducts to the reinforcement cage at intervals not exceeding 30 inches for steel pipes
and 24 inches for plastic ducts, (Small ducts and very flexible ducts may require closer supports).
Any auxiliary ties and support bars needed for these purposes will be considered incidental and
at no extra cost to the project. Prevent the concrete cover requirements from being violated by
any auxiliary ties and support bars.
After installation in the forms, ensure that the ends of the ducts are sealed
at all times to prevent entry of water, debris and fine material. Following each pour of concrete,
demonstrate that all empty ducts are free of water and are unobstructed and undamaged.
Immediately prior to installation of the prestressing steel, again
demonstrate to the satisfaction of the Engineer that all ducts are unobstructed and free of water
and debris.
452-6.5.3 Anchor Plates and Castings: Prior to placing concrete in the forms,
fix all tendon anchor plates and anchor castings in their respective position in the forms,
connected to their duct and sealed to prevent mortar intrusion. Ensure that anchor plates and
castings are rigidly fixed in the forms to maintain their correct alignment and position during
concrete placement and consolidation.
452-6.5.4 Reinforcing Steel: Fabricate and place reinforcing steel in accordance
with the Contract Plans or as superseded by the approved shop drawings and as required herein.
Do not cut out or remove reinforcing steel to permit proper alignment of
post-tensioning ducts. Replace any bar that cannot be fabricated to clear the ducts by additional
bars with adequate lap lengths and submit the details to the Engineer for approval.
In the plane of the reinforcement parallel to the nearest surface of the
concrete, ensure that bars do not vary from plan placement by more than 1 inch, nor by more
than one-eighth of the spacing between bars, whichever is less. In the direction perpendicular to
this plane of reinforcement, ensure that bars do not vary from plan placement by more than
1/4 inches. The top and bottom cover of reinforcing steel must be within 1/4 inches of the cover
dimensioned in the Plans. The edge cover of the reinforcing steel must be within 1 inch of the
cover dimensioned in the Plans.
452-6.6 Concrete Placement, Consolidation and Finishing:
452-6.6.1 General: Do not deposit concrete into the forms until the entire set-up
of the forms, reinforcement, ducts, anchorages and embedded items have been thoroughly
inspected and checked. Do not place concrete until the Engineer is satisfied that all the above
items have been properly inspected and checked, and the rate of producing and placing the
concrete will be sufficient to complete the casting and finishing operations within the scheduled
time, that experienced concrete finishers are available where required for finish work and that all
necessary finishing tools and equipment are on hand at the site of the work and are in satisfactory
condition for use.
During conveying and placement, protect concrete against undue drying or
rise in temperature and inclement weather.
452-6.6.2 Concrete Placement Equipment: Use concrete placement equipment
of a size and design which permits placing concrete within the specified time. Clean all
equipment at the end of each operation or workday and, just prior to reuse, check the equipment
again and clean off hardened concrete and foreign materials.
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Place concrete by belt conveyors and by pumping in accordance with
400-7.6 and 400-7.7, respectively.
452-6.6.3 Concrete Placement Sequence:
(1) Superstructure box segments: First place concrete in the central portion
of the bottom slab between the inside edges of the internal web forms, leaving a narrow gap of
6 inches to 12 inches for inspection and consolidation of the bottom corners when the next load
is placed in the webs. Then place the concrete in the bottom corners of each web to connect and
consolidate with that already placed in the bottom slab. Then place concrete in the remainder of
the webs in lifts not exceeding 24 inches at a time up to the top of the webs but not into the slab
over the webs. Place concrete in the top slab in the outer wing and mid slab regions between
webs before placing, completing and consolidating zones over the top of the webs.
(2) Substructure and Pier Shaft Segments: Cast precast pier shaft segments
vertically. Place the concrete in uniform lifts of approximately 24 inches to 36 inches and
consolidate well.
(3) Obtain the Engineers approval on any alternative sequences to the
above, or for any other precast components.
452-6.6.4 Concrete Placement and Consolidation: Discharge individual loads
of concrete into the forms, and place and consolidate in the required locations. After discharge
into the forms, do not bodily move concrete from place to place within the forms by mechanical
vibrators or other similar equipment.
Place and consolidate concrete with care so that post-tensioning ducts,
anchorages and any other embedded items are maintained in their proper positions and are not
damaged.
Consolidate all concrete using approved vibrators together with any other
equipment necessary to perform the work as specified. Use internal vibrators having a minimum
frequency of 8,000 vibrations per minute and sufficient amplitude to consolidate the concrete
effectively. Provide at least two stand-by vibrators in working condition for emergency use in
case of malfunction.
Use of external vibrators for consolidating concrete when the concrete is
inaccessible for adequate consolidation by internal means. When external vibration is used,
construct the forms sufficiently rigid to resist displacement or damage.
Vibrate concrete in a manner which avoids displacement or damage to
reinforcement, post-tensioning ducts, anchorages and other embedded items.
No construction joints are allowed within a segment, except as detailed in
the Plans.
452-6.6.5 Finishing: Strike off the roadway surface of the segment with an
approved mechanical screed operated by a self contained power source.
Furnish and use a straightedge at least 24 inches longer than the segment
while finishing the concrete deck surface of superstructure box girder segments. Use the
straightedge approximately parallel to the centerline of the segment to strike an accurate surface
between the bulkhead and the top of the match cast segment at all positions across the segment
width.
Give all other surfaces of segments and precast components a Class 3
Finish at the precast site in accordance with 400-15.
452-6.7 Curing:
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452-6.7.1 General: Where casting cells are intended to operate on a short (daily)
cycle and it can be demonstrated to the satisfaction of the Engineer that the required initial
concrete strengths for the removal of the forms, application of prestress, moving and handling of
the segments and that the final concrete strength can be achieved in a timely and consistent
manner, then steam curing will not be required. However, take precautions to promote proper
curing by methods approved by the Engineer and in accordance with Section 400. Such
precautions must meet or exceed the following:
(a) To prevent moisture loss, cover all exposed surfaces (those not in
contact with a form or match cast segment) as soon as possible after casting with a moisture tight
covering (wet curing blankets or other approved equal systems). Avoid spoiling the deck surface
finish. Keep the cover on or within 12 inches of the deck surface.
(b) Keep the moisture-tight covering substantially in place throughout
succeeding operations such as geometry control survey, stripping of internal forms, wing forms
and shifting of and working with a segment in a match cast position. Keep the concrete surface
wet throughout these operations.
(c) After stripping of the side and core forms, continue curing of the
precast concrete by the application of a Type 2 (white pigmented) membrane curing compound
as specified in 925-2 to all exposed surfaces (including segment exterior once exposed by
removal from the form). Apply an approved debonding compound to match cast surfaces to
serve both as a bond breaker and seal for curing.
(d) Maintain the moisture tight covering for at least 72 hours.
As an alternative, steam curing may be used.
(e) While the new cast segment is in contact with the match cast segment,
cover the match cast segment with curing blankets, or other approved equal system, to minimize
the effects of differential temperature between the segments.
452-6.7.2 Steam Curing: Meet the requirements of Section 400 modified by the
following requirements when steam curing is used.
(1) Provide a device or devices for simultaneously recording the
temperature of three widely separated locations per casting cell. Locate the three temperature
sensors near the top, middle and bottom of the enclosure or as otherwise approved by the
Engineer. Identify the charts with the hours, dates and segment number and deliver to the
Engineer immediately after steam curing is completed unless otherwise approved.
(2) Apply an approved debonding compound to match cast surfaces to
serve both as a bond breaker and seal for curing.
(3) Expose match cast segments to the same curing environment
(temperature and humidity) as the new cast segment until the new segment reaches the required
strength to allow the removal of the forms.
452-6.8 Removal of Forms: Prior to removing the forms, protect the plastic concrete
from adverse weather effects.
Keep supporting forms in place until the concrete has reached the required
strength for form removal as specified in the Plans, in this Section, or as approved by the
Engineer.
Test cylinders, made and cured in the same manner as the segment, to confirm the
form release strength prior to removing form. With the Engineers approval, a strength curve
chart may be established to determine the time necessary for achieving the required form release
strength, in accordance with the specifications for form removal.
511
Avoid cracking or damaging the segment when removing the forms, especially
match cast surfaces and shear keys. Notify the Engineer of any damage which occurs and repair
in an approved manner.
452-6.9 Test Samples: Provide additional test samples and testing for compressive
strength on precast segments and field closure joints to control the construction activities and to
ensure adequate strength of these components at various stages of their manufacture and
assembly.
Make test cylinders, in accordance with Section 346, cured in the same manner as
the structural components to ensure adequate compressive strength has been achieved in
accordance with the plan requirements for the following conditions:
(a) Prior to release of prestressing for components which are to be
pretensioned.
(b) Prior to form release and/or moving the components to storage.
(c) Prior to post-tensioning transverse tendons if the component is less
than 28 days old.
(d) Prior to placing a component into position in the structure and/or
stressing of longitudinal post-tensioning tendons if the component is less than 28 days old.
Determine the number of cylinders in accordance with the proposed method for
casting, transporting and erecting the various components.
Provide the results of the compression testing of one or more test cylinders for
controlling the time of execution of the various construction operations. Obtain the Engineers
approval for meeting the Specification requirements on casting, curing and testing of concrete
test cylinders.
No direct payment will be made for the concrete testing. All costs for such testing
will be included in the bid items for the various precast structural components.
452-6.10 Age at Erection: Unless otherwise approved by the Engineer, precast
components must be at least 14 days old prior to incorporating into the structure.
452-6.11 Tolerances:
452-6.11.1 General: The following tolerances apply to the fabrication of precast
components:
(1) Superstructure Box Segments:
Width of Web
Depth of bottom slab
Depth of top slab
Overall depth of segment
Overall width of segment
Length of segment
Diaphragm dimensions
1/4 inch
3/16 inch
3/16 inch
3/16 inch
1/4 inch
3/8 inch
3/8 inch
(2) Precast Box Pier Segments
Height (Individual Element)
Width and Breadth (Individual Element)
Thickness (wall)
(3) All Fabricated Segments:
512
1/4 inch
1/4 inch
1/4 inch
Ends (deviation from a plane per 20 ft width
or depth
Flat Surface (deviation from a plane at any
location)
1/4 inch per 20 ft not to exceed 1/2 inch.
0.025 in/ft not to exceed a total of 1/4 in.
452-6.11.2 Corrections: Control dimensions from segment to segment, including cast-inplace segments, and compensate for any deviations within a single segment or series of segments
so that the overall dimensions of the completed structure meet the dimensions and overall
erection tolerances shown in the Plans and allowed by this Section.
452-6.11.3 Repairs: Repair minor breakage, spalling, or honeycomb (not over 1 inch
deep) by a method approved by the Engineer. Major breakage, spalling, or honeycomb in excess
of 1 inch deep is subject to the Engineers structural review. If found to be satisfactory, repair
these areas using a method approved by the Engineer. Do not perform surface finishing or repairs
on the matching joint surfaces of precast segments until after final erection of the segment,
except as herein noted. If more than 20%, but less than 40% of the total contact surface of all
shear keys in any single web is broken, spalled or honeycombed, grind the damaged areas to
produce a cylindrical depression into sound concrete to a depth and width approximately equal to
the shear key dimensions. Complete necessary repairs to shear keys damaged at the casting site
prior to shipping the segment to the erection site. After erection of the segments adjacent to the
damaged keys and prior to erection of additional segments, carefully pack the voids left by the
depressions with an epoxy mortar as approved by the Engineer. With the Engineers approval, an
alternate method of repair may be used. The Engineer will consider the segment unsatisfactory
for use if more than 40% of the total contact surface of all shear keys in any single web is
broken, spalled or honeycombed. Use an Engineer approved method for repairing damaged
alignment keys located in the top and bottom slabs. The Engineer will consider a segment
unsatisfactory for use if more than 50% of the total contact surface of all alignment keys in any
element of the slab (wing overhang, central portion between webs, etc.) is broken, spalled or
honeycombed. Remove and dispose segments found to be unsatisfactory and not repairable after
structural review and cast a new segment at no expense to the Department.
452-7 Precast Segment Handling, Storage and Shipment.
Handle segments with care to prevent damage. Handle segments using only the devices
shown on the shop drawings for this purpose. Store all precast segments level in the upright
position. Firmly support all precast segments for storage and shipment on an approved three
point bearing system which does not introduce a twist under self weight. Do not stack
superstructure segments one upon another unless approved by the Engineer.
Prior to shipment the Engineer will thoroughly inspect each segment for damage.
Thoroughly clean the faces of all joints of laitance, bond breaking compound and any other
foreign material by light sand blasting prior to shipment. Make no repairs of minor spalls or
chipped areas on the joint surfaces until after erection of the segment. Upon arrival at the bridge
site the Engineer will inspect each segment again. If in the Engineers opinion, any damage has
occurred during shipment that will impair the function of the segment (structurally, aesthetically,
etc.), the segment will be rejected. Replace any rejected segment with an approved segment at no
cost to the Department. Provide firm support at bearing locations noted above. Fully secure the
segments against shifting during transport. Provide a storage area of suitable stability for the
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segments to prevent differential settlement of the segment supports during the entire period of
storage.
452-8 Erection.
452-8.1 Erection Manual: Before commencing erection operations, submit proposals for
all segment erection operations to the Engineer for approval. This submittal must be in the form
of an Erection Manual and include but not necessarily be limited to:
(1) A detailed step-by-step sequence for the erection of each segment including all
intermediate procedures relating to erection equipment, temporary and permanent posttensioning and making of closures between spans and/or cantilevers and other required
sequencing.
(2) Positioning, use and sequencing of falsework, jacking and/or releasing of
falsework, temporary towers, supports, tie-downs, counterweights, closure devices and the like.
(3) Positioning, use and sequencing of erection equipment such as cranes, beam
and winch devices, gantries, trusses and the like, both on and off the structure, including the
movement, introduction and/or removal of any supports onto or connections with the structure.
Include drawings and calculations for the structural effects of erection equipment on the
structure.
(4) Detailed scheduling of all temporary and permanent post-tensioning
operations and sequences in accordance with the segment erection and closure operations and
other required scheduling.
(5) Stressing forces and elongations for post-tensioning.
(6) Sequencing of grouting operations.
(7) A method for the field survey control for establishing and checking the erected
geometry (elevations and alignments) with particular attention to the setting of critical segments
such as, for example, pier segments for balanced cantilever erection. This information may be
included in the Erection Manual or may be provided later as a supplementary or separate
document.
(8) Any other relevant operations as required and applicable to the structure type
and construction method.
Do not start erection without the Engineers approval of the erection manual.
452-8.2 Erection Geometry Control:
452-8.2.1 General: Numerical or graphical methods may be used for alignment
control and checking during erection. Establish the key stages for checking of the erection in the
erection manual and obtain the Engineers review and approval. Key stages would include, for
example, setting a pier segment during cantilever erection and various intermediate points during
subsequent segment erection, at span closure and upon completion.
Prepare a table of elevations and alignments required at each key stage of
erection in accordance with the Plans, as cast geometry, camber and erection elevations for
establishing erection controls and submit to the Engineer for approval.
Carefully check elevations and alignments at each stage of erection and
correct as required to avoid any possible accumulation of errors.
If geometric corrective measures are necessary, the Engineer will require
the Specialty Engineer to develop the means and methods to ensure the epoxy joint remains
watertight and free from localized stress concentrations. The Specialty Engineer will be required
to submit the corrective measures to the Engineer for approval. Use shims made of ASTM A240
Type 304 wire cloth (roving) with a maximum of 1/8 inch thickness.
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452-8.2.2 Span-by-Span and Wet Joint Erection: Position each span segment
according to the final longitudinal alignment, grade, camber and cross-slope. Keep the horizontal
and vertical alignment of the pier segment within 1/16 inches of that required by the approved
erection plans.
Correct any deviation more than the tolerance allowed above using a
method approved by the Engineer.
452-8.2.3 Balanced Cantilever and Progressive Cantilever Erection: Check
the alignment and elevations of the cantilevers, using two independent surveys, within one hour
of sunrise on each day that segments are to be erected. Check the measurements made by each
survey and ensure they agree to within 1/4 inches. When measurements do not agree, discontinue
erection of segments until discrepancies in measurements are resolved to the satisfaction of the
Engineer.
Accurate positioning of the pier segments is very important as it will
establish the line and grade for cantilevers in each direction. Position each pier segment
according to the final longitudinal alignment, grade and cross-slope and ensure no further
erection continues until and unless these segments are properly located on the piers by the means
provided. Keep the horizontal and vertical alignments of the pier segment within 1/16 inch of the
alignment values required to control points as established by the approved erection plans.
Check at each key stage of erection, in accordance with approved erection
procedures, the ends of cantilevers for required elevations and alignment. Correct any deviation
from the required alignment by a method approved by the Engineer.
452-8.3 Erection Tolerances:
(1) Ensure that maximum differential between outside faces of adjacent segments
in the erected position does not exceed 3/16 inches.
(2) Ensure that transversely, the angular deviation from the theoretical slope
difference between two successive segment joints not exceed 0.001 rad.
(3) Ensure that longitudinally, the angular deviation from the theoretical slope
change between two successive segments does not exceed 0.003 rad.
(4) Dimensions from segment to segment will compensate for any deviations
within a single segment so that the overall dimensions of the completed structure meets the
dimensions shown in the Plans such that the accumulated maximum error does not exceed
1/1000 of the span length for either vertical profile and/or horizontal alignment.
Carefully check elevations and alignments at each stage of erection and correct as
required to avoid any possible accumulation of errors.
452-8.4 Other Miscellaneous Erection Requirements:
452-8.4.1 Span-by-Span and Wet Joint Erection:
452-8 .4.1.1 Closure Joints: Use concrete meeting the same specifications
and criteria as the concrete in the segments. Ensure that concrete reaches the minimum required
strength as shown in the Plans or in the Specifications prior to stressing the continuity posttensioning. Ensure that the closure joint forms provide tolerances as specified under 452-5.11
Tolerances.
452-8.4.1.2 Wet Joints: Where forming joints between segments using
cast-in-place concrete, the above conditions for closure joints also apply to wet joints. In
addition, the cast-in-place Wet Joints cannot be less than 3 inches wide, nor greater than
9 inches wide unless otherwise approved by the Engineer.
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452-8.4.1.3 Formwork: Adequately support formwork at all wet joints
and closure joints to take all loads applied and do not remove them until the concrete in the joints
has reached its required strength and the longitudinal tendons have been tensioned.
452-8.4.2 Balanced Cantilever and Progressive Cantilever Erection:
452-8.4.2.1 Deformations: For computing deformations due to time
dependent stress variations, the erection time assumptions are shown in the Plans.
Deformations due to creep and shrinkage and the concrete modulus
of elasticity have been computed using the latest edition of the FDOTs Segmental Bridge
Design Criteria. Obtain the Engineers approval for method of calculating the above parameters.
452-8.4.2.2 Temperature Restrictions: Meet the requirements of 453-4
for substrate temperatures, epoxy formulation and thermal controls where precast segments are
jointed with epoxy. Measure the substrate temperature at the mid-depth of the top slab for box
girder sections or 4 inches from the top surface for slabs and other sections.
452-8.4.2.3 Permissible Loads on Cantilever: During balanced
cantilever erection, unbalance the cantilever by only one segment at any time. In addition to the
unbalanced load due to one segment, the cantilevers are designed for loads applied by the
erection equipment as listed in the Plans. Use alternate erection methods which comply with the
assumptions in the Plans or otherwise approved by the Engineer.
452-8.4.2.4 Span Closure Joints: Use concrete for closure joints which
comply with the same specifications and criteria as the concrete in the segments. Ensure that
concrete reaches the minimum required strength as shown in the Plans or in the Specifications
prior to stressing the transverse or continuity post-tensioning. Ensure that the closure joint forms
provide tolerances as specified for precast segments.
452-8.4.2.5 Falsework and Formwork: Support falsework and formwork
at closure pours by the cantilever ends or terminating segments of each series of segments to be
joined. Secure cantilever together vertically, longitudinally, and transversely so that the applied
loads will yield equal deflections to both cantilevers. Do not remove securing devices until the
closure pour concrete has reached its required strength and longitudinal continuity tendons are
tensioned. Submit calculations and details to verify that the devices and methods have adequate
rigidity and do not impose excessive loads and stresses on the structure.
452-8.4.3 Precast Box Pier Construction - Erection Tolerances:
(1) Ensure that maximum differential between outside faces of adjacent
segments in the erected position does not exceed 3/16 inches.
(2) Ensure that the rotational angular deviation, measured about a vertical
line, between two successive segment joints does not exceed 0.001 rad.
(3) Ensure that the maximum angular deviation of a segment from a
vertical line does not exceed 0.003 rad. and that the maximum overall deviation from the
vertical, measured in any direction, does not exceed 0.01 inches per foot of height.
(4) Ensure the base precast segment is within 1/2 inch of the Plan location.
452-8.5 Epoxy Jointing of Precast Segments: Meet the requirements of Section 453 for
epoxy jointing precast segments. Select the appropriate epoxy material based on the job
requirements as either normal or slow set epoxy within the formulation temperature range based
on the substrate temperature.
452-8.6 Packed Mortar Joints for Joints, Bearings or setting Pier Shaft Segments:
Where designated on the Plans, place packed mortar after the precast element or bearing has
been set at the proper final elevation.
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Pressure grouting the joint may be allowed with the Engineers approval of the
materials and method to be used. Additionally, where precast piers are shown connected to the
footings by packed mortar, temporarily supporting the base segment and casting the footing
around the segment will be allowed. Minimum penetration of the base segment into the footing
must be 2 inches. No additional payment for this operation or for additional footing concrete will
be made.
Mortar for packing consists of one part cement and one part fine aggregate, by
volume, mixed with a non-shrink admixture as recommended by the manufacturer. Mix the dry
elements thoroughly to a uniform mixture. Add water to produce a mealy, slightly adhesive
mixture. Pack the mortar until a water sheen is produced on the surface of the mortar.
Build a form around the joint leaving one side open. Secure the form to withstand
the required packing forces. Insert a small amount of mortar into the open joint to form a
2 inches thick bead on the opposite side of the form. Pack this bead by striking a special tool
made of 1/2 inch by 2 inch steel having a length approximately 10 inches longer than the largest
dimension of the joint being packed with a 2 pound hammer. Continue compaction until water
begins to bleed out of the mortar. When bleeding has occurred, insert another bead of mortar and
pack as described above. Continue this process until the joint is filled to the limits shown in the
Plans.
452-9 Barrier And Median Setting.
Prior to forming the barriers, accurately establish the as-constructed gutter line elevations
at intervals not exceeding 10 feet. Then form the base of the barrier and median to provide an
inside vertical face which extends from the surface of the concrete structure to an elevation
located 3 inches (or as shown in the Plans) above the theoretical gutter line elevations. Maintain
the plan vertical height of the barriers as a minimum when variations exist between the plan
profile and the actual profile of the gutter.
452-10 Bridge Deck Surface.
Provide a Class 4 Floor Finish in accordance with Section 400 for Long Bridges upon
completion of superstructure segment erection and prior to opening to traffic. Install expansion
joints in accordance with Section 400.
452-11 Watertight Decks.
Check all segment joints, closure joints and deck hole repairs to assure every location is
watertight, upon completion of all milling and grinding activities on the riding surface. Repair all
locations showing evidence of leaks by cutting a 3/8 inches wide x 5/8 inches deep groove along
the leak interface. Clean and completely fill the groove with epoxy meeting the requirements of
Section 453. Dispense the epoxy into the groove using a pneumatic gun and epoxy cartridges.
Clean all excess epoxy bonding agent from external visible surfaces in a way not to damage or
stain the concrete surface. Do not smear epoxy over areas located more than 1 inch from each
side of the groove.
452-12 Method of Measurement.
Precast superstructure and substructure segment concrete, including cast-in-place
concrete for closure and wet joint pours, will be measured by volume according to the quantities
represented by the dimensions of the segments and cast-in-place pours on the Contract Plans or
approved shop drawings; whichever is the lesser.
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All reinforcement in precast superstructure and substructure segments, cast-in-place
closures and wet-joints will be measured by weight according to the quantities represented by the
reinforcement details in the Plans or approved shop drawings; whichever is the lesser.
All permanent post-tensioning in the superstructure and substructure will be measured by
weight according to the quantities represented by the details in the Plans or approved shop
drawings; whichever is the lesser.
452-13 Basis of Payment.
452-13.1 General: Payment will be in accordance with the following:
452-13.2 Precast Segments-Concrete: Payment for precast superstructure and
substructure segment concrete will be at the Contract bid prices per cubic yard for the various
classes of concrete called for.
Such prices and payments will be full compensation for manufacture, storage,
transport, assembly and erection of the segments complete and in place, including filling all
concrete blockouts and similar miscellaneous details. These prices and payments will also
include the furnishing and the application of epoxy bonding agent and Class 5 applied finish
coating when specified in the Plans, providing temporary and permanent segment access details,
material testing, special erection equipment, temporary post-tensioning, tools, labor and
incidental items necessary for completing the work in accordance with the Plans, Specifications
and approved shop drawings.
Cast-in-place concrete for closure and wet joint pours will be paid for under these
items which also include the cost of all formwork, closure devices and other temporary
construction needed to make these closures and joints and cast-in-place segments or portions
thereof as designated in the Plans.
Include the cost of providing a Class 4 floor finish on the bridge deck and
approach slab surfaces in the cost of superstructure and approach slab concrete.
The Bridge floor grooving will be measured and paid for separately.
No additional payment will be made for extra concrete necessitated by approved
modifications to the segments or structure needed to accommodate the Contractors construction
methods.
452-13.3 Precast Segments-Reinforcement: Payment for reinforcement in precast
segments, closure pours, wet joints and other cast-in-place concrete joints and details will be at
the Contract bid price per pound for reinforcing steel (superstructure) and for reinforcing steel
(substructure).
No additional payment will be made for extra reinforcement necessitated by
approved modifications to the segments or structure for the purposes of the Contractors
construction methods.
452-13.4 Precast Segments-Post-Tensioning: Payment for permanent post-tensioning
will be in accordance with Section 462.
No additional payment will be made for extra permanent or temporary posttensioning necessitated by approved modifications to the segments or structure for the purposes
of the Contractors construction methods, nor will payment be made for temporary tendons
which are approved to be left in the structure, either stressed or unstressed, for the convenience
of the Contractors operations.
452-13.5 Precast Segments-Partial Payment: Partial payment for precast segments will
be made at 65% of the bid price per cubic yard of concrete and per pound of reinforcement when
the segment has been cast and accepted. Remaining payment will be made when the segment has
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been erected and accepted for incorporation into the structure. Payment for post-tensioning will
be in accordance with Section 462.
452-13.6 Precast Segment-Non-Compliance: Any penalties or deductions for noncompliance with regard to concrete, reinforcement or post-tensioning will be applied to the work
affected in accordance with the requirements of the respective specifications.
452-13.7 Precast Segment Production: Preparatory operations for superstructure
segment casting will be paid for separately at the Contract Lump Sum price for precast segment
production. This item consists of the work necessary for establishing and putting into operation
segment casting facilities. It includes preparatory work, operations, acquisition or lease of real
property, acquisition or lease of segment manufacturing equipment, acquisition or lease of
equipment for the handling, transport and storage of the segments, and all other work or
operations which must be performed or costs incurred prior to the manufacture of the concrete
segments, including engineering services such as shop drawings.
Partial payments will be made as indicated below:
a) Upon production of documentary evidence, such as paid invoices,
canceled checks or similar executed financial instruments, the cost for the acquisition of the
casting forms for the precast segments by purchase, lease or manufacture will be paid up to a
limit of 25% of the Lump Sum Price bid.
b) When the first precast superstructure segment has been cast out of the
first operable casting form and the segment is approved and accepted by the Engineer, 25% of
the Lump Sum Price bid will be paid.
c) Thereafter, when each succeeding superstructure segment has been cast
out of any operable casting form and approved and accepted by the Engineer, 5% of the Lump
Sum Price bid will be paid for each segment up to a limit of 50% of the Lump Sum Price bid
(i.e., 5% for each of the next ten acceptable segments).
The total Lump Sum Price bid under this item will not exceed the least of:
a) 12% of the sum of the amounts paid for the concrete in the precast
segments only (i.e., excluding any cast-in-place concrete in joints, closures or designated cast-inplace segments) or
b) 5% of the Contract amount excluding mobilization and this item.
The balance of the Lump Sum Price not paid after completion of casting the first
11 satisfactory superstructure segments will be paid after completion of the erection of the first
span or closure of the first pair of cantilevers, whichever occurs first.
452-13.8 Payment Items:
Payment will be made under:
Item No. 400- 4- 39-Class IV Concrete (Precast Superstructure
Segments)-per cubic yard.
Item No. 400- 4- 40-Class IV Concrete (Precast Substructure Segments)per cubic yard.
Item No. 400- 8- 40-Class V Concrete (Precast Substructure Segments)per cubic yard.
Item No. 415- 1-4-Reinforcing Steel (Superstructure)-per pound.
Item No. 415- 1-5-Reinforcing steel (Substructure)-per pound.
Item No. 452- 70-Precast Segment Production-lump sum.
519
SECTION 453
EPOXY JOINTING OF PRECAST SEGMENTS
453-1 Description.
Furnish, mix and apply a two-component epoxy bonding system to the match cast faces
of joints between precast concrete superstructure and/or substructure segments in accordance
with the Contract Documents.
In its workable state, or open time, the epoxy bonding agent must function as a lubricant
for joining the segments. In its hardened state, the epoxy bonding agent must provide a
watertight seal between the precast concrete segments. The hardened epoxy bonding agent must
provide intimate contact for stress transfer by completely filling all interstitial space between the
match cast segment faces.
This Section applies to precast segmental structures with multiple shear joints in webs
and joints with suitable shear keys in precast substructure segments.
453-2 Acceptance of Epoxy Bonding System.
Use only epoxy systems that are on the Departments Qualified Products List (QPL).
Manufacturers seeking evaluation of their products must submit an application conforming to the
requirements of Section 6.
Provide to the Engineer a manufacturers certification conforming to the requirements of
Section 6, which confirms that each manufactured lot meets the requirements of this Section and
is the same as the material listed on the QPL.
453-3 Qualifications of Contractors Personnel.
For mixing, handling and applying the epoxy bonding agent, provide direct supervision
by a person with knowledge and experience, or trained by a technical representative of the
manufacturer in the use of this material. Arrange for a technical representative of the
manufacturer to be at the site as an advisor at the beginning of this work.
Ensure that all personnel who will be working with the epoxy bonding agent are
thoroughly familiar with the safety precautions necessary for use of this material.
453-4 Material.
453-4.1 General: Use only epoxy bonding agents for match-cast joints between precast
segments which are thermosetting 100% solid compositions that do not contain solvent or any
non-reactive organic ingredient except for pigment required for coloring and meet the
requirements of ASTM C881, Type VI Grade 3 as modified below. Use epoxy bonding agents
composed of two components, a resin and a hardener, with each component distinctly pigmented
so that mixing produces a third color similar to the concrete in the segments.
Epoxy bonding agents must be insensitive to damp conditions during application
and, after curing, must exhibit high bonding strength to cured concrete, good water resistivity,
low creep characteristics and tensile strength greater than the concrete.
453-4.2 Packaging, Identification and Use: Use only components packaged in two
parts, in sealed containers, proportioned in the proper reacting ratio, ready for combining and
mixing in accordance with the manufacturers instructions. Each container must bear a label
and/or stamp designating the manufacturers name, brand name, the component type (resin or
hardener), the range of substrate (surface of concrete) temperature over which the application is
520
suitable, material classification, the date of formulation, the shelf life of the material, and the
manufacturers lot number.
Provide instructions, furnished by the manufacturer, for the safe storage,
handling, mixing and application of the material.
Do not use any material from containers which are damaged or have been
previously opened. Combining of epoxy bonding components from bulk supplies will not be
permitted. Only full packets of components will be mixed.
453-4.3 Classification of Epoxy Material: Epoxy bonding agents which remain
workable for a short open time (about one hour) are referred to herein as normal set epoxy.
Epoxy bonding agents which remain workable over an extended open time (about eight hours)
are referred to herein as slow set epoxy.
453-4.4 Formulation for Temperature Range: Epoxy bonding agents must be
formulated to provide application temperature ranges which are suitable for the erection of
match cast segments with substrate temperatures between 40F and 115F with a minimum of at
least two, but preferably three, formulations dividing the range into approximately equal
subranges which overlap by at least 5F.
453-4.5 Physical Requirements:
453-4.5.1 General: Epoxy bonding agents proportioned as designated by the
manufacturer and mixed in accordance with the manufacturers recommendations shall meet the
requirements of ASTM C881. For the properties listed below, modify the ASTM test procedures
as noted. The components of the epoxy-bonding agent shall be conditioned to the temperature at
which testing is to be done prior to mixing the test specimen.
453-4.5.2 Contact Time (Open Time) and Contact Strength: The contact time
(open time) of the mixed epoxy-bonding agent shall be:
Normal-Set Epoxy ................. 60 minutes, minimum
Slow-Set Epoxy ........................... 6 hours, minimum
The above contact time (open time) will be deemed acceptable if a slant
cylinder test specimen, prepared and tested in accordance with the conditions below, sustains the
following stress (contact strength) on the slant plane calculated as the axial (vertical) load
divided by the area of the slant ellipse:
Normal-Set Epoxy ...................... 1,000 psi at 48 hours after joining
Slow-Set Epoxy ............................ 1,000 psi at 14 days after joining
The cement mortar/concrete material for the slant-cylinder test shall have
a compressive strength of at least 4,500 psi at 28 days when tested to ASTM C39. The slantcylinder test procedure must be in accordance with ASTM C882 with the following
modifications:
1. Delay joining of the sloped surfaces for the following period of
time, measured from the time the epoxy was mixed:
Normal-Set Epoxy ....................... 60 minutes
Slow-Set Epoxy .................................6 hours
2. During the period between mixing of the epoxy and joining of
the sloped surfaces, the specimens will be uncovered and maintained at the maximum
temperature of the application range for the formulation tested.
3. After joining, cure at the maximum temperature of the
formulation range at the time periods specified above prior to testing.
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For slow-set epoxy, prepare an additional test specimen and test it to
failure at 36 hours. The formulation of the slow-set epoxy is acceptable only if the epoxybonding agent exhibits a brittle break.
453-4.5.3 Compressive Yield Strength: The compressive yield strength of the
epoxy-bonding agent shall be:
Normal-Set Epoxy .................................... 2,000 psi at 24 hours
................................................................... 6,000 psi at 48 hours
Slow-Set Epoxy ..........................................2,000 psi at 7 days
....................................................................6,000 psi at 14 days
Determine compressive yield strength in accordance with ASTM D695 with the following
conditions:
1. Pour the epoxy-bonding agent into the mold for forming specimens
within ten minutes after starting mixing of the components.
2. Prior to testing, cure the specimens at the minimum temperature of the
formulation range for the time periods specified above.
453-4.5.4 Bond Strength: Bond strength shall be:
Normal-Set Epoxy ...................... 1,000 psi at 48 hours after joining
Slow-Set Epoxy ............................ 1,000 psi at 14 days after joining
Determine the bond strength in accordance with ASTM C882 with the following modifications:
1. The test cylinder of concrete shall have a compressive strength of at
least 6,000 psi at seven days age.
2. Delay joining of the sloped surfaces for the following period of time,
measured from the time the epoxy was mixed:
Normal-Set Epoxy ................................... 60 minutes
Slow-Set Epoxy .............................................6 hours
3. During the period between mixing of the epoxy and joining of the
sloped surfaces, the specimens will be uncovered and maintained at the minimum temperature of
the application range for the formulation tested.
4. After joining, cure at the minimum temperature of the formulation
range for the time periods specified above prior to testing.
453-5 Construction Requirements.
453-5.1 General: Apply an epoxy bonding agent meeting the requirements of this
Section to mating surfaces of all match-cast precast concrete segments.
Prior to the manufacture of epoxy for the project, a site meeting will be held with
representatives from the Engineer, Contractor and epoxy manufacturer, to discuss the selection
of the proper formulations, storage and handling, mixing and application of the epoxy.
Have the necessary cleaning materials immediately available at the location of the
segment joining, in the event that the segments must be separated and cleaned or epoxy
reapplied.
Include in the erection manual required by Section 452, details of erection and
post-tensioning operations which assure that the time elapsing between mixing components of
the first batch of epoxy bonding agent applied to the joining surfaces of precast concrete
segments and the application of a compressive contact pressure across the joint does not exceed
522
70% of the open time for the particular formulation of epoxy bonding agent used. Also, include
details of how the minimum, closing, contact pressure of approximately 40 psi will be applied
uniformly to each joint to which epoxy is applied during the epoxy curing period. Contact
pressure may be attained through combinations of weight and temporary and/or permanent posttensioning.
453-5.2 Cleanliness of Surfaces to be Joined: Ensure that the application surfaces are
free from oil, form release agent, laitance or any other deleterious material that would prevent
the epoxy bonding agent from bonding to the concrete surface. Remove laitance by light
sandblasting, wire brushing. Do not destroy the surface shape and profile of the mating surfaces.
Ensure that the surfaces have no free moisture on them at the time the epoxy
bonding agent is applied. Free moisture will be considered present if a dry rag, after being wiped
over the surface, becomes damp.
453-5.3 Substrate Temperatures and Epoxy Formulation: Apply the epoxy bonding
agent only when the substrate temperature of both surfaces to be joined is between 40F
and115F. The formulation of the epoxy bonding agent must have an application temperature
range that conforms to the substrate temperature of the surfaces being joined. If the mating
surfaces have different substrate temperatures, then use the formulation for the higher
temperature in hot weather periods. In cold weather periods, use the formulation for the lower
temperature. Thermal control precautions may be taken in accordance with 453-5.7 below.
453-5.4 Mixing of Epoxy Bonding Agent: Mix the two components of the epoxy
bonding agent in strict accordance with the manufacturers instructions, using only full and
undamaged containers. Only open the containers immediately before being combined and do not
use any which have an expired shelf life. Thoroughly stir each container of component before
combining the components. Combine the two components and thoroughly mix until a uniform
color is achieved. Mix with a properly sized mechanical mixer operating at no more than
600 rpm and/or in accordance with the recommendations of the epoxy manufacturer.
Do not mix until the segments to be joined are within approximately 18 inches of
their final position. Schedule mixing of the epoxy bonding agent so that the material in a batch is
applied to the face of a joint within a maximum of 20 minutes after combining the components.
The Engineer, at his discretion, may require a dry run to check the fit of two
surfaces before applying the epoxy.
453-5.5 Application and Amount of Epoxy: Begin application immediately after a
batch has been mixed. Uniformly apply the epoxy bonding agent in accordance with the
manufacturers recommendations by spatula or gloved hand a nominal thickness of 1/16 inches.
Apply the epoxy to all areas of both faces to be joined. Do not exclude epoxy from around holes
formed by ducts. Apply additional epoxy thickness, equal to the shim thickness, to segment faces
when shims are placed in a joint.
The amount of epoxy may be adjusted provided that a sufficient amount is applied
to completely fill all interstitial space in the joint and to extrude a small bead from the joint after
application of the compressive contact pressure.
If a bead of epoxy is not extruded all around the joint, then determine the reason
why before proceeding.
Do not use an epoxy bonding agent from a batch for which the time since
combining the components has exceeded 20 minutes.
453-5.6 Mating of Segments: Immediately after each mating surface is covered with
epoxy bonding agent, bring the segments together and apply the specified compressive contact
523
pressure in accordance with the approved erection procedures. The contact pressure may be
increased at any time after the epoxy has taken an initial set. Do not reduce the contact pressure
until the epoxy in the joint has properly hardened and cured. If the contact pressure is reduced,
do not subject the joint to tensile stress.
A discernable bead line of extruded epoxy bonding agent must be apparent along
the exposed edges of the joint. Fill all areas of the joint which do not show a bead of epoxy by
dispensing additional epoxy, meeting the requirements of this specification, into the joint using a
pneumatic gun with epoxy cartridges. Inject epoxy to a minimum depth of 1 inch.
Catch and retain epoxy which is squeezed out of the joint in areas over
waterways, roadways, buildings, etc.
Clean all extruded epoxy bonding agent from external visible surfaces in a way
not to damage or stain the concrete surface. Do not smear surplus extruded epoxy bonding agent
over large areas (areas more than 1 inch from each side of the joint), visible surfaces or surfaces
to which a cover coat, Class 5 applied finish coat or similar or texturing is to be applied later.
Immediately after the segments are joined, swab all embedded (internal) posttensioning ducts or conduits passing through the joints to smooth out any extruded epoxy
bonding agent.
If the time between combining the components of the epoxy bonding agent and
applying the compressive contact pressure exceeds 70% of the minimum open time, immediately
separate the segments and clean in accordance with 453-5.8.
453-5.7 Thermal Controls:
453-5.7.1 Cooling in Hot Weather: If the substrate temperature exceeds 115F,
do not proceed with epoxy jointing. The Contractor may take precautions to keep the mating
substrate surfaces cool by shading and/or wetting with clean water except that the above
requirements for no moisture at the time of application must be strictly adhered to.
453-5.7.2 Artificial Heating in Cold Weather: If electing to erect segments in
cold weather when the substrate temperature of the mating concrete surfaces is below 40F, an
artificial environment may be used to increase the substrate temperature subject to the following:
1. Make the artificial environment by an enclosure surrounding the joint
through which warm air is circulated, or heating is provided by radiant heaters.
2. Raise the temperature of the concrete substrate across the entire joint
surface to at least 40F.
3. Prevent localized heating and the temperature of the substrate
exceeding 95F at any point on the surface. Direct flame heating of the concrete is not allowed.
4. Maintain the temperature of the substrate surfaces between 40F and
95F for at least 24 hours after joining the surfaces.
5. The Contractor may propose, for review by the Engineer, an optional
method of raising and maintaining the substrate temperature of the mating surfaces. Any optional
method must meet the thermal restrictions above.
Epoxy jointing operations may proceed if the air temperature is above
45F and rising and the limitations above are met.
453-5.8 Failure to comply with Time Limits or Incomplete Jointing: If the time limit
between mixing of the epoxy-bonding agent and the application of the contact pressure is
exceeded, or if the joint is incompletely filled and sealed, separate the segments and remove all
epoxy from the faces using spatulas and approved solvent. Do not re-apply epoxy until the faces
have been properly cleaned and solvents dispersed, for a period of 24 hours.
524
453-6 Removal of Support to Segments.
453-6.1 Span-by-Span Erection: Ensure that precast concrete segments remain fully
supported by the erection truss or system until at least 20 hours after mixing of the last batch of
epoxy bonding agent applied to any joint in the span.
453-6.2 Cantilever Erection: Independent support to a newly erected cantilever segment
may be removed when the epoxy bonding agent in the third previous mating joint has set. It is
not necessary for the epoxy bonding agent in the new joint or the immediately previous joint to
be set prior to removing the independent support of the new segment provided that the temporary
and/or permanent post-tensioning has been installed to carry the load of the new and previous
segment along with any applied construction loading as per the requirements of the erection
system.
453-7 Record of Jointing.
Record and submit to the Engineer on a weekly basis the following information:
1. General:
a) Date and time of jointing,
b) Segment numbers or spans jointed,
c) Weather conditions
2. For each joint (identified by location or segment numbers):
a) manufacturers lot number of epoxy bonding agent components.
b) Temperature of the concrete on the joint surface at the middle of each
segment when application of the epoxy bonding agent began.
c) Time of mixing first batch of epoxy bonding agent applied to the joint
and completion of application.
d) Time of applying the required compressive contact pressure.
3. Details of any repairs performed including reason for repair, joint location,
volume of epoxy used, method of application, etc.
453-8 Basis of Payment.
No separate payment will be made for the work of epoxy jointing of precast concrete
segments. The cost of this work will be included in payment for the various precast concrete
items.
525
SECTION 455
STRUCTURES FOUNDATIONS
Index
A. General .......................................................................................... 455-1 through 455-2
B. Piling ............................................................................................ 455-3 through 455-12
C. Drilled Shafts ............................................................................ 455-13 through 455-24
D. Spread Footings ........................................................................ 455-25 through 455-37
E. Structures (Other Than Bridge) FoundationsAuger Cast Piles........................................................................ 455-38 through 455-50
A. GENERAL
455-1 General Requirement.
The Contractor may examine available soil samples and/or rock cores obtained during the
soil boring operations at the appropriate District Materials Office.
455-1.1 Protection of Existing Structures: When the Plans require excavation or
foundation construction operations in close proximity to existing structures, take all reasonable
precautions to prevent damage to such structures. The requirements described herein apply to all
types of structures (on or off the right-of-way) that may be adversely affected by foundation
construction operations (including phase construction) due to vibrations, ground loss, ground
heave, or dewatering. Protect utilities as described in-the applicable provisions of Section 7.
Survey and monitor structures for settlement in a manner approved by the
Engineer, recording elevations to 0.001 foot. Employ a qualified Specialty Engineer to inspect
and document the condition of structures prior to and after construction of excavations and
foundation construction. Inspect and monitor the following structures:
(1) as shown in the Plans.
(2) within a distance of ten shaft diameters or the estimated depth of
drilled shaft excavation, whichever is greater.
(3) within a distance of three times the depth of other excavations.
(4) within 200 feet of sheet pile installation and extraction operations
(5) for projects with pile driving operations, inspect and document the
condition of all structures within a distance, in feet, of pile driving operations equal to 0.25 times
the square root of the impact hammer energy, in foot-pounds. Survey and monitor for settlement
all structures within a distance, in feet, of pile driving operations equal to 0.5 times the square
root of the impact hammer energy, in foot-pounds.
Obtain the Engineers approval of the number and location of monitoring points.
Record elevations:
(1) before beginning construction,
(2) daily during the driving of any casings, piling, or sheeting,
(3) weekly for two weeks after stopping pile driving,
(4) during excavation,
(5) during blasting,
(6) or as directed by the Engineer.
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Notify the Engineer of any movements detected and immediately take any
remedial measures required to prevent damage to the existing structures.
The Department will make the necessary arrangements to provide right of way
entry to the existing structures.
Adequately document the condition of the structures and all existing cracks with
descriptions and pictures. Prepare two reports documenting the condition of the structures: one
report before beginning foundation construction operations and a second report after completing
foundation construction operations. The Department will take ownership of both reports. Do not
perform pre-driving and post-driving surveys of the condition of bridges owned by the
Department except when shown in the Contract Documents.
When shown in the Contract Documents, employ a qualified Specialty Engineer
to monitor and record vibration levels during the driving of casings, piling, sheeting, or blasting
operations. Provide vibration monitoring equipment capable of detecting velocities of 0.1 inches
per second or less.
Upon detecting settlement or heave of 0.005 feet, vibration levels reaching
0.5 inches per second, levels otherwise shown in the Contract Documents, or damage to the
structure, immediately stop the source of vibrations, backfill any open excavations, and contact
the Engineer for instructions.
When excavating for construction, the Contractor is responsible for evaluating the
need for, design of, and providing any necessary precautionary features to protect adjacent
structures from damage, including, but not limited to, selecting construction methods and
procedures that will prevent damaging caving of the shaft excavation and monitoring and
controlling the vibrations from construction activities, including driving of casings, driving of
sheeting, and blasting. When sheeting and shoring are not detailed in the Plans, employ a
qualified Specialty Engineer to design the sheeting and shoring, and to sign and seal the plans
and specification requirements. Send these designs to the Engineer for his record before
beginning construction.
When shown in the Contract Documents or when authorized by the Engineer,
install the piling to the depth required to minimize the effects of vibrations or ground heave on
adjacent structures by approved methods other than driving (preformed holes, predrilling, jetting,
etc.). In the event the Department authorizes the use of preformed pile holes to meet this
requirement, the Department will pay for this work as described in 455-5.9.3.
When shown in the Plans or directed by the Engineer, install a piezometer near
the right of way line and near any structure that may be affected by lowering the ground water
when dewatering is required. Monitor the piezometer and record the ground water elevation level
daily. Notify the Engineer of any ground water lowering near the structure of 12 inches or more.
455-1.2 Excavation: Complete all excavation of the foundations prior to installing piles
or shafts unless otherwise authorized by the Engineer. After completing pile/shaft installation,
remove all loose and displaced materials from around the piles/shafts, leaving a clean, solid
surface. Compact the soil surface on which concrete is to be placed or which will support the
forming system for the concrete to support the load of the plastic concrete without settling or
causing the concrete to crack, or as shown in the Contract Documents. The Engineer will not
require the Contractor to compact for excavations made below water for seals or when the
footing or cap or forming system (including supports) does not rest on the ground surface.
455-1.2.1 Abutment (End Bent) Fill: Place and compact the fill before installing
end-bent piling/shafts, except when:
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(1) driving specified test piling in end bents or,
(2) the Plans show uncased piles through proprietary retaining wall fills.
When installing piles/shafts or casing prior to placing fill, take necessary
precautions to prevent displacement of piles/shafts during placing and compacting fill materials
within 15 feet of the piles/shafts or casing. Reference and check the position of the piles/shafts or
casing at three approximately equal intervals during construction of the embankment.
Place embankment material in 6 inch loose lifts in the 15 foot area around
the piles/shafts or casing. Compact embankment material within the 15 foot area adjacent to the
piles/shafts or casing to the required density with compaction equipment weighing less than
1,000 pounds. When installing piles/shafts prior to the completion of the surrounding fills, do not
cap them until placing the fills as near to final grade as possible, leaving only the necessary
working room for construction of the caps.
Provide permanent casings installed prior to placement of the fill, for all
drilled shafts through mechanically stabilized fills (for example, behind proprietary retaining
walls) for shafts installed after fill placement. Install temporary casings through the completed
conventional fill when permanent casings are not required.
Provide permanent casings, if required, before the fill is placed extending
a sufficient distance into the existing ground to provide stability to the casings during
construction of the abutment fill.
455-1.3 Cofferdams: Construct cofferdams as detailed in the Plans. When cofferdams
are not detailed in the Plans, employ a qualified Specialty Engineer to design cofferdams, and to
sign and seal the plans and specification requirements. Send the designs to the Engineer for his
records before beginning construction.
Provide a qualified diver and a safety diver to inspect the conditions of the
foundation enclosure or cofferdam when the Contract Documents require a seal for construction.
Equip these divers with suitable voice communications, and have them inspect the foundation
enclosure and cofferdam periphery including each sheeting indentation and around each piling or
drilled shaft to ensure that no layers of mud or other undesirable materials were left above the
bottom of seal elevation during the excavation process. Also have the divers check to make sure
the surfaces of the piles or drilled shafts are sufficiently clean to allow bond of the concrete
down to the minimum bottom of seal elevation. When required, ensure that there are no mounds
of stone, shell, or other authorized backfill material left after placement and grading. Assist the
Engineer as required to ensure that the seal is placed as specified and evaluate the adequacy of
the foundation soils or rock. Correct any deficiencies found by the divers. Upon completion of
inspection by the divers, the Department may also elect to inspect the work before authorizing
the Contractor to proceed with subsequent construction operations. Furnish the Engineer a
written report by the divers indicating the results of their underwater inspection before requesting
authorization to place the seal concrete.
455-1.4 Vibrations on Freshly Placed Concrete (Drilled Shafts and Piers): Ensure
that freshly placed concrete is not subjected to vibrations greater than 1.5 inches per second from
pile driving and/or drilled shaft casing installation sources located within the greater dimension
of three shaft diameters (measured from the perimeter of the shaft closest to the vibration source)
or 30 feet (from the nearest outside edge of freshly placed concrete to the vibration source) until
that concrete has attained its final set as defined by ASTM C403 except as required to remove
temporary casings before the drilled shaft elapsed time has expired.
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455-2 Static Compression Load Tests.
455-2.1 General: Employ a professional testing laboratory, or Specialty Engineer with
prior load test experience on at least three projects, to conduct the load test in compliance with
these Specifications, to record all data, and to furnish reports of the test results to the Engineer
except when the Contract Documents show that the Department will supply a Geotechnical
Engineer to provide these services.
Perform the load test by applying a load up to the load required in the Contract
Documents or to the failure load, whichever occurs first.
Do not apply test loads to piles sooner than 48 hours (or the time interval shown
in the Plans) after driving of the test pile or reaction piles, whichever occurs last.
Allow up to four weeks after the last load test for the analysis of the load test data
and to provide all the estimated production tip elevations. If the Contractor is willing to construct
production foundation elements in areas designated by the Engineer, tip elevations will be
determined in these areas beginning seven days after the receipt of the load test data which
represents the designated area.
Do not begin static load testing of drilled shafts until the concrete has attained a
compressive strength of 3,400 psi. The Contractor may use high early strength concrete to obtain
this strength at an earlier time to prevent testing delays.
Load test piles/shafts in the order directed by the Engineer. The Department will
furnish certain load test equipment and/or personnel when shown in the Plans. Inspect all
equipment to be furnished by the Department at least 30 days prior to use, and notify the
Engineer of any equipment that is not in satisfactory operating condition. The Department will
consider any necessary repairs ordered by the Engineer to place the equipment in satisfactory
operating condition as Unforeseeable Work. Provide the remainder of the equipment and
personnel needed to conduct the load tests. Unless shown otherwise in the Contract Documents,
provide all equipment, materials, labor, and technical personnel required to conduct the load
tests, including determination of anchor reaction member depths. In this case, provide a loading
apparatus designed to accommodate the maximum load plus an adequate safety factor.
While performing the load test, provide safety equipment, and employ safety
procedures consistent with the latest approved practices for this work. Include with these safety
procedures, adequate support for the load test plates and jack to prevent them from falling in the
event of a release of load due to hydraulic failure, test pile/shaft failure, or any other cause.
Include in the bid the cost of transporting load test equipment and instrumentation
supplied by the Department from their storage location to the job site and back. Handle these
items with care. The Contractor is responsible for the safe return of these items. After completion
of the static load tests, return all Department furnished equipment in satisfactory operating
condition. Repair all damage to the test equipment furnished by the Department to the
satisfaction of the Engineer. Clean all areas of rust on structural steel items, and recoat those
areas in accordance with Section 560. Return all load test equipment supplied by the Department
within 30 days after completing the load tests.
The Contractor is responsible for the equipment from the time it leaves its storage
area until the time it is returned. During this time, insure the equipment against loss or damage
for the replacement cost thereof (the greater of $150,000 or the amount shown in the Plans) or
for the full insurable value if replacement cost insurance is not available.
Notify the Engineer at the preconstruction conference, or no later than 30 days
before beginning test pile installation, of the proposed testing schedule so that items supplied by
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the Department may be reserved. Notify the Department at least ten working days before pick-up
or return of the equipment. During pick-up, the Department will complete a checklist of all
equipment placed in the Contractors possession. The Department will later use this checklist to
verify that the Contractor has returned all equipment. Provide personnel and equipment to load
or unload the equipment at the Departments storage location. Provide lifting tongs or nylon
slings to handle Department owned test girders. Do not perform cutting, welding, or drilling on
Department owned girders, jacks, load cells, or other equipment.
455-2.2 Loading Apparatus: Provide an apparatus for applying the vertical loads as
described in one of the following:
(1) As shown and described in the Contract Documents.
(2) As supplied by the Contractor, one of the following devices designed to
accommodate a load at least 20% higher than that shown in the Contract Documents or described
herein for test loads:
(a) Load Applied by Hydraulic Jack Acting Against Weighted Box or
Platform: Construct a test box or test platform, resting on a suitable support, over the pile, and
load it with earth, sand, concrete, pig iron, or other suitable material with a total weight greater
than the anticipated maximum test load. Locate supports for the weighted box or platform at least
6 feet or three pile/shaft diameters, whichever is greater, measured from the edge of the pile or
shaft to the edge of the supports. Insert a hydraulic jack with pressure gauge between the test pile
or shaft and the underside of the reaction beam, and apply the load to the pile or shaft by
operating the jack between the reaction beam and the top of the pile or shaft.
(b) Load Applied to the Test Pile or Shaft by Hydraulic Jack Acting
Against Anchored Reaction Member: Construct reaction member anchorages as far from the test
piles/shafts as practical, but in no case closer than the greater of 3 pile/shaft diameters or 6 feet
from the edge of the test pile/shaft. Attach a girder(s) of sufficient strength to act as a reaction
beam to the upper ends of the anchor piles or shafts. Insert a hydraulic jack with pressure gauges
between the head of the test pile/shaft and the underside of the reaction beam, and apply the test
load to the pile/shaft by operating the jack between the reaction beam and the pile/shaft head.
If using drilled shafts with bells as reaction member anchorages,
locate the top of the bell of any reaction shaft anchorage at least three shaft diameters below the
bottom of the test shaft.
(c) Combination Devices: The Contractor may use a combination of
devices (a) and (b), as described above, to apply the test load to the pile or shaft.
(d) Other systems proposed by the Contractor and approved by the
Engineer: When necessary, provide horizontal supports for loading the pile/shaft, and space them
so that the ratio of the unsupported length to the minimum radius of gyration of the pile does not
exceed 120 for steel piles, and the unsupported length to the least cross-section dimension does
not exceed 20 for concrete piles or drilled shafts. Ensure that horizontal supports provide full
support without restraining the vertical movement of the pile in any way.
When required by the Contract Documents, apply a horizontal load
to the shaft either separately or in conjunction with the vertical load. Apply the load to the test
shaft by hydraulic jacks, jacking against Contractor provided reaction devices. After receiving
the Engineers approval of the proposed method of load application, apply the horizontal load in
increments, and relieve it in decrements as required by the Contract Documents.
455-2.2.1 Modified Quick Test:
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(a) Loading Procedure: Apply vertical loads concentric with the longitudinal axis
of the tested pile/shaft to accurately determine and control the load acting on the pile/shaft at any
time. Place the load on the pile/shaft continuously, in increments equal to approximately 5% of
the maximum test load specified until approaching the failure load, as indicated by the measuring
apparatus and/or instruments. Then, apply increments of approximately 2.5% until the pile/shaft
plunges or attains the limiting load. The Engineer may elect to stop the loading increments
when he determines the Contractor has met the failure criteria or when a settlement equal to 10%
of the pile/shaft width or diameter is reached. Apply each load increment immediately after
taking and verifying the complete set of readings from all gauges and instruments. Apply each
increment of load within the minimum length of time practical, and immediately take the
readings. Complete the addition of a load increment and the completion of the readings within 5
to 15 minutes. The Engineer may elect to hold the maximum applied load up to one hour.
Remove the load in decrements of about 10% of the maximum test load.
Remove each decrement of load within the minimum length of time practical, and immediately
take the readings. Complete the removal of a load decrement and the taking of the readings
within 5 to 15 minutes. The Engineer may also require up to two reloading cycles with five
loading increments and three unloading decrements. Record the final recovery of the pile/shaft
until movement is essentially complete for a period up to one hour after the last unload interval.
(b) Failure Criteria and Nominal Resistance: Use the criteria described herein to
establish the failure load. The failure load is defined as the load that causes a pile/shaft top
deflection equal to the calculated elastic compression plus 0.15 inches plus 1/120 of the
pile/shaft minimum width or the diameter in inches for piles/shafts 24 inches or less in width,
and equal to the calculated elastic compression plus 1/30 of the pile/shaft minimum width or
diameter for piles/shafts greater than 24 inches in width. Consider the nominal resistance of any
pile/shaft so tested as either the maximum applied load or the failure load, whichever is smaller.
455-2.3 Measuring Apparatus: Provide an apparatus for measuring movement of the
test piles/shafts that consists of all of the following devices:
(1) Wire Line and Scale: Stretch a wire as directed by the Engineer between two
supports located at a distance at least:
(a) 10 feet from the center of the test pile but not less than 3.5 times the
pile diameter or width.
(b) 12 feet from the centerline of the shaft to be tested but not less than
three shaft diameters.
Locate the wire supports as far as practical from reaction beam anchorages. At
over-water test sites, the Contractor may attach the wire line as directed by the Engineer to the
sides of the service platform. Mount the wire with a pulley on one support and a weight at the
end of the wire to provide constant tension on the wire. Ensure that the wire passes across the
face of a scale mounted on a mirror attached to the test pile/shaft so that readings can be made
directly from the scale. Use the scale readings as a check on an average of the dial readings.
When measuring both horizontal and vertical movement, mount separate wires to indicate each
movement, horizontal or vertical. Measure horizontal movements from two reference wires set
normal to each other in a horizontal.
(2) Wooden Reference Beams and Dial Gauges: Attach wooden reference beams
as detailed in the Plans or approved by the Engineer to independent supports. For piles, install
the greater of 3.5 times the pile diameter or width or 10 feet from the centerline of the test pile.
For drilled shafts, install at the greater of three shaft diameters or 12 feet from the centerline of
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the shaft to be tested. Locate the reference beam supports as far as practical from reaction beam
anchorages. For over-water test sites, the Contractor may attach the reference beams as directed
by the Engineer between two diagonal platform supports. Attach dial gauges, with their stems
resting either on the top of the pile/shaft or on lugs or similar reference points on the pile/shaft,
to the fixed beams to record the movement of the pile/shaft head. Ensure that the area on the
pile/shaft or lug on which the stem bears is a smooth surface which will not cause irregularities
in the dial readings.
For piles, the minimum acceptable method for measuring vertical
movement is two dial gauges, each with 0.001 inch divisions and with 2 inch minimum travel,
placed at 180 degrees or at the diagonal corners of the pile.
For shafts, ensure that three dial gauges, each with 0.001 inch divisions
and with 2 inch minimum travel, placed at 120 degree intervals around the shaft, are the
minimum acceptable method for measuring vertical movement. Ensure that four dial gauges,
each with 0.001 inch divisions and with 2 inch minimum travel, placed at 90 degree intervals are
the minimum required for measuring horizontal movement.
(3) Survey Level: As a check on the dial gauges, determine the elevation of a
point near the top of the test pile/shaft (on plan datum) by survey level at each load and unload
interval during the load test. Unless approved otherwise by the Engineer, level survey precision
is 0.001 foot. Alternately, the surveyor may read an engineers 50 scale attached near the
pile/shaft head. Determine the first elevation before applying the first load increment; make
intermediate readings immediately before a load increment or an unload decrement, and after the
final unload decrement that completely removes the load. Make a final reading at the time of the
last recovery reading or as directed by the Engineer.
For over-water test sites, when shown in the Plans or directed by the
Engineer, the Contractor shall drive an H pile through a 36 inch casing to provide a stable
support for the level and to protect it against wave action interfering with level measurements.
Provide a suitable movable jig for the surveyor to stand. Use a jig that has a minimum of three
legs, has a work platform providing at least 4 feet width of work area around the casing, and is
approved by the Engineer before use. The described work platform may be supported by the
protective casing when approved by the Engineer.
455-2.4 Load Test Instrumentation:
(1) General: The intent of the load test instrumentation is to measure the test load
on top of the pile/shaft and, when provided in the Contract Documents, its distribution between
side friction and end bearing to provide evaluation of the preliminary design calculations and
settlement estimates and to provide information for final pile/shaft length design. Ensure that the
instrumentation is as described in the Contract Documents.
When requested by the Engineer, provide assistance during installation of
any instrumentation supplied by the Department. Supply 110 V, 60 Hz, 30 A of AC electric
power in accordance with the National Electric Code (NEC) to each test pile/shaft site during the
installation of the instrumentation, during the load testing, and during any instrumented redrives
ordered by the Engineer.
Place all of the internal instrumentation on the rebar cage before
installation in the test shaft. Construct the rebar cage at least two days before it is required for
construction of the test shaft. Provide assistance during installation of instrumentation supplied
by the Department, including help to string, place, and tie the instrumentation and any assistance
needed in moving or repositioning the cage to facilitate installation. Place the rebar cage in one
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segment complete with its instrumentation. The Engineer may require multiple lift points and/or
a suitable stiffleg (length of H pile or other suitable section) to get the cage in a vertical
position without causing damage to the instrumentation. Successfully demonstrate the lifting and
handling procedures before the installing instrumentation.
(2) Hydraulic Jack and Load Cell: Provide hydraulic jack(s) of adequate size to
deliver the required test load to the pile/shaft unless shown otherwise in the Plans. Before load
testing begins, furnish a certificate from a reputable testing laboratory showing a calibration of
gauge readings for all stages of jack loading and unloading for jacks provided. Ensure that the
jack has been calibrated within the preceding six months unless approved otherwise. Recalibrate
the jack after completing load testing if so directed by the Engineer. Ensure that the accuracy of
the gauge is within 5% of the true load.
Provide an adequate load cell approved by the Engineer that has been
calibrated within the preceding six months. Provide an approved electrical readout device for the
load cell. Before beginning load testing, furnish a certificate from a reputable testing laboratory
showing a calibration of readings for all stages of loading and unloading for load cells furnished
by the Contractor. Ensure that the accuracy of the load cell is within 1% of the true load.
If the Department supplies the Contractor with the jack and/or load cell,
have the equipment calibrated and include the cost in the cost for static load test.
(3) Telltales: When shown in the Contract Documents, provide telltales that
consist of an unstressed steel rod placed, with appropriate clearance and greased for reducing
friction and corrosion, inside a constant-diameter pipe that rests on a flat plate attached to the end
of the pipe at a point of interest shown in the Plans. Construct telltales in accordance with details
shown in the Contract Documents. Install dial gauges reading to 0.001 inch with 1 inch
minimum travel as directed by the Engineer to measure the movement of the telltale with respect
to the top of the pile/shaft.
(4) Embedded Strain Gauges: When shown in the Contract Documents, provide
strain gauges which shall be placed in the test shaft to measure the distribution of the load.
Ensure that the type, number, and location of the strain gauges are as shown in the Plans or as
directed by the Engineer. Use strain gauges that are waterproof and have suitable shielded cable
that is unspliced within the shaft.
455-2.5 Support Facilities: Furnish adequate facilities for making load and settlement
readings 24 hours per day. Provide such facilities for the instrumented area, and include lighting
and shelter from rain, wind, and direct sunlight.
455-2.6 Load Test Personnel Furnished by the Contractor: Provide a certified welder,
together with necessary cutting and welding equipment, to assist with the load test setup and to
make any necessary adjustments during the load test. Provide personnel to operate the jack,
generators, and lighting equipment, and also provide one person with transportation to assist as
required during load test setup and conducting of the load tests. Provide qualified personnel, as
determined by a Specialty Engineer or testing lab, required to read the dial gauges, take level
measurements, and conduct the load test, except when the Contract Documents show that the
Department will provide these personnel.
455-2.7 Cooperation by the Contractor: Cooperate with the Department, and ensure
that the Department has access to all facilities necessary for observation of the conduct and the
results of the test.
455-2.8 Required Reports: Submit a preliminary static load test report to the Engineer
within five days after completing the load test. When the Contract Documents do not require
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internal instrumentation, submit the final report within ten days after completing the load test.
Furnish the final report of test results for internally instrumented shafts within 30 days after
completing the load test. Include in the report of the load test the following information:
(1) A tabulation of the time of, and the amount of, the load and settlement
readings, and the load and recovery readings taken during the loading and unloading of the
pile/shaft.
(2) A graphic representation of the test results, during loading and unloading of
pile/shaft top movement as measured by the average of the dial gauge readings, from wireline
readings and from level readings.
(3) A graphic representation of the test results, when using telltales, showing
pile/shaft compression and pile/shaft tip movement.
(4) The estimated failure and safe loads according to the criteria described herein.
(5) Remarks concerning any unusual occurrences during the loading of the
pile/shaft.
(6) The names of those making the required observations of the results of the load
test, the weather conditions prevailing during the load test, and the effect of weather conditions
on the load test.
(7) All supporting data including jack and load cell calibrations and certificates
and other equipment requiring calibration.
(8) When the Contract Document requires internal instrumentation of the
pile/shaft, furnish all of the data taken during the load test together with instrument calibration
certifications. In addition, provide a report showing an analysis of the results of axial load and
lateral load tests in which soil resistance along and against the pile/shaft is reported as a function
of deflection.
Provide the necessary report(s) prepared by the Specialty Engineer responsible for
collection and interpretation of the data, except when the Contract Documents show that the
Department will provide a Geotechnical Engineer.
455-2.9 Disposition of Loading Material: After completing all load tests, clean, remove
all rust and debris from Department equipment, repaint all areas having damage to the paint in
accordance with Section 560, and return all load test equipment supplied by the Department to its
designated storage area. Repair any structural damage to Department owned equipment to the
satisfaction of the Engineer. Notify the Department at least ten working days in advance so that
arrangements can be made to unload the equipment. Remove all equipment and materials, which
remains the Contractors property, from the site. Clean up and restore the site to the satisfaction
of the Engineer.
455-2.10 Disposition of Tested Piles/Shafts: After completing testing, cut off the tested
piles/shafts, which are not to be incorporated into the final structure, and any reaction piles/shafts
at an elevation 24 inches below the finished ground surface. Take ownership of the cut-offs and
provide areas for their disposal.
B. PILING
455-3 Description.
Furnish and install concrete, steel, or wood piling including driving, jetting, preformed
pile holes, cutting off, splicing, dynamic load testing, and static load testing of piling.
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455-4 Classification.
The Department classifies piling as follows:
(1) Treated timber piling.
(2) Prestressed concrete piling.
(3) Steel piling.
(4) Test piling.
(5) Sheet piling.
(a) Concrete sheet piling.
(b) Steel sheet piling.
(6) Polymeric Piles (see Section 471 for requirements).
455-5 General Requirements.
455-5.1 Site Preparation:
455-5.1.1 Predrilling of Pile Holes: Predrilled pile holes are either starter holes
to the depth described in this section or holes drilled through embankment/fill material down to
the natural ground surface. When using low displacement steel piling such as structural shapes,
drive them through the compacted fill without the necessity of drilling holes through the fill
except when the requirements for predrilling are shown in the Plans. When using concrete or
other high displacement piles, drill pile holes through fill, new or existing, to at least the
elevation of the natural ground surface. Use the range of drill diameters listed below for square
concrete piles.
12 inch square piles ......................... 15 to 17 inches
14 inch square piles ......................... 18 to 20 inches
18 inch square piles ......................... 22 to 26 inches
20 inch square piles ......................... 24 to 29 inches
24 inch square piles ......................... 30 to 34 inches
30 inch square piles ......................... 36 to 43 inches
For other pile sizes, use the diameter of the drills shown in the Plans or
approved by the Engineer. Accurately drill the pile holes with the hole centered over the Plan
location of the piling. Maintain the location and vertical alignment within the tolerances allowed
for the piling.
For predrilled holes required through rock or other hard (i.e. debris,
obstructions, etc.) materials that may damage the pile during installation, predrill hole diameters
approximately 2 inches larger than the largest dimension across the pile cross-section. Fill the
annular space around the piles as described in 455-5.9.1 with clean A-3 sand or sand meeting the
requirements of 902-3.3.
In the setting of permanent and test piling, the Contractor may initially
predrill holes to a depth up to 10 feet or 20% of the pile length whichever is greater, except that,
where installing piles in compacted fill, predrill the holes to the elevation of the natural ground
surface. With prior written authorization from the Engineer, the Contractor may predrill holes to
greater depths to minimize the effects of vibrations on existing structures adjacent to the work
and/or for other reasons the Contractor proposes. Perform such work the Engineer allows but
does not require at no expense to the Department. When the Engineer requires such work, the
Department will pay for such work as Preformed Pile Holes as described in 455-5.9.
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455-5.1.2 Underwater Driving: Underwater driving is defined as any driving
through water which is above the pile head at the time of driving.
When conducting underwater driving, provide a diver equipped with voice
communications to aid in placing the hammer back on the pile for required cushion changes or
for subsequent redriving, to attach or recover instrumentation the Engineer is using, to inspect
the condition of the pile, or for other assistance as required.
Select one of the following methods for underwater driving:
(a) Accomplish underwater driving using conventional driving
equipment and piling longer than authorized so that the piling will extend above the water
surface during final driving. When choosing this option, furnish a pile hammer that satisfies the
requirements of this Section for use with the longer pile.
(b) Accomplish underwater driving using an underwater hammer
that meets the requirements of this Section and is approved by the Engineer. When choosing this
option, provide at least one pile longer than authorized at each pile group, extending above the
water surface at final driving. At each group location, drive the longer pile first. The Engineer
will evaluate the adequacy of the underwater driving system. The Engineer may use the pile tip
elevation of the longer pile that the Contractor has driven and the Engineer has accepted, to
evaluate the acceptability of the piles driven with the underwater hammer.
(c) Accomplish underwater driving using conventional driving
equipment with a suitable approved pile follower. When choosing this option, provide at least
one pile longer than required at each pile group, extending above the water surface at final
driving. At each group location, drive the full length pile first without using the follower. The
Engineer will evaluate the adequacy of the follower used for underwater driving. The Engineer
may choose to perform a dynamic load test on the first pile the Contractor drives with the
follower in each group. The Engineer may use the pile tip elevation of the longer pile, that the
Contractor has driven and the Engineer has accepted, to evaluate the acceptability of the piles
driven with the follower.
Prior to use, submit details of the follower for the Engineers evaluation
and approval along with the information required in 455-10. Include the weight, cross-section
details, stiffness, type of materials, and dimensions of the follower.
455-5.2 Pile Hammers: All equipment is subject to satisfactory field performance. Use a
variable energy hammer to drive concrete piles. Hammers will be rated based on the theoretical
energy of the ram at impact. Supply driving equipment which provides the required resistance at
a blow count ranging from 3 blows per inch (36 blows per foot) to 10 blows per inch (120 blows
per foot) at the end of initial drive, unless approved otherwise by the Engineer after satisfactory
field trial. When the Engineer determines the stroke height or bounce chamber pressure readings
do not adequately determine the energy of the hammer, provide and maintain a device to
measure the velocity of the ram at impact. Determine the actual hammer energy in the field so
that it is consistent with the hammer energy used for each bearing capacity determination. When
requested, furnish to the Engineer all technical specifications and operating instructions related
to hammer equipment.
455-5.2.1 Air/steam: Variable energy air/steam hammers shall be capable of
providing at least two ram stroke lengths. The short ram stroke length shall be approximately
half of the full stroke for hammers with strokes up to 4 feet and no more than 2 feet for hammers
with maximum strokes lengths over 4 feet. Operate and maintain air/steam hammers within the
manufacturers specified ranges. Use a plant and equipment for steam and air hammers with
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sufficient capacity to maintain, under working conditions, the hammer, volume and pressure
specified by the manufacturer. Equip the plant and equipment with accurate pressure gauges
which are easily accessible to the Engineer. The Engineer will not accept final bearing on piles
the Contractor drives with air/steam hammers unless the Contractor operates the hammers within
10% of the manufacturers rated speed in blows per minute, unless otherwise authorized by the
Engineer.
455-5.2.2 Diesel: Variable energy diesel hammers shall have at least three fuel
settings that will produce reduced strokes. Operate and maintain diesel hammers within the
manufacturers specified ranges. Determine the rated energy of diesel hammers using measured
ram stroke length multiplied by the weight of the ram for open end hammers and by methods
recommended by the manufacturer for closed end hammers.
Provide the Engineer with a chart from the hammer manufacturer equating
stroke and blows per minute for the open-end diesel hammer to be used. Also provide and
maintain in working order for the Engineers use an approved device to automatically determine
and display ram stroke for open-end diesel hammers.
Equip closed-end (double acting) diesel hammers with a bounce chamber
pressure gauge, in good working order, mounted near ground level so the Engineer can easily
read. Also, provide the Engineer with a chart, calibrated to actual hammer performance within
30 days prior to initial use, equating bounce chamber pressure to either equivalent energy or
stroke for the closed-end diesel hammer to be used.
455-5.2.3 Hydraulic: Variable energy hydraulic hammers shall have at least three
hydraulic control settings that provide for predictable stroke control. The shortest stroke shall be
a maximum of 2 feet for the driving of concrete piles. The remaining strokes shall include full
stroke and approximately halfway between minimum and maximum stroke.
Determine the hammer energy according to the manufacturers
recommendations. When pressure measuring equipment is required to determine hammer energy,
calibrate the pressure gauges before use.
455-5.2.4 Vibratory: Vibratory hammers of sufficient capacity (force and
amplitude) may be used to drive steel sheet piles and, with approval of the Engineer, to drive
steel bearing piles a sufficient distance to get the impact hammer on the pile (to stick the pile).
The Engineer will determine the allowable depth of driving using the vibratory hammer based on
site conditions. However, in all cases, use a power impact hammer for the last 15 feet or more of
the final driving of steel bearing piles for bearing determinations after all piles in the bent/pier
have been driven with a vibratory hammer. Do not use vibrating hammers to install concrete
piles, or to install support or reaction piles for a load test.
455-5.3 Cushions and Pile Helmet:
455-5.3.1 Capblock: Provide a capblock (also called the hammer cushion) as
recommended by the hammer manufacturer. Use commercially manufactured capblocks
constructed of durable manmade materials with uniform known properties. Do not use wood
chips, wood blocks, rope, or other material which permit excessive loss of hammer energy. Do
not use capblocks constructed of asbestos materials. Obtain the Engineers approval for all
proposed capblock materials and proposed thickness for use. Maintain capblocks in good
condition, and change them when charred, melted, or otherwise significantly deteriorated. The
Engineer will inspect the capblock before driving begins and weekly or at appropriate intervals
determined by the Engineer based on field trial. Replace or repair any hammer cushion which
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loses more than 25% of its original thickness, in accordance with the manufacturers instructions,
before permitting further driving.
455-5.3.2 Pile Cushion: Provide a pile cushion that is adequate to protect the pile
from being overstressed in compression and tension during driving. Use a pile cushion sized so
that it will fully fill the lateral dimensions of the pile helmet minus one inch but does not cover
any void or hole extending through the top of the pile. Determine the thickness based upon the
hammer-pile-soil system. For driving concrete piles, use a pile cushion made from pine plywood
or oak lumber. Alternative materials may be used with the approval of the Engineer. Obtain the
Engineers approval for all pile cushions. Do not use materials previously soaked, saturated or
treated with oil. Maintain pile cushions in good condition and change when charred, splintered,
excessively compressed, or otherwise deteriorated to the point it will not protect the pile against
overstressing in tension and/or compression. Protect cushions from the weather, and keep them
dry. Do not soak the cushions in any liquid. Replace the pile cushion, if during the driving of any
pile, the cushion is either compressed more than one-half the original thickness or begins to burn.
Provide a new cushion for each pile unless approved otherwise by the Engineer after satisfactory
field trial.
Reuse pile cushions in good condition to perform all set-checks and
redrives. Use the same cushion to perform the set-check or redrive as was used during the initial
driving, unless this cushion is unacceptable due to deterioration, in which case use a similar
cushion.
455-5.3.3 Pile Helmet: Provide a pile helmet suitable for the type and size of
piling being driven. Use a pile helmet deep enough to adequately contain the required thickness
of pile cushion and to assist in maintaining pile-hammer alignment. Use a pile helmet that fits
loosely over the pile head and is at least 1 inch larger than the pile dimensions. Use a pile helmet
designed so that it will not restrain the pile from rotating.
455-5.4 Leads: Provide pile leads constructed in a manner which offers freedom of
movement to the hammer and that have the strength and rigidity to hold the hammer and pile in
the correct position and alignment during driving. When using followers, use leads that are long
enough and suitable to maintain position and alignment of the hammer, follower, and pile
throughout driving.
455-5.5 Followers: Use followers only for underwater driving. Obtain the Engineers
approval for the type of follower, when used, and the method of connection to the leads and pile.
Use followers constructed of steel with an adequate cross-section to withstand driving stresses.
When driving concrete piles, ensure that the cross-sectional area of the follower is at least 18%
of the cross-sectional area of the pile. When driving steel piles, ensure that the cross-sectional
area of the follower is greater than or equal to the cross-sectional area of the pile. Provide a pile
helmet at the lower end of the follower sized according to the requirements of 455-5.3.3. Use
followers constructed that maintain the alignment of the pile, follower, and hammer and still
allow the pile to be driven within the allowable tolerances. Use followers designed with guides
adapted to the leads that maintain the hammer, follower, and the piles in alignment.
Use information from driving full length piles described in 455-5.1.2 compared to
driving piles with the follower and/or dynamic load tests described in 455-5.13 to evaluate the
adequacy of the follower and to establish the blow count criteria when using the follower.
455-5.6 Templates and Ground Elevations: Provide a fixed template, adequate to
maintain the pile in proper position and alignment during driving with swinging leads or with
semi-fixed leads. Where practical, place the template so that the pile can be driven to cut-off
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elevation before removing the template. Ensure that templates do not restrict the vertical
movement of the pile.
Supply a stable reference close to the pile, which is satisfactory in the opinion of
the Engineer, for determination of the pile penetration. At the time of driving piles, furnish the
Engineer with elevations of the original ground and template at each pile or pile group location.
Note the highest and lowest elevation at each required location and the ground elevation at all
piles.
455-5.7 Water Jets: Use jet pumps, supply lines, and jet pipes that provide adequate
pressure and volume of water to freely erode the soil. Do not perform jetting without prior
approval by the Engineer or unless allowed by the Plans.
Do not perform jetting in the embankment or for end bents. Where conditions
warrant, with approval by the Engineer, perform jetting on the holes first, place the pile therein,
then drive the pile to secure the last few feet of penetration. Only use one jet for prejetting or
jetting through piles constructed with a center jet-hole. Use two jets when using external jets.
When jetting and driving, position the jets slightly behind the advancing pile tip (approximately
3 feet or as approved by the Engineer). When using water jets in the driving, determine the pile
bearing only from the results of driving after withdrawing the jets, except where using jets to
continuously eliminate soil resistance through the scour zone, ensure that they remain in place as
directed by the Engineer and operating during pile bearing determination. Where practical,
perform jetting on all piles in a pile group before driving begins. When large pile groups or pile
spacing and batter make this impractical, or when the Plans specify a jet-drive sequence, set
check a sufficient number of previously driven piles in a pile group to confirm their capacity
after completing all jetting.
455-5.8 Penetration Requirements: Measure the penetration of piles from the elevation
of natural ground, scour elevation shown in the Plans, or the bottom of excavation, whichever is
lower. When the Contract Documents show a minimum pile tip elevation or a minimum depth of
penetration, drive the tip of the pile to this minimum elevation or this minimum penetration
depth. In all such cases, the Engineer will accept the bearing of a pile only if the Contractor
achieves the required bearing when the tip of the pile is at or below the specified minimum tip
elevation or depth of penetration and below the bottom of the preformed or predrilled pile hole.
When the Plans do not show a minimum depth of penetration, scour elevation, or
minimum tip elevation, ensure that the required penetration is at least 10 feet into firm bearing
material or at least 20 feet into soft material unless otherwise permitted by the Engineer. If a
scour elevation is shown in the Plans, achieve these penetrations below the scour elevation. The
Engineer may accept a penetration between 15 feet and 20 feet when there is an accumulation of
five consecutive feet or more of firm bearing material. Firm bearing material is any material
offering a driving resistance greater than or equal to 30 tons per square foot of gross pile area as
determined by the Dynamic Load Testing (455-5.11.4). Soft material is any material offering less
than these resistances. The gross pile area is the actual pile tip cross-sectional area for solid
concrete piles, the product of the width and depth for H piles, and the area within the outside
perimeter for pipe piles and voided concrete piles.
Do not drive piles beyond practical refusal (20 blows per inch). To meet the
requirements in this Subarticle, provide penetration aids, such as jetting or preformed pile holes,
when piles cannot be driven to the required penetration without reaching practical refusal.
If the Contractor encounters unforeseeable, isolated obstructions that the
Contractor cannot practically penetrate by driving, jetting, or preformed pile holes, and the
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Contractor must remove the pile to obtain the required pile penetration, the Department will pay
the costs for such removal as Unforeseeable Work.
455-5.9 Preformed Pile Holes:
455-5.9.1 Description: Preformed pile holes serve as a penetration aid when all
other pile installation methods fail to produce the desired penetration and when authorized by the
Engineer to minimize the effects of vibrations on adjacent structures. Preformed pile holes are
necessary when the presence of rock or strong strata of soils will not permit the installation of
piles to the desired penetration by driving or a combination of jetting and driving, when
determined necessary by the Engineer, or when authorized by the Engineer to minimize the
effects of vibrations on adjacent existing structures. The Engineer may require preformed holes
for any type of pile. Drive all piles installed in preformed pile holes to determine that the bearing
requirements have been met.
For preformed holes which are required through material that caves during
driving to the extent that the preformed hole does not serve its intended purpose, case the hole
from the surface through caving material. After installing the pile to the bottom of the casing,
remove the casings unless shown otherwise in the Plans. Determine bearing of the pile after
removing the casing unless shown otherwise in the Plans. Fill all voids between the pile and soil
remaining after driving through preformed holes with clean A-3 sand or sand meeting the
requirements of 902-3.3, after the pile has achieved the required minimum tip elevation, unless
grouting of preformed pile holes is shown in the Plans. If pile driving is interrupted during sand
placement, drive the pile at least 20 additional blows after filling all of the voids between the pile
and soil with sand at no additional compensation.
455-5.9.2 Provisions for Use of Preformed Pile Holes: The Department
generally anticipates the necessity for preformed pile holes and includes directions in the
Contract Documents. The Department will pay for preformed pile holes when the Contractor
establishes that the required results cannot be obtained when driving the load bearing piles with
specified driving equipment, or if jetting is allowed, while jetting the piles and then driving or
while jetting the piles during driving.
455-5.9.3 Conditions Under Which Payment Will Be Made: The Department
will make payment for preformed pile holes shown in the Plans, required by the Engineer or
where the Contractor demonstrates that such work is necessary to achieve the required
penetration of the pile. The Department considers, but does not limit to, the following conditions
as reasons for preformed pile holes:
(a) Inability to drive piles to the required penetration with driving and
jetting equipment.
(b) To penetrate a hard layer or layers of rock or strong stratum that the
Engineer considers not sufficiently thick to support the structure.
(c) To obtain greater penetration into dense (strong) material and into
dense material containing holes, cavities or unstable soft layers.
(d) To obtain penetration into a stratum in which it is desired to found the
structure.
(e) To minimize the effects of vibrations or heave on adjacent existing
structures.
(f) To minimize the effects of ground heave on adjacent piles.
455-5.9.4 Construction Methods: Construct preformed pile holes by drilling, or
driving and withdrawing a suitable punch or chisel at the locations of the piles. Construct a hole
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that is equal to or slightly greater than the largest pile dimension for the entire length of the hole
and of sufficient depth to obtain the required penetration. Carefully form the preformed hole by
using a drill or punch guided by a template or other suitable device, and do not exceed the
minimum dimensions necessary to achieve the required penetration of the pile. When the Plans
call for grouting the preformed pile holes, provide the minimum dimension of the pile hole that
is 2 inches larger than the largest pile dimension. Construct the holes at the Plan position of the
pile and the tolerances in location, and ensure the hole is straight and that the batter is the same
as specified for the pile. Loose material may remain in the preformed pile hole if the conditions
in 455-5.9.3 are satisfied.
455-5.9.5 Grouting of Pile Holes: Grout preformed pile holes for bearing piles,
when the Plans require grouting after driving. Clean the preformed pile holes, and fill them with
cement grout as shown in the Plans. Use grout that has a minimum compressive strength of
3,000 psi at 28 days or as specified. Pump the grout through three or more grout pipes initially
placed at the bottom of the preformed hole. The Contractor may raise the grout pipes when
necessary to prevent clogging and to complete the grouting operations. Maintain the grout pipes
below the surface of the previously placed grout. Continue grouting until the grout reaches the
ground surface all around the pile. Provide divers to monitor grouting operations when the water
depth is such that it is impractical to monitor from the ground surface. When grouting is shown
in the Plans, include the cost in the price for piles. In the event that the Engineer determines the
Contractor must grout and the required grouting is not shown in the Plans, the Department will
pay for the grouting work as Unforeseeable Work.
455-5.10 Bearing Requirements:
455-5.10.1 General: Drive piles to provide the bearing capacities required for
carrying the loads shown in the Plans. For all types of bearing piles, consider the driving
resistance as determined by the methods described herein sufficient for carrying the specified
loads as the minimum bearing which is accepted for any type of piles. Determine pile bearing
using the method described herein or as shown in the Plans.
The Engineer may accept a driven pile when the pile has achieved
minimum penetration, the blow count is generally increasing and the minimum required bearing
capacity obtained for 24 inches of consecutive driving. At his discretion, the Engineer may also
accept a driven pile when the minimum penetration is achieved and driving has reached practical
refusal in firm material.
455-5.10.2 Blow Count Criteria: The Engineer will determine the number of
blows required to provide the required bearing according to the methods described herein.
Determine the pile bearing by computing the penetration per blow with less than 1/4 inches
rebound averaged through 12 inches each of penetration. When it is considered necessary by the
Engineer, determine the average penetration per blow by averaging the penetration per blow
through the last 10 to 20 blows of the hammer.
455-5.10.3 Practical Refusal: Practical refusal is defined as 20 blows per inch
with the hammer operating at the highest setting or setting determined by the Engineer and less
than 1/4 inches rebound per blow. Stop driving as soon as the Engineer determines that the pile
has reached practical refusal. The Engineer will generally make this determination within
2 inches of driving. When the required pile penetration cannot be achieved by driving without
exceeding practical refusal, use other penetration aids such as jetting or preformed pile holes.
455-5.10.4 Set-checks and Pile Redrive:
541
(a) Set-checks: In the event that the Contractor has driven the pile to
approximately 12 inches above cut-off without reaching the required resistance, the Engineer
may require the Contractor to interrupt driving up to two hours prior to performing a set-check.
Provide an engineers level or other suitable equipment for elevation determinations to determine
accurate pile penetration during the set-checks. In the event the results of the initial set-checks
are not satisfactory, the Engineer may direct additional set-checks. The Engineer may accept the
pile as driven when a set-check shows that the Contractor has achieved the minimum required
pile bearing and has met all other requirements of this Section.
(b) Pile Redrive: Pile redrive consists of redriving the pile after the
following working day from initial driving to determine time effects, to reestablish pile capacity
due to pile heave, or for other reasons determined by the Engineer. Redrive piles as directed by
the Engineer.
(c) Uninstrumented Set-Checks and Uninstrumented Pile Redrive: The
Engineer may consider the pile to have sufficient bearing resistance when the specified set-check
criteria is met through the last 10 to 20 blows of the hammer at the specified minimum stroke
and the total penetration is less than six inches with less than 1/4 inches rebound per blow. When
the total penetration during a set-check or redrive is greater than six inches or pile rebound
exceeds 1/4 inches per blow, the Engineer may consider the pile to have sufficient bearing
resistance when the specified blow count criteria is achieved in accordance with 455-5.10.1.
(d)Instrumented Set-Checks and Instrumented Pile Redrive: When
considered necessary by the Engineer, dynamic load tests will be used to determine whether the
pile bearing is sufficient. The Engineer may consider the pile to have sufficient bearing
resistance when dynamic measurements demonstrate the static pile resistance during at least one
hammer blow exceeds the required pile resistance, the average static pile resistance during the
next five hammer blows exceeds 95% of the required pile resistance and the static pile resistance
during all subsequent blows exceeds 90% of the required pile resistance.
455-5.10.5 Pile Heave: Pile heave is the upward movement of a pile from its
originally driven elevation. Drive the piles in an approved sequence to minimize the effects of
heave and lateral displacement of the ground. Monitor piles previously driven in a pile group for
possible heave during the driving of the remaining piles. When required by the Engineer, take
elevation measurements to determine the magnitude of the movement of piles and the ground
surface resulting from the driving process. Redrive all piles that have heaved 1/4 inches or more
unless the Engineer determines that the heave is not detrimental to pile capacity. The Department
will pay for all work in conjunction with redriving piles due to pile heave under the pile redrive
item.
455-5.10.6 Piles with Insufficient Bearing: In the case that the Engineer
determines that the safe bearing capacity of any pile is less than the required bearing capacity,
the Contractor may splice the pile and continue driving or may extract the pile and drive a pile of
greater length, or, if so ordered by the Engineer, drive additional piles until reducing the required
bearing per pile to the determined bearing capacity of the piles already driven.
455-5.11 Methods to Determine Pile Capacity:
455-5.11.1 General: Dynamic load tests using Embedded Data Collector (EDC)
equipment and the UF Method of analysis, or an externally mounted instrument system and
signal matching analyses will be used to determine pile capacity for all structures or projects
unless otherwise shown on the Plans. When necessary, the Engineer may require static load tests
to confirm pile capacities. When the Contract Documents do not include items for static load
542
tests, the Engineer will consider all required static load testing Unforeseeable Work. Notify the
Engineer two working days prior to placement of piles within the template and at least one
working day prior to driving piles. Do not drive piles without the presence of the Engineer.
If the internally mounted system fails to communicate properly with the receiving
system, allow the Engineer sufficient time to mobilize back-up equipment for performing
dynamic load testing.
455-5.11.2 Wave Equation:
(a) General: Use Wave Equation Analysis for Piles (WEAP) programs to
evaluate the suitability of the proposed driving system (including the hammer, follower,
capblock and pile cushions) as well as to estimate the driving resistance, in blows per 12 inches
or blows per inch, to achieve the pile bearing requirements and to evaluate pile driving stresses.
The Engineer may modify the scour resistance shown in the Plans
if the dynamic load test is used to determine the actual soil resistance through the scour zone.
Also, the Engineer may make modifications in scour resistance when the Contractor proposes
drilling and/or jetting to reduce the soil resistance in the scour zone.
Use Wave Equation Analyses to show the hammer is capable of
driving to a resistance equal to at least 2.0 times the factored design load plus the scour and
down drag resistance (if applicable) shown in the Contract Documents, without overstressing the
piling in compression or tension and without reaching practical refusal (20 blows per inch).
Ensure that the hammer provided also meets the requirements described in 455-5.2.
(b) Required Equipment For Driving: Hammer approval is solely based on
satisfactory field trial including dynamic load test results and Wave Equation Analysis. Supply a
hammer system that meets the requirements described in the specifications based on the above
analysis. Obtain approval from the Engineer for the pile driving system based on satisfactory
field performance.
In the event piles require different hammer sizes, the Contractor
may elect to drive with more than one size hammer or with a variable energy hammer, provided
the hammer is properly sized and cushioned, will not damage the pile, and will develop the
required resistance.
(c) Maximum Allowed Pile Stresses:
(1) General: The maximum allowed driving stresses for concrete,
steel, and timber piles are given below. In the event Wave Equation analyses show that the
hammer will overstress the pile, modify the driving system or method of operation as required to
prevent overstressing the pile. In such cases provide additional cushioning or make other
appropriate agreed upon changes. For penetration of weak soils by concrete piles, use thick
cushions and/or reduced stroke to control tension stresses during driving.
(2) Concrete Piles: Use the wave equation to evaluate the proposed
pile cushioning. Use the following equations to determine the maximum allowed pile stresses as
predicted by the wave equation, and measured during driving when driving prestressed concrete
piling:
s apc = 0.7 f c 0.75 f
(1)
pe
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0.5
s apt = 6.5 (f c ) + 1.05 f
pe
0.5
s apt = 3.25 (f c ) + 1.05 f
pe
s apt = 500
(2a) for piles less than 50 feet long
(2b) for piles 50 feet long and greater
(2c) within 20 feet of a mechanical splice
where:
sapc= maximum allowed pile compressive stress, psi
sapt= maximum allowed pile tensile stress, psi
fc= specified minimum compressive strength of concrete, psi
fpe= effective prestress (after all losses) at the time of driving, psi, taken as
0.8 times the initial prestress force (fpe= 0 for dowel spliced piles).
(3) Steel Piles: Ensure the maximum pile compression and tensile
stresses as predicted by the Wave Equation, and/or measured during driving are no greater than
0.9 times the yield strength (0.9 fy) of the steel.
(4) Timber Piles: Ensure the maximum pile compression and
tensile stresses as predicted by the wave equation, and/or measured during driving are no greater
than 3.6 ksi for Southern Pine and Pacific Coast Douglas Fir and 0.9 of the ultimate parallel to
the grain strength for piles of other wood.
455-5.11.3 Temporary Piles: Submit for the Engineers approval, a Wave
Equation analysis signed and sealed by a Specialty Engineer which establishes the driving
criteria for temporary piles. The required driving resistance is equal to the design (service) load
multiplied by the appropriate factor of safety plus the scour and down drag resistance shown in
the Plans (no safety factor is required) or the ultimate bearing capacity shown in the Plans,
whichever is higher:
The factor of safety applied to the design (service) load is:
2.0 .................................... when static load tests are required.
2.5 ............................................. when Dynamic Load Testing
............................. and Wave Equation Analysis are required.
3.0 ......... when only the Wave Equation Analysis is required.
455-5.11.4 Dynamic Load Tests: Dynamic load testing consists of estimating
pile capacity by the analysis of electronic data collected from blows of the hammer during
driving of an instrumented pile.
455-5.11.5 Static Load Tests: Static load testing consists of applying a static load
to the pile to determine its capacity. Use The Modified Quick Test Procedure in accordance with
455-2.2.1.
455-5.11.6 Fender Pile Installation: For piles used in fender systems, regardless
of type or size of pile, either drive them full length or jet the piles to within 2 feet of cutoff and
drive to cutoff elevation to seat the pile. The Engineer will not require a specific driving
resistance unless noted in the Plans. Use methods and equipment for installation that do not
damage the piles. If the method or equipment used causes damage to the pile, modify the
methods or equipment at no expense to the Department.
455-5.11.7 Structures Without Test Piles: For projects without test piles, the
Engineer will dynamically test the first pile(s) in each bent or pier at locations shown in the Plans
to determine the blow count criteria for the remaining piles. When locations are not shown in the
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Plans, allow for dynamic load tests at 5% of the piles at each bent or pier (rounded up to the next
whole number). If the Engineer requires additional dynamic load tests for comparison purposes,
the Contractor will be paid for an additional dynamic load test as authorized by the Engineer in
accordance with 455-11.5.
When using externally mounted instruments, allow the Engineer one working day
after driving the dynamic load tested piles for the Engineer to complete the signal matching
analyses and determine the driving criteria for the subsequent piles in the bent or pier.
455-5.12 Test Piles:
455-5.12.1 Description: Drive piles of the same cross-section and type as the
permanent piles shown in the Plans, in order to determine any or all of the following:
(a) the installation criteria for the piles.
(b) the nature of the soil.
(c) the lengths of permanent piles required for the work.
(d) the driving resistance characteristics of the various soil strata.
(e) the amount of work necessary to obtain minimum required pile
penetration.
(f) the ability of the driving system to do the work.
(g) the need for point protection.
Because test piles are exploratory in nature, drive them harder (within the
limits of practical refusal), deeper, and to a greater bearing resistance than required for the
permanent piling. Except for test piles which are to be statically or Statnamically load tested,
drive test piles their full length or to practical refusal. Splice test piles which have been driven
their full length and have developed only minimal required bearing, and proceed with further
driving.
As a minimum, unless otherwise directed by the Engineer, do not cease
driving of test piles until obtaining the required bearing capacity continuously, where the blow
count is increasing, for 10 feet unless reaching practical refusal first. For test piles which are to
be statically or Statnamically load tested, ignore this minimum and drive these piles as
anticipated for the production piles.
When test piles attain practical refusal prior to attaining minimum
penetration, perform all work necessary to attain minimum penetration and the required bearing.
Where practical, use water jets to break the pile loose for further driving. Where jetting is
impractical, extract the pile and install a preformed pile hole through which driving will
continue. The Department will consider the work of extracting the pile to be Unforeseeable
Work.
When driving test piles other than low displacement steel test piles, have
preforming equipment available at the site and water jets as specified in 455-5.7 when jetting is
allowed, ready for use, before the test pile driving begins.
The Engineer may elect to interrupt pile driving up to four times on each
test pile, two times for up to two hours and two additional times during the next working day of
initial driving to determine time effects during the driving of test piles.
Install instruments on test piles when dynamic load tests are included in
the Plans or when directed by the Engineer.
455-5.12.2 Location of Test Piles: Drive all test piles in the position of
permanent piles at the designated locations. Ensure that all test piles designated to be statically
load tested are plumb. In the event that all the piles are battered at a static load test site, the
545
Engineer will designate an out-of-position location for driving a plumb pile for the static load
test.
455-5.12.3 Equipment for Driving: Use the same hammer and equipment for
driving test piles as for driving the permanent piles. Also use the same equipment to redrive
piles.
455-5.13 Dynamic Load Tests: The Engineer will take dynamic measurements during
the driving of piles designated in the Plans or authorized by the Engineer . Install instruments
prior to driving and assist the Engineer in monitoring all blows delivered to the pile. All test piles
will have dynamic load tests. The Engineer will perform dynamic load tests to evaluate any or all
of the following:
1. Evaluate suitability of Contractors driving equipment, including hammer,
capblock, pile cushion, and any proposed follower.
2. Determine pile capacity.
3. Determine pile stresses.
4. Determine energy transfer to pile.
5. Determine distribution of soil resistance.
6. Evaluate soil variables including quake and damping.
7. Evaluate hammer-pile-soil system for Wave Equation analyses.
8. Evaluate pile installation problems.
9. Other.
Either install EDCs in the piles in accordance with Design Standards, Index
No. 20602 or attach instruments (strain transducers to measure force and accelerometers to
measure acceleration) with bolts to the pile for dynamic load testing.
Make each pile to be dynamically tested with externally attached instruments
available to drill holes for attaching instrumentation and for wave speed measurements. Support
the pile with timber blocks placed at appropriate intervals. Ensure that the pile is in a horizontal
position and does not contact adjacent piles. Provide a sufficient clear distance at the sides of the
pile for drilling the holes. The Engineer will furnish the equipment, materials, and labor
necessary for drilling holes and taking the wave speed measurements. If the Engineer directs
dynamic load testing, instrumented set-checks or instrumented redrives, provide the Engineer
safe access to the top of the piles for drilling the attachment holes. After placing the leads
provide the Engineer reasonable means of access to the piles to attach the instruments and for
removal of the instruments after completing the pile driving.
The Engineer will monitor the stresses in the piles with the dynamic test
equipment during driving to ensure the Contractor does not exceed the maximum allowed
stresses. If necessary, add additional cushioning, replace the cushions, or reduce the hammer
stroke to maintain stresses below the maximum allowable. If dynamic test equipment
measurements indicate non-axial driving, immediately realign the driving system. If the cushion
is compressed to the point that a change in alignment of the hammer will not correct the problem,
add cushioning or change the cushion as directed by the Engineer.
Drive the pile to the required penetration and resistance or as directed by the
Engineer. Dynamic load testing of a pile may average up to two hours longer than for driving an
uninstrumented pile.
When directed by the Engineer, perform instrumented set-checks or redrives. Do
not use a cold diesel hammer for a set-check or redrive unless in the opinion of the Engineer it is
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impractical to do otherwise. Generally, warm up the hammer by driving another pile or applying
at least 20 blows to a previously driven pile or to timber mats placed on the ground.
455-5.14 Pile Lengths:
455-5.14.1 Test Pile Length: Provide the length of test piles shown in the Plans
or as directed by the Engineer.
455-5.14.2 Production Pile Length
455-5.14.2.1 Structures With Test Piles: When test pile lengths are
shown in the Plans, the production pile lengths are based on information available during design
and are approximate only. The Engineer will determine final pile lengths in the field which may
vary significantly from the lengths or quantities shown in the Plans.
455-5.14.2.2 Structures Without Test Piles: Authorized lengths are
provided as Production Pile Order Lengths in the Pile Data Table in the Structure Plans. Use
these lengths for furnishing the permanent piling for the structure.
455-5.14.3 Authorized Pile Lengths: The authorized pile lengths are the lengths
determined by the Engineer based on all information available before the driving of the
permanent piles, including, but not limited to, information gained from the driving of test piles,
dynamic load testing, static load testing, supplemental soil testing, etc. When authorized by the
Department, soil freeze information obtained during set checks and pile redrives may be used to
determine authorized pile lengths for sites with extreme soil conditions. The Contractor may
elect to provide piling with lengths longer than authorized to suit his method of installation or
schedule. When the Contractor elects to provide longer than authorized pile lengths, the
Department will pay for the furnished length as either the originally authorized length or the
length between cut-off elevation and the final accepted pile tip elevation, whichever is the longer
length.
Within five working days after driving all the test piles, completing all
load tests, completing all redrives, and receiving all test reports, the Engineer will furnish the
Contractor an itemized list of authorized pile lengths. Use these lengths for furnishing the
permanent piling for the structure. If the Contractor is willing to start his pile driving operations
in zones consisting of at least four test piles designated by the Engineer, and if the Contractor so
requests in writing at the beginning of the test pile program, the Department will furnish pile
lengths for these designated phases within five working days after driving all the test piles,
completing all load tests, completing all redrives, and receiving all test reports for those
designated zones. The Engineer will furnish the driving criteria for piles within three working
days of furnishing pile lengths.
On multiple phase projects, the Engineer will not furnish pile lengths on
subsequent phases until completing the piling on initial phases.
455-5.15 Allowable Driving Tolerances:
455-5.15.1 General: Meet the tolerances described in this Subarticle to the piles
that are free standing without lateral restraint (after the template is removed). After the piles are
driven, do not move the piles laterally to force them to be within the specified tolerances. The
Contractor may move battered piles laterally to overcome the dead load deflections caused by the
piles weight. When this is necessary, submit calculations signed and sealed by a Specialty
Engineer to the Engineer that verify the amount of dead load deflection prior to moving any
piles.
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455-5.15.2 Position: Ensure that the final position of the pile head at cut-off
elevation is no more than 3 inches laterally in the X or Y coordinate from the Plan position
indicated in the Plans.
455-5.15.3 Axial Alignment: Ensure that the axial alignment of the driven piles
does not deviate by more than 1/4 inches per foot from the vertical or batter line indicated in the
Plans.
455-5.15.4 Elevation: Ensure that the final elevation of the pile head is no more
than 1-1/2 inches above, or more than 4 inches below, the elevation shown in the Plans, however
in no case shall the pile be embedded less than 8 inches into the cap or footing.
For fender piles, cut off piles at the elevation shown in the Plans to a
tolerance of plus 0.0 inches to minus 2.0 inches using sawing or other means as approved by the
Engineer to provide a smooth level cut.
455-5.15.5 Deviation From Above Tolerances: When the Contractor has failed
to meet the above tolerances, the Contractor may propose a redesign to incorporate out of
tolerance piles into pile caps or footings, at no expense to the Department. Ensure the
Contractors Engineer of Record performs any redesign and signs and seals the redesign
drawings and computations. Do not begin any proposed construction until the redesign has been
reviewed for acceptability and approved by the Engineer.
455-5.16 Disposition of Pile Cut-offs, Test Piles, and Load Test Materials:
455-5.16.1 Pile Cut-offs:
(a) Steel Piling: Unless shown otherwise in the Plans, the Department will
retain ownership of cut-off sections, or portions of cut-off sections, and unused piling 20 feet
long or longer that are not damaged. Deliver them to the Departments nearest maintenance yard.
Ensure that sections of piles delivered to the maintenance yard are straight and undamaged. Cut
off the damaged portions prior to delivery. Take ownership of cut-off sections less than 20 feet
long. Remove them from the job, and dispose of them.
(b) Other Pile Types: Upon completion of all work under the Contract in
connection with piling, unless shown otherwise in the Plan, take ownership of any unused cut-off
lengths remaining, and remove them from the right-of-way. Provide areas for their disposal.
455-5.16.2 Test Piles: Where so directed by the Plans or the Engineer, cut off, or
build-up as necessary, test piles, and leave them in place as permanent piles. Extract and replace
test piles driven in permanent position and found not suitable for use due to actions of the
Contractor at no expense to the Department. Pull, or cut off at an elevation 2 feet below the
ground surface or bottom of proposed excavation, test piles driven out of permanent position,
and dispose of the removed portion of the test pile.
When test piles are required to be driven in permanent pile positions, the
Contractor may elect to drive the test pile out of position, with the approval of the Engineer,
provided that a replacement pile is furnished and driven by the Contractor at no expense to the
Department in the position that was to be occupied by the test pile. Under this option, the
Department will pay for the test pile in the same manner as if it were in permanent position.
Unless otherwise directed in the Plans or by the Engineer, retain
ownership of test piles that are pulled or cut off and provide areas for their disposal.
455-6 Timber Piling.
455-6.1 Description: Drive timber piles constructed of round timber of the kind and
dimensions specified in the Plans at the locations and to the elevations shown in the Plans, or as
directed by the Engineer.
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455-6.2 Materials: Meet the timber piling requirements of Section 953. Treat the piles
according to the applicable provisions of Section 955. Treat all cuts and drilled holes in
accordance with 470-3.
455-6.3 Preparation for Driving:
455-6.3.1 Caps: Protect the heads of timber piles during driving, using a cap of
approved type, that will distribute the hammer blow over the entire cross-section of the pile.
When necessary cut the head of the pile square before beginning pile driving.
455-6.3.2 Collars: Provide collars or bands to protect piles against splitting and
brooming at no expense to the Department.
455-6.3.3 Shoes: Provide piles shod with metal shoes, of a design satisfactory to
the Engineer, at no expense to the Department. Shape pile tips to receive the shoe and install
according to the manufacturers directions.
455-6.4 Storage and Handling: Store and handle piles in the manner necessary to avoid
damage to the piling. Take special care to avoid breaking the surface of treated piles. Do not use
cant dogs, hooks, or pike holes when handling and storing the piling.
455-6.5 Cutting Off: Saw off the tops of all timber piles at the elevation indicated in the
Plans. Saw off piles which support timber caps to the exact plane of the superimposed structure
so that they exactly fit it. Withdraw and replace broken, split, or misplaced piles.
455-6.6 Build-ups: The Engineer will not permit splices or build-ups for timber piles.
Extract piles driven below Plan elevation and drive a longer pile.
455-6.7 Pile Heads:
455-6.7.1 Piles with Timber Caps: On piles wider than the timber caps, dress off
to a slope of 45 degrees the part of the pile head projecting beyond the sides of the cap. Coat the
cut surface with the required preservative over which place a sheet of copper, of a weight of
10 ounces per square foot or greater, meeting the requirements of ASTM B370. Provide a cover
measuring at least 4 inches more in each dimension greater than the diameter of the pile. Bend
the cover down over the pile and fasten the edges with large head copper nails or three wraps of
No. 12 copper wire.
455-6.7.2 Fender and Bulkhead Piles: First paint the heads of fender piles and
of bulkhead piles with preservative and then cover with copper as provided above for piles
supporting timber caps.
455-7 Prestressed Concrete Piling.
455-7.1 Description: Provide prestressed concrete piles that are manufactured, cured,
and driven in accordance with the requirements of the Contract Documents. Provide piles full
length without splices when transported by barge or the pile length is less than or equal to
120 feet. When piles are transported by truck and the pile length exceeds 120 feet but is less than
the maximum length for a three point pick-up according to Design Standards, Index No. 20600,
and splicing is desired, provide minimal splices. Include the cost of the splices in the cost of the
pile.
455-7.2 Manufacture: Fabricate piles in accordance with Section 450. When EDCs will
be used for dynamic load testing, supply and install in square prestressed concrete piles in
accordance with Design Standards, Index No 20602. Ensure the EDCs are installed by personnel
approved by the manufacturer.
455-7.3 Storage and Handling:
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455-7.3.1 Time of Driving Piles: Drive prestressed concrete piles at any time
after the concrete has been cured in accordance with Section 450, and the concrete compressive
strength is equal to or greater than the specified 28 day compressive strength.
455-7.3.2 Storage: Support piles on adequate dunnage both in the prestress yard
and at the job site in accordance with the locations shown in the Standard Indexes to minimize
undue bending stresses or creating a sweep or camber in the pile.
455-7.3.3 Handling: Handle and store piles in the manner necessary to eliminate
the danger of fracture by impact or of undue bending stresses in handling or transporting the
piles from the forms and into the leads. In general, lift concrete piles by means of a suitable
bridge or slings attached to the pile at the locations shown in the Standard Indexes. Construct
slings used to handle piles of a fabric material or braided wire rope constructed of six or more
wire ropes which will not mar the corners or the surface finish of the piles. Do not use chains to
handle piles. During transport, support concrete piles at the lifting locations shown in the
Standard Indexes or fully support them throughout 80% or more of their length. In handling piles
for use in salty or brackish water, exercise special care to avoid damaging the surface and
corners of the pile. If an alternate transportation support arrangement is desired, submit
calculations, signed and sealed by the Specialty Engineer, for approval by the Engineer prior to
transporting the pile. Calculations must show that the pile can be transported without exceeding
the bending moments calculated using the support locations shown in the Plans.
455-7.4 Cracked Piles: The Engineer will reject any pile that becomes cracked in
handling to the point that a transverse or longitudinal crack extends through the pile, shows
failure of the concrete as indicated by spalling of concrete on the main body of the pile adjacent
to the crack, or which in the opinion of the Engineer will not withstand driving stresses. The
Engineer will not reject any pile for the occasional minor surface hairline cracking caused by
shrinkage or tensile stress in the concrete from handling.
Do not drive piling with irreparable damage, which is defined as any cracks that
extend through the pile cross-sectional area that are, or will be, below ground or water level at
the end of driving. Such cracks are normally evidenced by emitting concrete dust during their
opening and closing with each hammer blow. Remove and replace broken piles or piles cracked
to the extent described above at no expense to the Department. The Engineer will accept cracks
less than 0.005 inches which do not extend through the pile. Using approved methods, cut off
and splice or build-up to cut-off elevation piles with cracks greater than 0.005 inches at the pile
head or above ground or water level, and piles with cracks above ground or water level which
extend through the cross-sectional area of the pile. The Engineer, at his discretion, may require
correction of pile damage or pile cracks by cutting down the concrete to the plane of sound
concrete below the crack and rebuilding it to cut-off elevation, or the Engineer may reject the
pile. Extract and replace rejected piles that cannot be repaired, at no expense to the Department.
Take appropriate steps to prevent the occurrence of cracking, whether due to
handling or driving. When cracking occurs during driving, take immediate steps to prevent
additional cracking by using thicker cushions or reducing the ram stroke length. Revise handling
and transporting equipment and procedures as necessary to prevent cracking during handling and
transportation.
455-7.5 Preparation for Transportation: Cut any strands protruding beyond the ends of
the pile flush with the surface of the concrete using an abrasive cutting blade before transporting
the piles from the casting yard.
Cut and patch the metal lifting devices in accordance with 450-9.2.1.
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455-7.6 Method of Driving: Unless otherwise directed, drive piles by a hammer or by
means of a combination of water jets and hammer when jetting is allowed. When using jets in
combination with a hammer, withdraw the jets and drive the pile by the hammer alone to secure
final penetration and to rigidly fix the tip end of the pile. Keep jets in place if they are being used
to continuously eliminate the soil resistance in the scour zone.
455-7.7 Extensions and Build-ups Used to Increase Production Lengths:
455-7.7.1 General: Where splices and build-ups for concrete piles are necessary,
construct such splices and build-ups in accordance with Design Standards, Index No. 20601. The
Contractor may construct build-ups less than 2 feet in length in accordance with 455-11.8. When
splicing a prestressed precast section onto the original pile, and after driving, the length of
spliced section below cut-off elevation is 4 feet or less, remove the pile concrete to the cut-off
elevation and leave the dowels in place to be incorporated into the cap as directed by the
Engineer. The Contractor may cut the length of dowels which becomes exposed to a length of
48 inches from the plane of pile-splice.
These requirements are not applicable to specially designed piling. Make
splices for special pile designs as shown in the Plans.
455-7.7.2 Extensions to be Driven or Those 21 feet or Longer: Construct
extensions to be driven or extensions 21 feet or longer in length in accordance with the details
shown in the Plans and in a manner including the requirements, sequences, and procedures
outlined below:
(a) Cast a splice section in accordance with Section 450 with the dowel
steel in the correct position and alignment.
(b) Drill dowel holes using an approved steel template that will position
and align the drill bit during drilling. Drill holes a minimum of 2 inches deeper than the length of
the dowel to be inserted.
(c) Clean the drilled dowel holes by inserting a high pressure air hose to
the bottom of the hole and blowing the hole clean from the bottom upward. Eliminate any oil,
dust, water, and other deleterious materials from the holes and the concrete surfaces to be joined.
(d) Place forms around joints between the pile sections.
(e) Mix the adhesive components in accordance with the manufacturers
directions. Do not mix sand or any other filler material with the epoxy components unless it is
prepackaged by the manufacturer for this specific purpose. Use adhesives meeting the
requirements of Section 926 for Type B Epoxy Compounds.
(f) After ensuring that all concrete surfaces are dry, fill the dowel holes
with the adhesive material.
(g) Insert the dowels of the spliced section into the adhesive filled holes of
the bottom section and position the spliced section so that the axes of the two sections are in
concentric alignment and the ends of the abutting sections are spaced 1/2 inches apart. The
Contractor may use small steel spacers of the required thickness provided they have 3 inches or
more of cover after completing the splice. Fill the space between the abutting sections
completely with the adhesive.
(h) Secure the spliced sections in alignment until the adhesive is cured in
accordance with the manufacturers directions for the time appropriate with the prevailing
ambient temperatures. Do not utilize the crane to secure the pile extension during the adhesive
cure time. Utilize alignment braces to maintain the proper pile alignment during the epoxy cure
time.
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(i) After curing is completed, remove alignment braces and forms and
clean and dress the spliced area to match the pile dimensions.
455-7.7.3 Precast Reinforced Build-ups: Construct precast reinforced build-ups
in accordance with the requirements of this Subarticle, Section 346, and Section 400. Provide the
same material for the form surfaces for precast build-ups as was used to form the prestressed
piles. Use concrete of the same mix as used in the prestressed pile and dimension the crosssection the same as piling being built up. Install build-ups as specified in 455-7.7.2(b) through
455-7.7.2(i). Apply to the build-ups the same surface treatment or sealant applied to the
prestressed piles.
455-7.8 Pre-Planned Splices: Splices shall be made by the doweled splice method
contained in the Standard Indexes or may be made using proprietary splices which are listed on
the Departments Qualified Products List (QPL). Splice test piles in the same manner as the
production piles. Include in the pile installation plan, the chosen method of splicing and the
approximate locations of the splice. Generally, place the splice at approximately the midpoint
between the estimated pile tip and the ground surface, considering scour if applicable. Stagger
the splice location between adjacent piles by a minimum of 10 feet. Obtain the Engineers
approval prior to constructing any pile sections. Construct piles which are to be spliced using the
doweled splice with preformed dowel holes in the bottom section and embedded dowels in the
upper section.
When electing to use dowel splices, assist the Engineer in performing a dynamic
load test on each dowel spliced pile to verify the splicing integrity at the end of driving. Replace
any damaged pile splices in accordance with 455-11.2.7. Provide the Engineer 48 hours advance
notification prior to driving piles with epoxy-bonded dowel splices.
Mechanical pile splices shall be capable of developing the following capacities in
the pile section unless shown otherwise in the Plans and capable of being installed without
damage to the pile or splice:
a) Compressive strength = (Pile Cross sectional area) x (28 day concrete
strength)
b) Tensile Strength = (Pile Cross sectional area) x 900 psi
Pile Size (inches)
18
20
24
30
Bending Strength (kip-feet)
245
325
600
950
455-7.9 Pile Cut-offs: After the completion of driving, cut piles off which extend above
the cut-off elevation with an abrasive saw. Make the cut the depth necessary to cleanly cut
through the prestressed strands. Take ownership and dispose of cut-off sections not used
elsewhere as allowed by this Section.
455-8 Steel Piling.
455-8.1 Description: Furnish, splice, drive, and cut off structural steel shapes to form
bearing piles. Include in this work the installation of bracing members of structural steel by
bolting or welding, construction of splices and the filling of pipe piles with the specified
materials.
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455-8.2 Material: For the material in steel piles, pile bracing, scabs, wedges, and splices,
meet the requirements of Section 962.
455-8.3 Pile Splices: Order and use the full authorized pile length where practicable. Do
not splice to obtain authorized lengths less than 40 feet except when shown in the Plans. Locate
all splices in the authorized pile length in portions of the pile expected to be at least 15 feet
below the final ground surface after driving. When it is not practicable to provide authorized pile
lengths longer than 40 feet in a single length, use no more than one field splice per additional
40 feet of authorized pile length. Shop splices may be used to join single lengths of pile which
are at least 20 feet in length. One shorter segment of pile may be used to achieve the authorized
pile length when needed.
Where the pile length authorized is not sufficient to obtain the required bearing
value or penetration, order an additional length of pile and splice it to the original length.
Make all splices in accordance with details shown in the Plans and in compliance
with the general requirements of AWS D1.1 or American Petroleum Institute Specification
5L (API 5L).
455-8.4 Welding: Make all welded connections to steel piles by electric arc welding, in
accordance with details shown in the Plans and in compliance with the general requirements of
AWS D1.5. Electroslag welding is not permitted. Welds will be inspected by visual methods.
455-8.5 Pile Heads and Tips: Cut off all piles at the elevation shown in the Plans. If
using a cutting torch, make the surface as smooth as practical.
Where foundation material is so dense that the Contractor cannot drive the pile to
the required penetration and firmly seat it without danger of crumpling the tip, reinforce the tips
with approved cast steel point protectors, as shown in the Plans or required by the Engineer.
Construct point protectors in one piece of cast steel meeting the requirements of ASTM A27,
Grade 65-35 heat treated to provide full bearing for the piles. Attach points by welding according
to the recommendations of the manufacturer.
455-8.6 Pile Bent Bracing Members: Place structural steel sway and cross bracing, and
all other steel tie bracing, on steel pile bents and bolt or weld in place as indicated in the Plans.
Where piles are not driven into position in exact alignment as shown in the Plans, the Engineer
may require the use of fills and shims between the bracing and the flanges of the pile. Furnish
and place all fills and shims required to square and line up faces of flanges for cross bracing at
no additional expense to the Department.
455-8.7 Coating: Coat exposed parts of steel piling, wedging, bracing, and splices in
accordance with the provisions for coating structural steel as specified in Section 560.
455-8.8 Storage and Handling: While handling or transporting the piles from the point
of origin and into the leads, store and handle in the manner necessary to avoid damage due to
bending stresses. In general, lift steel piles by means of a suitable bridge or a sling attached to the
pile at appropriate points to prevent damage. Lift the pile from the horizontal position in a
manner that will prevent damage due to bending of the flanges and/or web.
455-8.9 Filling Pipe Piles: When required by the Plans, fill pipe piles with the specified
materials. Use clean concrete sands and concrete meeting the requirements of Section 346. Place
concrete in pipes containing water using methods in accordance with 455-15.9 with modified
tremie and pump line sizes. Concrete may be placed directly into pipes which are dry. Construct
and place reinforcement cages in accordance with 455-16. Reinforcement cages may be installed
before concrete placement or after concrete placement is completed if proper alignment and
position is obtainable.
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455-9 Sheet Piling.
455-9.1 Description: Leave permanent piling in place as part of the finished work and
generally remove temporary piling after each construction phase.
455-9.2 Materials: Meet the following requirements:
Concrete .............................................................Section 346
Bar Reinforcement .............................................Section 931
Prestressing Reinforcement................................Section 933
Steel Sheet Piles* ...............................................Section 962
*For temporary steel sheet piles meet the requirements specified in the Plans.
455-9.3 Steel Sheet Piling: Drive steel sheet piling and cut off true to line and grade.
Install steel sheet piling with a suitable hammer. Remove and replace any section damaged
during handling and installation at no additional expense to the Department.
455-9.3.1 Method of Installation: Where rock or strong material is encountered
such that the sheet piles cannot be set to grade by driving, remove the strong material by other
acceptable means, such as excavation and backfilling or by punching. When the Plans do not
indicate the existence of rock or strong material, work of removing, drilling or punching the
strong material or rock will be paid for as Unforeseeable Work.
455-9.4 Concrete Sheet Piling:
455-9.4.1 Description: Ensure that concrete sheet piling is of prestressed concrete
construction and manufactured, cured, and installed in accordance with the requirements of the
Contract Documents. Use these piles in bulkheads and abutments and at other locations as shown
in the Plans.
455-9.4.2 Manufacture of Piles: Ensure that the piles are fabricated in
accordance with Section 450.
455-9.4.3 Method of Installation: Jet concrete sheet piling to grade where
practical. The Engineer will require a minimum of two jets. Provide water at the nozzles of
sufficient volume and pressure to freely erode material adjacent to the piles. Where encountering
rock or strong material, such that the sheet piles cannot be set to grade by jetting, remove the
strong materials by other acceptable means, such as excavation and backfilling, drilling or by
punching with a suitable punch. When the Plans do not indicate the existence of rock or strong
material and the piles cannot be set by jetting, the Department will pay for the work of removing,
drilling or punching the strong material or rock as Unforeseeable Work.
455-9.4.4 Grouting and Caulking: Concrete sheet piles are generally detailed to
have tongues and grooves on their lower ends, and double grooves on their upper ends. Where so
detailed, after installation, clean the grooves of all sand, mud, or debris, and fully grout the
grooves. Use approved plastic bags (sheaths) which will meet the shape and length of the groove
to be grouted to contain the plastic grout within the double grooves. Provide grout composed of
one part cement and two parts sand. The Contractor may use clean local sand or sand meeting the
requirements of Section 902 in this grout. In lieu of sand-cement grout, the Contractor may use
concrete meeting the requirements of Section 347, using small gravel or crushed stone coarse
aggregate. Deposit the grout through a grout pipe placed within a watertight plastic sheath (bag)
extending the full depth of the double grooves and which, when filled, completely fills the slot
formed by the double grooves.
455-9.5 Storage and Handling: Handle and store all sheet piles in a manner to prevent
damage. Handle long sheet piles with fabric slings or braided wire rope constructed of six or
more wire ropes placed at appropriate lift points to prevent damage due to excessive bending.
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455-10 Pile Installation Plan.
455-10.1 General: Complete the Pile Driving Installation Plan form provided by the
Engineer. Return the Pile Driving Installation Plan information to the Engineer at the
preconstruction conference or no later than 30 days before driving the first pile. Ensure the Pile
Driving Installation Plan information includes the following:
1. List and size of proposed equipment including cranes, barges, driving
equipment, jetting equipment, compressors, and preformed pile hole equipment. Include
manufacturers data sheets on hammers.
2. Methods to determine hammer energy in the field for determination of pile
capacity. Include in the submittal necessary charts and recent calibrations for any pressure
measuring equipment.
3. Detailed drawings of any proposed followers.
4. Detailed drawings of templates.
5. Details of proposed load test equipment and procedures, including recent
calibrations of jacks and required load cells.
6. Sequence of driving of piles for each different configuration of pile layout.
7. Proposed schedule for test pile program and production pile driving.
8. Details of proposed features and procedures for protection of existing
structures.
9. Required shop drawings for piles, cofferdams, etc.
10. Methods and equipment proposed to prevent displacement of piles during
placement and compaction of fill within 15 feet of the piles.
11. Methods to prevent deflection of battered piles due to their own weight and to
maintain their as-driven position until casting of the pile cap is complete.
12. Proposed pile splice locations and details of any proprietary splices
anticipated to be used.
13. Methods and equipment proposed to prevent damage to voided or cylinder
piles due to interior water pressure.
455-10.2 Acceptance of Equipment and Procedures: All equipment and procedures are
subject to satisfactory field performance. Make any required changes that may result from
unsatisfactory field performance. The Engineer will give final acceptance after the Contractor
makes necessary modifications. Do not make any changes in the driving system after acceptance
without authorization of the Engineer. A hammer repaired on site or removed from the site and
returned is considered to have its performance altered (efficiency increased or decreased), which
is considered a change in the driving system and is subject to a dynamic load test in accordance
with 455-5.13 at no additional compensation.
455-11 Method of Measurement (All Piling).
455-11.1 Treated Timber Piling: The quantity to be paid for will be the length, in feet,
furnished, placed, and accepted according to the authorized lengths list, including any additions
and excluding any deletions thereto, as approved by the Engineer.
455-11.2 Prestressed Concrete Piling:
455-11.2.1 General: The quantity to be paid for will be the length, in feet, of
prestressed concrete piling furnished, driven and accepted according to the authorized lengths
list, including any additions and excluding any deletions thereto, as approved by the Engineer.
455-11.2.2 Furnished Length: The furnished length of precast concrete piles will
be considered as the overall length from head to tip. Final pay length will be based on the casting
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length as authorized in accordance with 455-5.14.3 subject to provisions of 455-11.2.3 through
455-11.2.8, 455-11.8, 455-11.9 and 455-11.13.
455-11.2.3 Build-ups: The lengths of pile build-ups in excess of 2 feet,
authorized by the Engineer, measured from the plane of cutback or the joint between the
sections, to head of build-up, will be included in the quantities of piling.
455-11.2.4 Piles Requiring Cut-offs: No adjustments in the length, in feet, of
piling will be made if cut-offs are required after the pile has been driven to satisfactory bearing.
455-11.2.5 Piles Driven Below Cut-off Elevation: Where a pile is driven below
cut-off elevation and satisfactory bearing is obtained so that no further driving is required, the
length of pile will be measured from cut-off elevation to tip of the pile.
455-11.2.6 Driving of Splice: If a pile is driven below cut-off and satisfactory
bearing is not obtained, and additional driving is required after construction of a satisfactory
splice, an additional 10 feet of piling will be paid for the additional driving. This compensation
for driving of splice, however, will not be allowed for test piles that are spliced and redriven.
455-11.2.7 Replacing Piles: In the event a pile is broken or otherwise damaged
by the Contractor to the extent that the damage is irreparable, in the opinion of the Engineer, the
Contractor shall extract and replace the pile at no additional expense to the Department. In the
event that a pile is mislocated by the Contractor, the Contractor shall extract and replace the pile
at no expense to the Department except when a design change proposed by the Contractor is
approved by the Department as provided in 455-5.15.5.
In the event that a pile is driven below cut-off without obtaining the
required bearing, and the Engineer elects to have the pile pulled and a longer pile substituted, it
will be paid for as Unforeseeable Work. In the event a pile is damaged or mislocated, and the
damage or mislocation is determined to be the Departments responsibility, the Engineer may
elect to have the pile extracted, and it will be paid for as Unforeseeable Work. If the extracted
pile is undamaged and driven elsewhere the pile will be paid for at 30% of the Contract unit price
for Piling. When the Department determines that it is responsible for damaged or mislocated pile,
and a replacement pile is required, compensation will be made under the item for piling, for both
the original pile and replacement pile.
The Contractor may substitute a longer pile in lieu of splicing and
building-up a pile. In this event, the Contractor will be paid for the original authorized length of
the pile, plus any additional length furnished by the Contractor up to the authorized length of the
build-up, as piling. The Contractor will be paid 30 feet of piling as full compensation for
extracting the original pile.
455-11.2.8 Underwater Driving: When the Contractor selects one of the optional
underwater driving methods, payment will be made by selecting the applicable method from the
following:
(a) Using a pile longer than the authorized length: Payment for piling will
be made only for the authorized length at that location unless the length of pile from cut-off
elevation to the final tip elevation is greater than the authorized length, in which case payment
for piling will be made from cut-off elevation to final tip elevation. No payment will be made for
pile splice, when this option is selected, unless the pile is physically spliced and the splice is
driven below cut-off elevation to achieve bearing. When making and driving a pile splice below
cut-off elevation to achieve bearing, the length to be paid for piling will be the length between
cut-off elevation and final pile tip elevation.
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(b) Using an underwater hammer: Payment for piling and pile splices will
be in accordance with 455-11.2.1 through 455-11.2.7 and 455-11.9.2. The Contractor shall
furnish additional lengths required to provide the full length confirmation pile at no expense to
the Department. Payment for piling for the full length confirmation pile will be the authorized
length of the pile, unless the length driven below cut-off elevation is greater than the authorized
length, in which case the length to be paid for will be the length between cut-off elevation and
the final tip elevation. Splices in confirmation piles will be paid for only when the splice is
driven below cut-off elevation.
(c) Using a pile follower: When a pile follower is used with a conventional
pile driving system, the method of payment will be the same as shown above in 455-11.9.2.
455-11.3 Steel Piling:
455-11.3.1 General: The quantity to be paid for will be the length, in feet, of steel
piling furnished, spliced, driven and accepted, up to the authorized length, including any
additions and excluding any deletions thereto as approved by the Engineer.
455-11.3.2 Point Protectors: The quantity to be paid for will be each for the total
of point protectors authorized, furnished, and properly installed.
455-11.4 Test Piles: The quantity to be paid for of test piles of various types, will be the
length, in feet, of test piling furnished, driven and accepted, according to the authorized length
list, and any extensions thereof as approved by the Engineer.
Where a test pile is left in place as a permanent pile, it will be paid for only as test
piles. Any extensions necessary to continue driving the pile for test purposes, as authorized by
the Engineer, will be paid for as test piles. Other extensions of piles, additional length paid for
splicing and build-ups will be included in the quantities of regular piling and will not be paid for
as test piling.
455-11.5 Dynamic Load Tests: Payment will be based on the number of dynamic load
tests as shown in the Plans or authorized by the Engineer, completed and accepted in accordance
with the Contract Documents. No separate payment will be made for dynamic load tests used to
evaluate the Contractors driving equipment. This will generally be done on the first test pile or
production pile driven on a project with each combination of proposed hammer and pile size
and/or a separate pile to evaluate any proposed followers, or piles driven to evaluate proposed
changes in the driving system. No payment will be made for dynamic load tests used to evaluate
the integrity of a pre-planned epoxy-bonded dowel splice. Include all costs associated with
dynamically testing production piles with epoxy-bonded dowel splices under Pay Item
No. 455-34. No payment will be made for dynamic load tests on test piles.
Payment for attaching equipment to each production pile for dynamic load testing
prior to initial driving and as authorized by the Engineer will be 20 feet of additional pile. No
payment will be made for attaching dynamic testing equipment for set-checks or redrives.
455-11.6 Steel Sheet Piling: The quantity to be paid for will be the plan quantity area, in
square feet, measured from top of pile elevation to the bottom of pile elevation and beginning
and end wall limits as shown in the Plans with no allowance for variable depth surface profiles.
Approved alternate support structures would be paid for as plan quantity computed for sheet pile.
Sheet piling used in cofferdams and to incorporate the Contractors specific means and methods,
and not ordered by the Engineer, will be paid for as required in Section 125.
455-11.7 Concrete Sheet Piling: The quantity to be paid for will be the product of the
number of such piles satisfactorily completed, in place, times their lengths in feet as shown in the
Plans or authorized by the Engineer. This quantity will be based upon piles 2-1/2 feet wide.
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When the Engineer approves, the Contractor may furnish the concrete sheet piling
in widths wider than shown in the Plans; then the number of piles shall be the actual number of
units completed times the width used divided by the width in the Plans.
455-11.8 Pile Splices: The quantity to be paid for authorized splices in concrete piling,
and test piling, which are made for the purpose of obtaining authorized pile lengths longer than
shown as the maximum length in the Standard Indexes, for obtaining greater lengths than
originally authorized by the Engineer, to incorporate test piling in the finished structure, for
further driving of test piling, or for splices shown in the Plans, will be 30 feet of additional
prestressed concrete piling under Pay Item No. 455-34.
For concrete piles and test piles, where the head of the pile to be spliced is not
more than 2 feet below the elevation of cut-off, the pile build-up may be cast with the cap. The
reinforcing steel and pile dimensions shall generally conform in every respect to a standard
splice. The quantity to be paid for will be 9 feet of prestressed concrete piling under Pay Item
No. 455-34 as compensation for drilling and grouting the dowels and reinforcing steel and
concrete used for-build up and all other costs for which provision has not otherwise been made.
The quantity to be paid for authorized splices in steel piling and test piling for the
purpose of obtaining lengths longer than the lengths originally authorized by the Engineer will be
20 feet of additional steel piling under Pay Item No. 455-35.
455-11.9 Set-Checks and Redrives:
455-11.9.1 Set Checks/Test Piles: There will be no separate payment for the
initial four set-checks performed the day of and the working day following initial driving. For
each additional set-check ordered by the Engineer and performed within the following working
day of initial driving, an additional quantity of 10 feet of piling will be paid.
455-11.9.2 Set Checks/Production Piles: There will be no separate payment for
the initial two set-checks performed the day of and the working day following initial driving. For
each additional set-check ordered by the Engineer and performed within the following working
day of initial driving, an additional quantity of 10 feet of piling will be paid.
455-11.9.3 Redrives: The quantity to be paid for will be the number of redrives,
each, authorized by the Engineer. Payment for any pile redrive (test pile or production pile)
ordered by the Engineer will consist of 20 feet of additional piling.
455-11.10 Pile Extraction: Piles authorized to be extracted by the Engineer and
successfully extracted as provided in 455-11.2.7 will be paid for as described in 455-11.2.7. No
payment for extraction will be made for piles shown in the Plans to be extracted or piling
damaged or mislocated by the Contractor that are ordered to be extracted by the Engineer.
455-11.11 Protection of Existing Structures: The quantity to be paid for will be at the
Contract lump sum price. When the Contract Documents do not include an item for protection of
existing structures, the cost of settlement monitoring as required by these Specifications will be
included in the cost of the piling items; however, work in addition to settlement monitoring will
be paid for as Unforeseeable Work when such additional work is ordered by the Engineer.
455-11.12 Static Load Tests: The quantity to be paid for will be the number of static
load tests of the designated tonnages, each, as shown in the Plans or authorized by the Engineer,
actually applied to piles, completed and accepted in accordance with the Plans and these
Specifications.
455-11.13 Preformed Pile Holes: The quantity added to the payment for piling will be
30% of the length of completed preformed pile holes from existing ground or the bottom of any
required excavation, whichever is lower, to the bottom of preformed hole acceptably provided,
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complete for the installation of the bearing piles, regardless of the type of pile (test pile or
production pile) installed therein. Only those holes authorized to be paid for, as provided in
455-5.9.3, will be included in the measurement for payment. The Engineer will authorize
payment for preformed pile holes only when the pile has been placed in proper position and has
achieved the required penetration.
455-12 Basis of Payment (All Piling).
455-12.1 Treated Timber Piling: Price and payment will be full compensation for
furnishing all materials, including collars, metal shoes, copper cover sheets, preservatives and
tar, and for wrapping pile clusters with wire cable, where so shown in the Plans.
455-12.2 Prestressed Concrete Piling: Price and payment will be full compensation for
the cost of furnishing and placing all reinforcing steel, predrilled holes, furnishing the material
for and wrapping pile clusters with wire cable where so shown in the Plans and grouting of
preformed pile holes when shown in the Plans.
455-12.3 Steel Piling: Price and payment will be full compensation for all labor,
equipment, and materials required for furnishing and installing steel piling, including welding
and painting as specified and the cost of predrilling pile holes described in 455-5.1.1. The cost of
any sand or concrete fill and reinforcing steel in pipe piles will be included in the price for steel
piling.
Bracing and other metal parts attached to or forming a part of piling or bracing
and not otherwise classified, will be measured and paid for as provided in Section 460.
455-12.4 Test Piles: Price and payment will be full compensation for all incidentals
necessary to complete all the work of this item except splices, build-ups, pile extractions and
preformed pile holes authorized by the Engineer and paid for under other pay items or payment
methods. The cost of all additional work not listed above necessary to ensure required
penetration and attain required bearing of the test piles will be included in the price bid per foot
of test pile, including driving and all other related costs.
455-12.5 Dynamic Load Tests:
455-12.5.1 Dynamic Load Tests/ Test Piles: All test piles will require dynamic
load tests, and include all costs associated with dynamic load tests in the pay items for test piles.
455-12.5.2 Dynamic Load Tests/ Production Piles: Payment will be full
compensation for all labor, equipment, materials, instrumentation and installation required to
assist the Engineer in performing this work.
455-12.6 Steel Sheet Piling:
455-12.6.1 Permanent Sheet Piling: Price and payment will be full
compensation for all labor, equipment, and materials required for furnishing and installing steel
sheet piling including preformed holes and coating, but will not include furnishing and placing
anchors when an anchored wall system is designed and detailed in the Plans. In such cases,
furnishing and installing anchors will be paid for separately.
455-12.6.2 Temporary Sheet Piling: For critical temporary steel sheet pile walls,
walls which are necessary to maintain the safety of the traveling public or structural integrity of
nearby structures, roadways and utilities during construction, that are detailed in the Plans, price
and payment will be full compensation for all labor, equipment, and materials required for
furnishing and installing steel sheet piling including preformed holes when shown in the Plans,
and including wales, anchor bars, dead men, soil anchors, proof tests, creep tests, and other
incidental items when an anchored wall system is required. Removal of the sheet piling, anchors,
and incidentals will be included in the cost per square foot for steel sheet piling (critical
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temporary). When the temporary steel sheet pile walls are not detailed in the Plans, the cost of
furnishing and installation shall be incidental to cost of other related items and no separate
payment shall be made. If the wall is not shown in the Plans, but deemed to be critical as
determined by the Engineer, then a design shall be furnished by the Department and paid for
separately under steel sheet piling (critical temporary).
455-12.7 Concrete Sheet Piling: Price and payment will be full compensation for
furnishing all materials, including reinforcing steel, grouting, plastic filter fabric, preformed
holes and installation.
455-12.8 Preformed Pile Holes: There is no separate pay item for preformed pile holes.
Payment will be made as the unit price for piling of the applicable pile type. Payment will be full
compensation for all labor, equipment, casings and materials required to perform this work.
455-12.9 Protection of Existing Structures: Price and payment will be full
compensation for all labor, equipment, and materials required to perform this work.
455-12.10 Point Protectors: Price and payment will be full compensation for all labor,
equipment, and materials required to perform this work.
455-12.11 Static Load Tests: Price and payment will be full compensation for all labor,
equipment, and materials required to perform this work.
455-12.12 Pile Cut-Off: Anticipate all piles will require cutting-off, and include all costs
associated with pile cut-off in the pay items for piling.
455-12.13 Payment Items: Payment will be made under:
Item No. 455- 2Treated Timber Piling - per foot.
Item No. 455- 14Concrete Sheet Piling - per foot.
Item No. 455- 18Protection of Existing Structures - lump sum.
Item No. 455- 34Prestressed Concrete Piling - per foot.
Item No. 455- 35Steel Piling - per foot.
Item No. 455- 36Concrete Cylinder Piling - per foot.
Item No. 455-119Test Loads - each.
Item No. 455-120Point Protection - each.
Item No. 455-133Sheet Piling - per square foot.
Item No. 455-143Test Piles (Prestressed Concrete) - per foot.
Item No. 455-144Test Piles (Steel) - per foot.
Item No. 455-145Test Piles (Concrete Cylinder) - per foot.
C. DRILLED SHAFTS
455-13 Description.
Construct drilled shaft foundations consisting of reinforced concrete drilled shafts
without bell footings.
455-14 Materials.
455-14.1 Concrete: For all concrete materials, meet the requirements of Section 346.
Use concrete that is specified in the Plans.
455-14.2 Reinforcing Steel: Meet the reinforcing steel requirements of Section 415.
Ensure that reinforcing steel is in accordance with the sizes, spacing, dimensions, and the details
shown in the Plans.
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455-15 Construction Methods and Equipment.
455-15.1 General Requirements:
455-15.1.1 Templates: Provide a fixed template, adequate to maintain shaft
position and alignment during all excavation and concreting operations, when drilling from a
barge. Do not use floating templates (attached to a barge). The Engineer will not require a
template for shafts drilled on land provided the Contractor demonstrates satisfactorily to the
Engineer that shaft position and alignment can be properly maintained. The Engineer will require
a fixed template, adequate to maintain shaft position and alignment during all excavation and
concreting operations, for shafts drilled on land when the Contractor fails to demonstrate
satisfactorily that he can properly maintain shaft position and alignment without use of a
template.
455-15.1.2 Drilled Shaft Installation Plan: At the preconstruction conference
submit a drilled shaft installation plan for review by the Engineer. Final approval will be subject
to satisfactory performance. Include in this plan the following details:
1. Name and experience record of drilled shaft superintendent or foreman
in responsible charge of drilled shaft operations. Ensure the drilled shaft superintendent or
foreman in responsible charge of the drilled shaft operations has a minimum of one year of
experience of installing drilled shafts of the size and depth shown in the Plans and a minimum of
three years experience in the construction of drilled shafts using the following methods:
a. Mineral slurry,
b. Casings up to the length shown in the Plans,
c. Shaft drilling operations on water under conditions as shown in
the Plans.
2. List and size of proposed equipment, including cranes, drills, augers,
bailing buckets, final cleaning equipment, desanding equipment, slurry pumps, core sampling
equipment, tremies or concrete pumps, casings, etc.
3. Details of sequence of construction operations and sequence of shaft
construction in bents or shaft groups.
4. Details of shaft excavation methods.
5. Details of slurry, including proposed methods to mix, circulate, desand,
test methods, and proposed testing laboratory to document test results.
6. Details of proposed methods to clean shaft after initial excavation.
7. Details of shaft reinforcement, including methods to ensure
centering/required cover, cage integrity during placement, placement procedures, cage support,
and tie downs.
8. Details of concrete placement, including elapsed concrete placement
times and proposed operational procedures for concrete tremie or pump, including initial
placement, raising during placement, and overfilling of the shaft concrete. Provide provisions to
ensure proper final shaft cutoff elevation.
9. Details of casing removal when removal is required, including
minimum concrete head in casing during removal.
10. Required submittals, including shop drawing and concrete design
mixes.
11. Details of any required load tests, including equipment and
procedures, and recent calibrations for any jacks or load cells.
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12. Proposed Cross-Hole Sonic Logging (CSL) Specialty Engineer to
perform, log, analyze, and report the test results.
13. Methods and equipment proposed to prevent displacement of casing
and/or shafts during placement and compaction of fill.
14. Provide the make and model of the shaft inspection device, if
applicable.
15. Details of environmental control procedures used to prevent loss of
slurry or concrete into waterways or other protected areas.
16. Proposed schedule for test shaft installation, load tests and production
shaft installation.
17. Other information shown in the Plans or requested by the Engineer.
18. For drilled shafts for miscellaneous structures constructed using
polymer slurry, identify the polymer slurry meeting the requirements of 455-15.8.2, the pH and
viscosity ranges recommended by the manufacturer for the materials to be excavated and a
description of the mixing method to be used. Submit the Material Safety Data Sheets (MSDS) for
the product, and certifications that the polymer slurry and components meet the requirements of
455-15.8.2. Submit the contact information for the manufacturers representative available for
immediate contact during shaft construction and the representatives schedule of availability.
The Engineer will evaluate the drilled shaft installation plan for
conformance with the Contract Documents. Within 20 days after receipt of the plan, the Engineer
will notify the Contractor of any additional information required and/or changes that may be
necessary in the opinion of the Engineer to satisfy the Contract Documents. The Engineer will
reject any part of the plan that is unacceptable. Submit changes agreed upon for reevaluation.
The Engineer will notify the Contractor within seven days after receipt of proposed changes of
their acceptance or rejection. All equipment and procedures are subject to trial and satisfactory
performance in the field.
Acceptance by the Engineer does not relieve the Contractor of the
responsibility to perform the work in accordance with the Contract Documents. The installation
plan is for the Contractor to explain the approach to the work and allow the Engineer an
opportunity to comment on the equipment and procedures chosen before field operations begin.
The Engineers acceptance is not a guarantee that the chosen methods and equipment are capable
of obtaining the required results, this responsibility lies with the Contractor.
455-15.1.3 General Methods & Equipment: Perform the excavations required
for the shafts, through whatever materials encountered, to the dimensions and elevations shown
in the Contract Documents, using methods and equipment suitable for the intended purpose and
the materials encountered. Provide drilling tools with a diameter not smaller than the shaft
diameter required in the Plans minus 1 inch. Provide equipment capable of constructing shafts
supporting bridges to a depth equal to the deepest shaft shown in the Plans plus 15 foot or plus
three times the shaft diameter, whichever is greater, except when the Plans require equipment
capable of constructing shafts to a deeper depth. Provide equipment capable of constructing
shafts supporting non-bridge structures, including mast arms, signals, signs and light supports to
a depth equal to the deepest shaft shown in the Plans plus 5 feet.
Construct drilled shafts according to the Contract Documents using
generally either the dry method, wet method, casing method, or permanent casing method as
necessary to produce sound, durable concrete foundation shafts free of defects. Use the
permanent casing method only when required by the Plans or authorized by the Engineer. When
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the Plans describe a particular method of construction, use this method except when permitted
otherwise by the Engineer, after field trial. When the Plans do not describe a particular method,
propose a method on the basis of its suitability to the site conditions and submit it for approval
by the Engineer.
Set a suitable temporary removable surface casing from at least 1 foot
above the ground surface to at least 1-1/2 shaft diameters below the ground surface to prevent
caving of the surface soils and to aid in maintaining shaft position and alignment. The Engineer
may require predrilling with slurry and/or overreaming to the outside diameter of the casing to
install the surface casing at some sites.
For drilled shafts installed to support mast arms, cantilever signs, overhead
truss signs, high mast light poles or other miscellaneous structures, provide temporary surface
casings from at least 1 foot above the ground surface to at least 5 feet below the ground surface.
Do not use a temporary casing greater than the diameter of the reinforcing steel cage, plus
24 inches. Fill the oversized temporary casing with drilled shaft concrete at no additional
expense to the Department. For miscellaneous structure foundations located within permanent
sidewalks or within 5 feet of curb sections, provide temporary surface casings from no lower
than the top of sidewalk to at least 5 feet below the ground surface.
For drilled shafts installed to support mast arms, cantilever signs, overhead
truss signs, high mast light poles or other miscellaneous structures, fill the excavation with
premixed mineral slurry meeting the requirements of 455-15.8.1 or polymer slurry meeting the
requirements of 455-15.8.2 before the drill advances to the bottom of the temporary casing. Do
not attempt to excavate the shaft using plain water or natural slurry. Do not attempt to excavate
the shaft using dry construction method unless specifically indicated in the Plans.
455-15.2 Dry Construction Method: Use the dry construction method only at sites
where the ground water table and soil conditions, generally stiff to hard clays or rock above the
water table, make it feasible to construct the shaft in a relatively dry excavation and where the
sides and bottom of the shaft are stable and may be visually inspected by the Engineer prior to
placing the concrete.
In applying the dry construction method, drill the shaft excavation, remove
accumulated seepage water and loose material from the excavation and place the shaft concrete
in a relatively dry excavation.
Use the dry construction method only when shaft excavations, as demonstrated in
a test hole, have 12 inches or less of seepage water accumulated over a four hour period, the
sides and bottom remain stable without detrimental caving, sloughing, or swelling for a four hour
period, and the loose material and water can be satisfactorily removed prior to inspection and
prior to placing concrete. Use the wet construction method or the casing construction method for
shafts that do not meet the requirements for the dry construction method.
455-15.3 Wet Construction Method: Use the wet construction method at all sites where
it is impractical to provide a dry excavation for placement of the shaft concrete.
The wet construction method consists of drilling the shaft excavation below the
water table, keeping the shaft filled with fluid (mineral slurry, natural slurry or water), desanding
and cleaning the mineral slurry and final cleaning of the excavation by means of a bailing
bucket, air lift, submersible pump or other approved devices and placing the shaft concrete (with
a tremie or concrete pump extending to the shaft bottom) which displaces the water or slurry
during concreting of the shaft excavation.
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Where drilled shafts are located in open water areas, construct the shafts by the
wet method using exterior casings extending from above the water elevation into the ground to
protect the shaft concrete from water action during placement and curing of the concrete. Install
the exterior casing in a manner that will produce a positive seal at the bottom of the casing so
that there is no intrusion or extrusion of water or other materials into or from the shaft
excavation.
Expandable or split casings that are removable are not permitted for use below the
water surface.
455-15.4 Temporary Casing Construction Method: Use the temporary casing method
at all sites where it is inappropriate to use the dry or wet construction methods without the use of
temporary casings other than surface casings. In this method, the casing is advanced prior to
excavation. When a formation is reached that is nearly impervious, seal in the nearly impervious
formation. Proceed with drilling as with the wet method to the projected depth. Proceed with the
placement of the concrete as with the dry method except withdraw the casing after placing the
concrete. In the event seepage conditions prevent use of the dry method, complete the excavation
and concrete placement using wet methods.
Where drilling through materials having a tendency to cave, advance the
excavation by drilling in a mineral slurry. In the event that a caving layer or layers are
encountered that cannot be controlled by slurry, install temporary removable casing through such
caving layer or layers. The Engineer may require overreaming to the outside diameter of the
casing. Take whatever steps are required to prevent caving during shaft excavation including
installation of deeper casings. If electing to remove a casing and replace it with a longer casing
through caving soils, backfill the excavation. The Contractor may use soil previously excavated
or soil from the site to backfill the excavation. The Contractor may use other approved methods
which will control the size of the excavation and protect the integrity of the foundation soils to
excavate through caving layers.
Before withdrawing the casing, ensure that the level of fresh concrete is at such a
level that the fluid trapped behind the casing is displaced upward. As the casing is withdrawn,
maintain the level of concrete within the casing so that fluid trapped behind the casing is
displaced upward out of the shaft excavation without mixing with or displacing the shaft
concrete.
The Contractor may use the casing method, when approved by the Engineer, to
construct shafts through weak caving soils that do not contribute significant shaft shear
resistance. In this case, place a temporary casing through the weak caving soils before beginning
excavation. Conduct excavation using the dry construction method where appropriate for site
conditions and the wet construction method where the dry construction method is not
appropriate. Withdraw the temporary casing during the concreting operations unless the Engineer
approves otherwise.
455-15.5 Permanent Casing Construction Method: Use the permanent casing method
when required by the Plans. In this method, place a casing to the prescribed depth before
beginning excavation. If the Contractor cannot attain full penetration, the Engineer may direct
the Contractor to excavate through the casing and advance the casing until reaching the desired
penetration. In some cases the Engineer may require the Contractor to overream the outside
diameter of the casing before placing the casing.
Cut the casing off at the prescribed elevation upon reaching the proper
construction sequence and leave the remainder of the casing in place.
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455-15.6 Excavations: When pilot holes and/or load tests are performed, the Engineer
will use the pilot hole and/or load test results to determine the authorized tip elevations and/or
the authorized installation criteria of the drilled shafts. Drilled shaft construction shall not begin
until pilot hole and/or load test reports are approved by the Engineer. Shaft tip elevations based
on pilot hole results and/or load tests may vary from the tip elevations presented in the Plans.
Extend drilled shaft excavations deeper by extra depth excavation when the Engineer determines
the material encountered while drilling the shaft excavation is unsuitable and/or is not the same
as anticipated in the design of the drilled shaft. In the absence of suitable strength tests or load
tests to evaluate materials excavated, construct the shafts no higher than the tip elevations shown
in the Plans.
455-15.6.1 Pilot Hole: When pilot holes are shown in the Plans core a pilot hole,
prior to shaft excavation, in accordance with ASTM D2113 Standard Practice for Diamond Core
Drilling for Site Excavation and the Departments Soils & Foundations Handbook using a double
or triple wall core barrel through part or all of the shaft, to a depth of 3 times the diameter of the
drilled shaft below the tip elevation shown in the Plans, as directed by the Engineer. The
Engineer may require the Contractor to cut any core to a total depth below the bottom of the
drilled shaft excavation of up to 5 times the diameter of the drilled shaft.
455-15.6.2 Cores: Take cores when shown in the Plans or directed by the
Engineer to determine the character of the material directly below the shaft excavation. Provide
equipment to retrieve the core from a depth of 5 times the diameter of the drilled shaft below the
bottom of the drilled shaft excavation in accordance with ASTM D2113 Standard Practice for
Diamond Core Drilling for Site Excavation. Cut the cores with an approved core barrel to a
minimum depth of 3 times the diameter of the drilled shaft below the bottom of the drilled shaft
excavation after completing the shaft excavation, as directed by the Engineer. The Engineer may
require the Contractor to cut any core to a total depth below the bottom of the drilled shaft
excavation of up to 5 times the diameter of the drilled shaft.
For cores or pilot holes, use only a double or triple wall core barrel
designed:
(a) to cut a core sample from 4 inches to 6 inches in diameter, at
least 5 feet in length, and,
(b) so that the sample of material cored can be removed from the
shaft excavation and the core barrel in an undisturbed state, and
The Engineer will inspect the cores and determine the depth of required
excavation. When considered necessary by the Engineer, take additional cores. Place the core
samples in suitable containers, identified by shaft location, elevation from and to, and job
number, and deliver to the Department within 48 hours after cutting. When called for in the
Plans, substitute Standard Penetration Tests (SPT) for coring. In such cases, supply these tests at
no additional cost per foot to the Department above that bid for core (shaft excavation).
Provide areas for the disposal of unsuitable materials and excess materials
as defined in 120-5 that are removed from shaft excavations, and dispose of them in a manner
meeting all requirements pertaining to pollution.
Furnish the additional drilled shaft concrete over the theoretical amount
required to complete filling any excavations for shafts which are larger than required by the
Plans or authorized by the Engineer, at no expense to the Department.
455-15.7 Casings: Ensure that casings are metal, of ample strength to withstand handling
and driving stresses and the pressure of concrete and of the surrounding earth materials, and that
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they are smooth and water tight. Ensure that the inside diameter of casing is not less than the
specified size of shaft except as provided below. The Department will not allow extra
compensation for concrete required to fill an oversize casing or oversize excavation.
The Engineer will allow the Contractor to supply casing with an outside diameter
equal to the specified shaft diameter (O.D. casing) provided he supplies additional shaft length at
the shaft tip. Determine the additional length of shaft required by the following relationship:
Additional Length =
where:
( D1 - D 2 ) L
D2
D1= casing inside diameter specified = shaft diameter specified
D2= casing inside diameter provided (D2 = D1 minus twice the wall
thickness).
L= authorized shaft length below ground for temporary casing methods or
below casing for permanent casing methods.
Bear all costs relating to this additional length including but not limited to the cost
of extra excavation, extra concrete, and extra reinforcing steel.
Remove all casings from shaft excavations except those used for the Permanent
Casing Method. Ensure that the portion of casings installed under the Permanent Casing Method
of construction below the shaft cut-off elevation remains in position as a permanent part of the
drilled shaft. The Contractor may leave casings if in the opinion of the Engineer the casings will
not adversely affect the shaft capacity in place. When casings that are to be removed become
bound in the shaft excavation and cannot be practically removed, drill the shaft excavation
deeper as directed by the Engineer to compensate for loss of capacity due to the presence of the
casing. The Department will not compensate for the casing remaining. The Department will pay
for the additional length of shaft under Pay Item No. 455-88.
If temporary casing is advanced deeper than the minimum top of rock socket
elevation shown in the Plans or actual top of rock elevation if deeper, withdraw the casing from
the rock socket and overream the shaft. If the temporary casing cannot be withdrawn from the
rock socket before final cleaning, extend the length of rock socket below the authorized tip
elevation one-half of the distance between the minimum top of rock socket elevation or actual
elevation if deeper, and the temporary casing tip elevation.
When the shaft extends above ground or through a body of water, the Contractor
may form the portion exposed above ground or through a body of water, with removable casing
except when the Permanent Casing Method is specified (see 455-23.7). When approved, the
Contractor may form drilled shafts extending through a body of water with permanent or
removable casings. However, for permanent casings, remove the portion of metal casings
between an elevation 2 feet below the lowest water elevation or 2 feet below ground whichever
is higher and the top of shaft elevation after the concrete is cured. Dismantle casings removed to
expose the concrete as required above in a manner which will not damage the drilled shaft
concrete. Dismantle removable casings in accordance with the provisions of 455-17.5.
Generally when removal of the temporary casing is required, do not start the
removal until completing all concrete placement in the shaft. The Engineer will permit
movement of the casing by rotating, exerting downward pressure, and tapping it to facilitate
extraction, or extraction with a vibratory hammer. Extract casing at a slow, uniform rate with the
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pull in line with the axis of the shaft. Withdraw temporary casings while the concrete remains
fluid.
When conditions warrant, the Contractor may pull the casing in partial stages.
Maintain a sufficient head of concrete above the bottom of the casing to overcome the
hydrostatic pressure of water outside the casing. At all times maintain the elevation of the
concrete in the casing high enough to displace the drilling slurry between the outside of the
casing and the edge of the hole while removing the casing.
The Contractor may use special casing systems in open water areas, when
approved, which are designed to permit removal after the concrete has hardened. Design special
casings so that no damage occurs to the drilled shaft concrete during their removal.
455-15.8 Slurry and Fluid in Excavation at Time of Concrete Placement:
455-15.8.1 Mineral Slurry: When mineral slurry is used in an excavation, use
only processed attapulgite or bentonite clays with up to 2% (by dry weight) of added polymer.
Use mineral slurry having a mineral grain size such that it will remain in suspension and having
sufficient viscosity and gel characteristics to transport excavated material to a suitable screening
system. Use a percentage and specific gravity of the material to make the suspension sufficient to
maintain the stability of the excavation and to allow proper placement of concrete. Ensure that
the material used to make the slurry is not detrimental to concrete or surrounding ground strata.
During construction, maintain the level of the slurry at a height sufficient to prevent caving of
the hole. In the event of a sudden significant loss of slurry such that the slurry level cannot
practically be maintained by adding slurry to the hole, backfill the excavation and delay the
construction of that foundation until an alternate construction procedure has been approved.
Thoroughly premix the slurry with clean fresh water prior to introduction
into the shaft excavation. Ensure that the percentage of mineral admixture used to make the
suspension is such as to maintain the stability of the shaft excavation. The Engineer will require
adequate water and/or slurry tanks when necessary to perform the work in accordance with these
Specifications. The Engineer will not allow excavated pits on projects requiring slurry tanks
without the written permission of the Engineer. Take the steps necessary to prevent the slurry
from setting up in the shaft, including but not limited to agitation, circulation, and/or adjusting
the composition and properties of the slurry. Provide suitable offsite disposal areas and dispose
of all waste slurry in a manner meeting all requirements pertaining to pollution.
Provide a CTQP qualified drilled shaft inspector to perform control tests
using suitable apparatus on the mineral slurry mixture to determine the following parameters:
(a) Freshly mixed mineral slurry: Measure the density of the
freshly mixed mineral slurry regularly as a check on the quality of the suspension being formed
using a measuring device calibrated to read within plus or minus0.5 pound per cubic foot.
(b) Mineral slurry supplied to the drilled shaft excavation: Perform
the following tests on the mineral slurry supplied to the shaft excavation and ensure that the
results are within the ranges stated in the table below:
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Item to be measured
Density
Range of Results at 68F
64 to 73 lb/ft3
(in fresh water environment)
66 to 75 lb/ft3
(in salt water environment)
Viscosity
30 to 50 seconds
pH
8 to 11
Sand Content
4% or less
Test Method
Mud density balance:
FM 8-RP13B-1
Marsh Cone Method:
FM 8-RP13B-2
Electric pH meter or pH
indicator paper strips:
FM 8-RP13B-4
FM 8-RP13B-3
The Contractor may adjust the limits in the above table when field
conditions warrant as successfully demonstrated in a test hole or with other methods approved by
the Engineer. The Engineer must approve all changes in writing before the Contractor can
continue to use them.
Perform tests to determine density, viscosity, and pH value to establish a
consistent working pattern, taking into account the mixing process and blending of freshly mixed
mineral slurry and previously used mineral slurry. Perform a minimum of four sets of tests to
determine density, viscosity, and pH value during the first 8 hours mineral slurry is in use.
When the results show consistent behavior, discontinue the tests for pH
value, and only carry out tests to determine density and viscosity during each four hours mineral
slurry is in use. If the consistent working pattern changes, reintroduce the additional tests for pH
value for the time required to establish consistency of the test values within the required
parameters.
(c) The Department may perform comparison tests as determined
necessary during the mineral slurry operations.
During construction, maintain the level of mineral slurry in the shaft
excavation within the excavation and at a level not less than 4 feet above the highest expected
piezometric water pressure along the depth of a shaft.
At any time the wet construction method of stabilizing excavations fails,
in the opinion of the Engineer, to produce the desired final result, discontinue this method of
construction, and propose modifications in procedure or alternate means of construction for
approval.
455-15.8.2 Polymer Slurry For Shafts For Miscellaneous Structures:
Materials manufactured expressly for use as polymer slurry for drilled
shafts may be used as slurry for drilled shaft excavations installed to support mast arms,
cantilever signs, overhead truss signs, high mast light poles or other miscellaneous structures. A
representative of the manufacturer must be on-site or available for immediate contact to assist
and guide the construction of the first three drilled shafts at no additional cost to the Department.
This representative must also be available for on-site assistance or immediate contact if problems
are encountered during the construction of the remaining drilled shafts as determined by the
Engineer. The Engineer will not allow polymer slurries during construction of drilled shafts for
bridge foundations. Use polymer slurry only if the soils below the casing are not classified as
organic, and the pH of the fluid in the hole can be maintained in accordance with the
manufacturers published recommendations. Submit the MSDS for the product, the
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manufacturers published mixing procedures, and the manufacturers published range of values
for pH and viscosity of the mixed slurry. Provide documentation that the polymer slurry and
components meet the following requirements:
a. The polymer slurries to be used on the project and their waste products
are classified as non-hazardous as defined by Resource Conservation and Recovery Act (RCRA)
Subpart C rules, Table 1 of 40 CFR 261.24 Toxicity Characteristic.
b. Pull out tests demonstrate the bond between the bar reinforcement and
the concrete is not materially affected by exposure to the slurry under typical construction
conditions, over the typical range of slurry viscosities to be used.
c. Load tests demonstrate the bond between the concrete and the soil is not
materially affected by exposure to the polymer slurry under typical construction conditions, over
the typical range of polymer slurry viscosities to be used for the project versus affect of exposure
to mineral slurry.
d. The method of disposal meets the approval of all federal, state and local
regulatory authorities.
Perform the following tests on the polymer slurry in the shaft excavation
and ensure that the results are maintained within the ranges stated in the table below:
Item to be measured
Density
Viscosity
Mixed Polymer Slurry Properties
Range of Results at 68F
62 to 64 lb/ft3
(fresh water)
64 to 66 lb/ft3
(salt water)
Range Published By The Manufacturer
for Materials Excavated
pH
Range Published By The Manufacturer
for Materials Excavated
Sand Content
0.5% or less
Test Method
Mud density balance:
FM 8-RP13B-1
Marsh Cone Method:
FM 8-RP13B-2
Electric pH meter or pH
indicator paper strips:
FM 8-RP13B-4
FM 8-RP13B-3
Polymer slurry may be mixed in the cased portion of the shaft in
accordance with the manufacturers published procedures.
During construction, maintain the level of the slurry at a height sufficient
to prevent caving of the hole. At any time the wet construction method of stabilizing excavations
fails, in the opinion of the Engineer, to produce the desired final result, discontinue this method
of construction, and propose modifications in procedure or alternate means of construction for
approval.
455-15.8.3 Fluid In Excavation At Time Of Concrete Placement: When any
fluid is present in any drilled shaft excavation, including shafts to support miscellaneous
structures, the applicable test methods and reporting requirements described in 455-15.8.1 apply
to tests of fluid in the shaft prior to placing the concrete.
Take samples of the fluid in the shaft from within 1 inch of the base of the
shaft and at intervals not exceeding 10 feet up the shaft, using an approved sampling tool
designed to sample over a depth range of 12 inches or less. Take whatever action is necessary
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prior to placing the concrete to bring the fluid within the specification and reporting
requirements, outlined in the tables in 455-15.8.1, except as follows:
The Engineer will not require tests for pH, viscosity or minimum density
when slurry has not been introduced into the shaft excavation.
When using polymer slurry to support the excavation for drilled shafts
installed to support mast arms, cantilever signs, overhead truss signs, high mast light poles or
other miscellaneous structures, take whatever action is necessary prior to placing the concrete to
bring the properties of the fluid within the ranges in 455-15.8.2.
Provide a CTQP qualified drilled shaft inspector to perform testing. The
Department may also perform comparison tests. Provide equipment for such comparison tests
when requested by the Engineer.
455-15.9 Tremies and Pumps:
455-15.9.1 General: The requirements of the applicable provisions of
Section 400 will apply when using a tremie or a pump to place drilled shaft concrete.
455-15.9.2 Dry Excavations: Ensure that the tremie for depositing concrete in a
dry drilled shaft excavation consists of a tube of solid construction, a tube constructed of sections
which can be added and removed, or a tube of other approved design. The Contractor may pass
concrete through a hopper at the top of the tube or through side openings as the tremie is
retrieved during concrete placement. Support the tremie so that the free fall of the concrete is less
than 5 feet at all times. If the free falling concrete causes the shaft excavation to cave or slough,
control the movement of concrete by reducing the height of free fall of the concrete and/or
reducing the rate of flow of concrete into the excavation.
455-15.9.3 Wet Excavations: Construct the tremie or pump line used to deposit
concrete beneath the surface of water so that it is water-tight and will readily discharge concrete.
Construct the discharge end of the tremie or pump line to prevent water intrusion and permit the
free flow of concrete during placement operations. Ensure that the tremie or pump line has
sufficient length and weight to rest on the shaft bottom before starting concrete placement.
During placement operations, ensure that the discharge end of the tremie
or pump line is within 6 inches of the bottom of the shaft excavation until at least 10 feet of
concrete has been placed. Ensure the discharge end of the tremie or pump line is continuously
embedded at least 10 feet into the concrete after 10 feet of concrete has been placed and until the
casing is overpoured sufficiently to eliminate all contaminated concrete. Ensure that the free fall
of concrete into the hopper is less than 5 feet at all times. Support the tremie so that it can be
raised to increase the discharge of concrete and lowered to reduce the discharge of concrete. Do
not rapidly raise or lower the tremie to increase the discharge of the concrete. Maintain a
continuous flow of concrete and a positive pressure differential of the concrete in the tremie or
pump line at all times to prevent water or slurry intrusion into the shaft concrete.
455-15.10 Excavation and Drilling Equipment:
455-15.10.1 General: All shaft excavation is unclassified shaft excavation. The
Engineer will require drilled shaft sidewall overreaming when inspections show it to be
necessary. These terms are defined in 455-15.10.2, 455-15.10.3, and 455-15.10.4, respectively.
Use excavation and drilling equipment having adequate capacity,
including power, torque, and crowd (downthrust), and excavation and overreaming tools of
adequate design, size, and strength to perform the work shown in the Plans or described herein.
When the material encountered cannot be drilled using conventional earth augers and/or
underreaming tools, provide special drilling equipment, including but not limited to rock augers,
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core barrels, rock tools, air tools, blasting materials, and other equipment as necessary to
continue the shaft excavation to the size and depth required. In the event blasting is necessary,
obtain all necessary permits. The Contractor is responsible for the effects of blasting on already
completed work and adjacent structures. The Engineer must approve all blasting.
455-15.10.2 Unclassified Shaft Excavation: Unclassified shaft excavation is
defined as all processes required to excavate a drilled shaft of the dimensions shown in the
Contract Documents to the depth indicated in the Plans plus 15 feet or plus 3 shaft diameters,
whichever is deeper, completed and accepted. Include in the work all shaft excavation, whether
the material encountered is soil, rock, weathered rock, stone, natural or man-made obstructions,
or materials of other descriptions.
455-15.10.3 Unclassified Extra Depth Excavation: Unclassified extra depth
excavation is defined as all processes required to excavate a drilled shaft of plan dimensions
which is deeper than the limits defined as unclassified shaft excavation.
455-15.10.4 Drilled Shaft Sidewall Overreaming: Drilled shaft sidewall
overreaming is defined as the unclassified excavation required to roughen its surface or to
enlarge the drilled shaft diameter due to softening of the sidewalls or to remove excessive
buildup of slurry cake when slurry is used. Increase the shaft radius a minimum of 1/2 inch and a
maximum of 3 inches by overreaming. The Contractor may accomplish overreaming with a
grooving tool, overreaming bucket, or other approved equipment.
Meet the limit for depth of sidewall overreaming into the shaft sidewall
material and the elevation limits between which sidewall overreaming is required.
455-15.11 Inspection of Excavations:
455-15.11.1 Dimensions and Alignment: Provide equipment for checking the
dimensions and alignment of each permanent shaft excavation. Determine the dimensions and
alignment of the shaft excavation under the observation and direction of the Department.
Generally check the alignment and dimensions by any of the following methods as necessary:
(a) Check the dimensions and alignment of dry shaft excavations using
reference stakes and a plumb bob.
(b) Check the dimensions and alignment of casing when inserted in the
excavation.
(c) Insert a casing in shaft excavations temporarily for alignment and
dimension checks.
(d) Insert a rigid rod or pipe assembly with several 90 degree offsets equal
to the shaft diameter into the shaft excavation for alignment and dimension checks.
Insert any casing, rod or pipe assembly, or other device used to check
dimensions and alignment into the excavation to full depth.
455-15.11.2 Depth: Generally reference the depth of the shaft during drilling to
appropriate marks on the Kelly bar or other suitable methods. Measure final shaft depths with a
suitable weighted tape or other approved methods after final cleaning.
455-15.11.3 Shaft Inspection Device (SID): When shown in the Plans, furnish
all power and equipment necessary for the Engineer to inspect the bottom conditions of a drilled
shaft excavation and to measure the thickness of bottom sediment or any other debris using a
SID. Provide a means to position and lower the SID into the shaft excavation to enable the bell
housing to rest vertically on the bottom of the excavation. Include all cost related to the
inspection device in the cost of drilled shaft items.
Furnish a SID meeting the following requirements:
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(a) A remotely operated, high resolution, color video camera
sealed inside a watertight bell housing.
(b) Provides a clear view of the bottom inspection on a video
monitor at the surface in real time.
(c) Provides a permanent record of the entire inspection with voice
annotation on a quality DVD with a resolution of not less than 720 x 480.
(d) Provides a minimum field of vision of 110 square inches, with
a graduated measuring device to record the depth of sediment on the bottom of the shaft
excavation to a minimum accuracy of 1/2 inch and a length greater than 1-1/2 inches.
(e) Provides sufficient lighting to illuminate the entire field of
vision at the bottom of the shaft in order for the operator and inspector to clearly see the depth
measurement scale on the video monitor and to produce a clear recording of the inspection.
(f) Provides a compressed air or gas system to displace drilling
fluids from the bell housing and a pressurized water system to assist in determination of bottom
sedimentation depth
Obtain the Engineers approval of the device in advance of the first
inspection contingent on satisfactory field performance. Notify the Engineer for approval before
a different device is used for any subsequent inspection.
455-15.11.4 Shaft Cleanliness Requirements: Adjust cleaning operations so a
minimum of 50% of the bottom of each shaft will have less than 1/2 inches of sediment at the
time of placement of the concrete. Ensure the maximum depth of sedimentary deposits or any
other debris at any place on the bottom of the shaft excavation does not exceed 1-1/2 inches. The
Engineer will determine shaft cleanliness by visual inspection for dry shafts, using divers or an
inspection device or other methods the Engineer deems appropriate for wet shafts.
When using slurry, meet the requirements of 455-15.8 at the time of
concrete placement.
455-15.11.4.1 Exceptions for Shafts for Miscellaneous Structures:
Ensure the depth of sedimentary deposits or other debris does not exceed 1 inch over the bottom
of the shaft when installing drilled shafts to support mast arms, cantilever signs, overhead truss
signs, high mast light poles or other miscellaneous structures.
455-15.11.5 Time of Excavation: Any unclassified excavation work lasting more
than 36 hours (measured from the beginning of excavation for all methods except the Permanent
Casing Method, which begins at the time excavation begins below the casing) before placement
of the concrete requires overreaming the sidewalls to the depth of softening or removing
excessive slurry cake buildup. Ensure that the minimum depth of overreaming the shaft sidewall
is 1/2 inches and the maximum depth is 3 inches. Provide any overreaming required at no
expense to the Department when exceeding the 36 hour limit unless the time limit is exceeded
solely to accomplish excavating deeper than the elevation shown in the Plans as ordered by the
Engineer. The Department will pay the Contractor for authorized overreaming resulting from
softening or excessive filtercake buildup which is indicated by test methods employed by the
Engineer during the initial 36 hour time period. The Department will pay the Contractor for
authorized overreaming when excavating deeper than the elevation shown in the Plans as ordered
by the Engineer exceeds the 36 hour time limit.
When using mineral slurry, adjust excavation operations so that the
maximum time that slurry is in contact with the bottom 5 feet of the shaft (from time of drilling
to concreting) does not exceed 12 hours. If exceeding the 12 hour time limit, overream the
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bottom 5 feet of shaft at no additional expense to the Department prior to performing other
operations in the shaft.
455-16 Reinforcing Steel Construction and Placement.
455-16.1 Cage Construction and Placement: Completely assemble and place as a unit
the cage of reinforcing steel, consisting of longitudinal bars, ties, and cage stiffener bars,
immediately after the Engineer inspects and accepts the shaft excavation and immediately prior
to placing concrete. Tie all intersections of drilled shaft reinforcing steel with cross ties or
figure 8 ties. Use double strand ties, ties with larger tie wire, U-bolts, or similar when
necessary. The Engineer will give final approval of the cage construction and placement subject
to satisfactory performance in the field.
455-16.2 Splicing Cage: If the bottom of the constructed shaft elevation is lower than the
bottom of the shaft elevation in the Plans, extend a minimum of one half of the longitudinal bars
required in the upper portion of the shaft the additional length. Continue the tie bars for the extra
depth, spaced on 2 foot centers, and extend the stiffener bars to the final depth. The Contractor
may lap splice these bars or use unspliced bars of the proper length. Do not weld bars to the
planned reinforcing steel unless shown in the Contract Documents.
For drilled shafts supporting mast arms, cantilever signs, overhead truss signs,
high mast light poles or other miscellaneous structures, if the shaft cleaning operations result in
excavating below the required tip elevation, the reinforcing steel cage may be spliced or
suspended.
455-16.3 Support, Alignment, and Tolerance: Tie and support the reinforcing steel in
the shaft so that the reinforcing steel will remain within allowable tolerances as specified in
455-20 and Section 415.
Use wheels or other approved noncorrosive spacing devices within 3 feet of the
bottom, within 6 feet of the top, and intervals not exceeding 10 feet along the shaft to ensure
concentric spacing for the entire length of the cage. Do not use block or wire type spacers. Use a
minimum of one spacer per 30 inches of circumference of cage with a minimum of four at each
level. Provide spacers at the bottom of the drilled shaft reinforcing cage as required to maintain
the proper position of the cage.
Check the elevation of the top of the steel cage before and after placing the
concrete. If the cage is not within the specified tolerances, correct, and do not construct
additional shafts until receiving approval from the Engineer.
455-16.4 Cross-Hole Sonic Logging (CSL) Tubes: Install CSL access tubes full length
in all drilled shafts from the tip of shaft to a point high enough above top of shaft to allow
CSLtesting, but not less than 30 inches above the top of the drilled shaft, ground surface or water
surface, whichever is higher. Equally space tubes around circumference of drilled shaft. Securely
tie access tubes to the inside of the reinforcing cage and align tubes to be parallel to the vertical
axis of the center of the cage. Access tubes from the top of the reinforcing cage to the tip of the
shaft shall be NPS 1-1/2 Schedule 40 black iron or black steel (not galvanized) pipe. Access
tubes above the top of the reinforcing cage may be the same black iron or black steel pipe or
Schedule 80 PVC pipe. Ensure that the CSL access tubes are free from loose rust, scale, dirt,
paint, oil and other foreign material. Couple tubes as required with threaded couplers, such that
inside of tube remains flush. Seal the bottom and top of the tubes with threaded caps. The tubes,
joints and bottom caps shall be watertight. Seal the top of the tubes with lubricated, threaded
caps sufficient to prevent the intrusion of foreign materials. Stiffen the cage sufficiently to
prevent damage or misalignment of access tubes during the lifting and installation of the cage.
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Exercise care in removing the caps from the top of the tubes after installation so as not to apply
excess torque, hammering or other stress which could break the bond between the tubes and the
concrete.
Provide the following number (rounded up to the next whole number of tubes)
and configuration of cross-hole sonic logging access tubes in each drilled shaft based on the
diameter of the shaft.
Shaft Diameter
Number of Tubes Required
36 to 48 inches
4
1 tube per foot
of Shaft Diameter
Greater than 48 inches
Configuration around the inside
of Circular Reinforcing Cage
90 degrees apart
360 degrees divided by the
Number of Tubes
Insert simulated or mock probes in each cross-hole-sonic access tube prior to
concreting to ensure the serviceability of the tube. Fill access tubes with clean potable water and
recap prior to concreting. Repair or replace any leaking, misaligned or unserviceable tubes as in
a manner acceptable to the Engineer prior to concreting.
For drilled shaft foundations requiring anchor bolts, verify CSL access tubes will
not interfere with anchor bolt installation before excavating the shaft. When CSL access tube
locations conflict with anchor bolt locations, move the CSL access tube location plus or minus
2 inches along the inner circumference of the reinforcing cage. Notify the Engineer before
excavating the shaft if the CSL access tube locations cannot be moved out of conflict with
anchor bolt locations.
When drilled shaft cages will be suspended in place from the top rather than
resting on the bottom of the excavation, clearly mark the top of shaft location on each tube.
455-17 Concrete Placement.
455-17.1 General: Place concrete in accordance with the applicable portions of
Sections 346 and 400, 455-15.2, 455-15.3, 455-15.4, 455-15.5, 455-15.8, 455-15.9, and the
requirements herein.
Place concrete as soon as possible after completing all excavation, cleaning the
shaft excavation, inspecting and finding it satisfactory, and immediately after placing reinforcing
steel. Continuously place concrete in the shaft to the top of the casing. Continue placing concrete
after the casing is full until good quality concrete is evident at the top of the casing. Place
concrete through a tremie or concrete pump using approved methods. After the shaft is
overpoured sufficiently to eliminate all contaminated concrete, additional concrete may be added
to the shaft without the use of a tremie or pump in accordance with Section 400.
If the pressure head is lost during concrete placement for any reason, the Engineer
may direct the Contractor to perform integrity testing at no expense to the Department.
Immediately after concreting, check the water levels in the CSL access tubes and
refill as necessary. If tubes become unserviceable, core new holes in the drilled shaft as directed
by the Engineer.
455-17.2 Placement Time Requirements: The elapsed time for placing drilled shaft
concrete includes the concrete mixing and transit time, the concrete placement time, the time
required to remove any temporary casing that causes or could cause the concrete to flow into the
space previously occupied by the casing, and the time to insert any required column steel, bolts,
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weldments, etc. Maintain a minimum slump of 5 inches throughout the elapsed time. Use
materials to produce and maintain the required slump through the elapsed time that meets the
class of concrete specified. Provide slump loss tests that demonstrate to the Engineer that the
concrete will maintain a 5 inch or greater slump for the anticipated elapsed time before
beginning drilled shaft construction.
455-17.3 Forms: When the top of shaft elevation is above ground, form the portion of
the shaft above ground with a removable form or another approved method to the dimensions
shown in the Plans.
When the shaft extends above the ground through a body of water, the Contractor
may form the portion through the water with removable forms except when the Permanent
Casing Method is specified.
When approved, the Contractor may form the portion through the water with
permanent forms, provided the forms are removed from 2 feet below the lowest water elevation
to the top of shaft elevation.
455-17.4 Riser Blocks: The Contractor may cast a riser block of equal diameter as the
column and of a maximum height of 6 inches at the top of the completed shaft. When this option
is chosen, extend any dowel steel above the top of shaft an additional 6 inches.
455-17.5 Curing: Cure the top surface in accordance with the applicable provisions of
Section 400, and construct any construction joint area as shown in the Plans. Protect portions of
drilled shafts exposed to a body of water from the action of water by leaving the forms in place
for a minimum of seven days after casting the concrete. The Contractor may remove forms prior
to seven days provided the concrete strength has reached 2,500 psi or greater as evidenced by
cylinder breaks.
455-17.6 Non-Destructive Testing of Drilled Shaft Integrity:
455-17.6.1 Cross-Hole Sonic Logging (CSL) Tests: Perform all CSL testing in
accordance with ASTM D6760. Test all drilled shafts in bridge bents or piers considered
nonredundant in the Plans, using CSL. For all other drilled shafts, perform CSL testing only on
drilled shafts selected by the Engineer. The minimum number of shafts tested is the number of
shafts indicated in the Plans. The Engineer may increase the number shafts tested as deemed
necessary.
Engage a qualified Specialty Engineer to perform the CSL testing. The
qualified CSL Specialty Engineer must have a minimum three years experience of CSL testing
and have a Florida Licensed Professional Engineer supervising the collection and interpretation
of data. The Contractor shall provide all necessary assistance to the CSL Specialty Engineer to
satisfactorily perform the testing.
When a shaft contains four tubes, test every possible tube combination.
For shafts with five or more tubes, test all pairs of adjacent tubes around the perimeter, and onehalf of the remaining number of tube combinations, as chosen by the Engineer.
After acceptance of production shafts by the Engineer, remove all water
from the access tubes or core holes and fill the tubes or core holes with a structural non-shrink
grout approved by the Engineer.
If the Contractor determines at any time during the non-destructive testing
and evaluation of the drilled shaft that the drilled shaft should be replaced, no further testing or
evaluation of that shaft is required.
455-17.6.1.1 Equipment: Furnish CSL test equipment as follows:
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1. Include ultrasonic transmitter and receiver probes for 1.5 inch
I.D. pipe which produce measurements with consistent signal strength and arrival time in
uniform, good quality concrete with all tube spacings on the project.
2. Include a microprocessor based data acquisition system for
display, storage, and transfer of data. Graphically display first pulse Arrival Time (FAT) during
data acquisition.
3. Electronically measure and record the relative position (depth)
of the probes in the tubes with each CSL signal.
4. Print the CSL logs for report presentation.
5. Provide report quality plots of CSL measurements that identify
each individual test.
6. Electronically store each CSL log in digital format, with shaft
identification, date, time and test details, including the transmitter and receiver gain.
455-17.6.1.2 Procedure: Perform CSL testing between 72 hours and
25 calendar days of shaft concrete placement and after the concrete compressive strength
exceeds 3,000 psi. Furnish information regarding the shaft, tube lengths and depths, construction
dates, and other pertinent shaft installation observations and details to the Department at the time
of testing. Verify access tube lengths and their condition in the presence of the Department, at
least 24 hours prior to CSL testing. If the access tubes do not provide access over the full length
of the shaft, repair the existing tube(s) or core additional hole(s), as directed by the Engineer, at
no additional cost to the Department.
Pull the probes simultaneously, starting from the bottoms of the
tubes, over an electronic depth measuring device. Perform the CSL tests with the source and
receiver probes in the same horizontal plane. Continuously record CSL signals at depth intervals
of 2.5 inches or less from the bottom of the tubes to the top of each shaft. Remove all slack from
the cables prior to pulling to provide accurate depth measurements in the CSL records.
Report any anomalies indicated by longer pulse arrival times and
significantly lower amplitude/energy signals to the Engineer and conduct further tests as required
to evaluate the extent of possible defects. Conduct offset CSL measurements between all tube
pair combinations in any drilled shafts with 30% or greater in velocity reduction. Record offset
measurements with source and receiver vertically offset in the tubes. These measurements add
four measurements per tube combination to the horizontal measurements described in this
section. Offset measurements are described by the angle (in degrees) and direction the signal
travels between the probes with respect to the horizontal plane: plus 45, plus 22.5 (source below
receiver), and minus 45, minus 22.5 (source above receiver). Record offset measurements from
the point where the higher probe is at least 5 feet below the velocity reduction to the point where
the lower probe is at least 5 feet above the velocity reduction. Provide offset CSL logs and 3-D
tomographic analysis of all CSL data at no additional cost to the Department in the event 30% or
greater in velocity reductions are detected.
455-17.6.1.3 Required Reports: Present the CSL testing and analysis
results to the Engineer in a report. Include CSL logs with analyses of first pulse arrival time
(FAT) versus depth and pulse energy/amplitude versus depth. Present a CSL log for each tube
pair tested with any defect zones identified on the logs and discussed in the test report as
appropriate. When offset measurements are required, perform 3-D tomographic analysis using all
offset data, and include color coded 3-D tomographic images in the report.
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455-17.6.1.4 Evaluation of CSL Test Results: The Engineer will
evaluate the observations during drilled shaft construction and CSL test results to determine
whether or not the drilled shaft construction is acceptable. Drilled shafts with velocity reduction
exceeding 30% are not acceptable without an engineering analysis.
455-17.6.1.5 Coring and/or Repair of Drilled Shafts: If the Engineer
determines a drilled shaft is unacceptable based on the CSL tests and tomographic analyses, or
observes problems during drilled shaft construction, core the shaft to allow further evaluation
and repair, or replace the shaft. If coring to allow further evaluation of the shaft and repair is
chosen, one or more core samples shall be taken from each unacceptable shaft for full depth of
the shaft or to the depth directed by the Engineer. The Engineer will determine the number,
location, and diameter of the cores based on the results of 3-D tomographic analysis of offset and
horizontal CSL data. Keep an accurate log of cores. Properly mark and place the cores in a crate
showing the shaft depth at each interval of core recovery. Transport the cores, along with five
copies of the coring log to the Engineer. Perform strength testing by an AASHTO certified lab
on portions of the cores that exhibit questionable concrete as determined by the Engineer. If the
drilled shaft offset CSL testing, 3-D tomographic analyses and coring indicate the shaft is
defective, propose remedial measures for approval by the Engineer. Such improvement may
consist of, but is not limited to correcting defective portions of the shaft, providing straddle
shafts to compensate for capacity loss, or providing a replacement shaft. Repair all detected
defects and conduct post repair integrity testing using horizontal and offset CSL testing and 3-D
tomographic imaging as described in this Section. Engage a Specialty Engineer to perform
gamma-gamma density logging to verify the integrity of the shaft outside the reinforcing cage in
the same locations offset CSL data was/is required. Submit all results to the Engineer within five
days of test completion for approval. Perform all work described in this Section at no additional
cost to the Department, and with no increase in contract time.
455-17.6.2 Access for Thermal Integrity Testing: Provide safe and secure
access and assistance to the Engineer, when requested, for the purpose of evaluating drilled shaft
integrity via internal temperature measurements using the Thermal Integrity Test Method as
described herein. The Thermal Integrity Test Method is based on measuring the heat generation
of hydrating cement. The analysis of measured temperature profiles requires knowledge of the
concrete mix used and soil profile for the purposes of determining heat generation and soil
insulation parameters. For typical drilled shaft concrete mixes, thermal testing should be
performed between one and two days after shaft concreting.
Provide access to the Engineer for testing the shafts within 4 hours of the peak
temperature generation, which is expected to occur between 24 hours and 48 hourrs after shaft
concrete placement. Provide access to the Engineer for testing all drilled shafts in bridge bents or
piers considered non-redundant in the Plans. Based on the observations during drilled shaft
construction, the Engineer may test one or all drilled shafts in bridge bents or piers considered
redundant in the Plans. For drilled shaft foundations supporting miscellaneous structures, only
drilled shafts selected by the Engineer will be tested.
455-17.6.2.1 Evaluation of Thermal Integrity Testing: The Engineer
will evaluate the observations during drilled shaft construction and the Thermal Integrity Test
results within three working days of testing the shaft. If the shaft is selected for CSL testing, the
evaluation will not be given to the Contractor before all CSL testing and analysis is complete and
reported to the Engineer.
455-17.6.2.2 Coring and/or Repair of Drilled Shafts: If the Engineer
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determines a drilled shaft is unacceptable based on the Thermal Integrity Testing, core the shaft
to allow further evaluation and repair, or replace the shaft in accordance with 455-17.6.1.5.
If repairs are performed, test in accordance with 455-17.6.1.5 and when requested,
assist the Engineer in retesting the shaft(s) in accordance with 455-17.6.2.
455-18 Test Holes.
The Engineer will use the construction of test holes (method shafts) to determine if the
methods and equipment used by the Contractor are sufficient to produce a shaft excavation
meeting the requirements of the Contract Documents. During test hole excavations, the Engineer
will evaluate the ability to control dimensions and alignment of excavations within tolerances; to
seal the casing into impervious materials; to control the size of the excavation under caving
conditions by the use of mineral slurry or by other means; to properly clean the completed shaft
excavation; to construct excavations in open water areas; to determine the elevation of ground
water; to place reinforcing steel and concrete meeting the requirements of these Specifications
within the prescribed time frame; and to execute any other necessary construction operation.
Revise the methods and equipment as necessary at any time during the construction of the test
hole when unable to satisfactorily carry out any of the necessary operations described above or
when unable to control the dimensions and alignment of the shaft excavation within tolerances.
Drill test holes out of permanent position at the location shown in the Plans or as directed
by the Engineer. Ensure the diameter and depth of the test hole or holes are the same diameter
and maximum depth as the production drilled shafts. Reinforce the test hole unless otherwise
directed in the Contract Documents. Fill the test hole with concrete in the same manner
production drilled shafts will be constructed. Backfill test holes which are not filled with
concrete with suitable soil in a manner satisfactory to the Engineer. Leave concreted test holes in
place, except remove the top of the shaft to a depth of 2 feet below the ground line. Use the same
procedure for shafts constructed in water. Restore the disturbed areas at the sites of test holes
drilled out of position as nearly as practical to their original condition. When the Contractor fails
to demonstrate to the Engineer the adequacy of his methods or equipment, and alterations are
required, make appropriate modifications and provide additional test holes at no expense to the
Department. Include the cost of all test holes in the cost of the drilled shafts. Make no changes in
methods or equipment after initial approval without the consent of the Engineer.
A separate test hole is not required for drilled shafts installed under mast arms, cantilever
signs, overhead truss signs, high mast light poles or other miscellaneous structures. The first
production shaft will serve as a test hole for determining acceptability of the installation method.
455-19 Test Bells.
Test bells are no longer used.
455-20 Construction Tolerances.
Meet the following construction tolerances for drilled shafts:
(a) Ensure that the top of the drilled shaft is no more than 3 inches laterally in the
X or Y coordinate from the position indicated in the Plans.
(b) Ensure that the vertical alignment of the shaft excavation does not vary from
the alignment shown in the Plans by more than 1/4 inches per foot of depth.
(c) After placing all the concrete, ensure that the top of the reinforcing steel cage
is no more than 6 inches above and no more than 3 inches below plan position.
578
(d) Ensure that the reinforcing cage is concentric with the shaft within a tolerance
of 1-1/2 inches. Ensure that concrete cover is a minimum of 4-1/2 inches unless shown otherwise
in the Plans.
(e) All casing diameters shown in the Plans refer to I.D. (inside diameter)
dimensions. However, the Contractor may use casing with an outside diameter equal to the
specified shaft diameter if the extra length described in 455-15.7 is provided. In this case, ensure
that the I.D. of the casing is not less than the specified shaft diameter less 1 inch. When
approved, the Contractor may elect to provide a casing larger in diameter than shown in the
Plans to facilitate meeting this requirement. When casing is not used, ensure that the minimum
diameter of the drilled shaft is 1 inch less than the specified shaft diameter. When conditions are
such that a series of telescoping casings are used, provide the casing sized to maintain the
minimum shaft diameters listed above.
(f) Ensure that the top elevation of the drilled shaft concrete has a tolerance of
plus 1 inch and minus 3 inches from the top of shaft elevation shown in the Plans.
(g) The dimensions of casings are subject to American Petroleum Institute
tolerances applicable to regular steel pipe.
(h) Use excavation equipment and methods designed so that the completed shaft
excavation will have a flat bottom. Ensure that the cutting edges of excavation equipment are
normal to the vertical axis of the equipment within a tolerance of plus or minus 3/8 inches per
foot of diameter.
455-21 Drilled Shaft Excavations Constructed out of Tolerance.
Do not construct drilled shaft excavations in such a manner that the concrete shaft cannot
be completed within the required tolerances. The Contractor may make corrections to an
unacceptable drilled shaft excavation by any combination of the following methods:
(a) Overdrilling the shaft excavation to a larger diameter to permit accurate
placement of the reinforcing steel cage with the required minimum concrete cover.
(b) Increasing the number and/or size of the steel reinforcement bars.
When the tolerances are not met, the Contractor may propose a redesign to
incorporate shafts installed out of tolerance into caps or footings. Incorporate shafts installed out
of tolerance at no expense to the Department. Ensure the Contractors Engineer of Record
performs any redesign and signs and seals the redesign drawings and computations. Do not begin
any proposed construction until the redesign has been reviewed for acceptability and approved
by the Engineer.
Backfill any out of tolerance shafts in an approved manner when directed by the Engineer
until the redesign is complete and approved. Furnish additional materials and work necessary,
including engineering analysis and redesign, to effect corrections of out of tolerance drilled shaft
excavations at no expense to the Department.
455-22 Load Tests.
When the Plans include load testing, perform all load tests in accordance with 455-2 or as
shown in the Contract Documents.
455-23 Method of Measurement.
455-23.1 Drilled Shafts: The quantity to be paid for will be the length, in feet, of the
reinforced concrete drilled shaft of the diameter shown in the Plans, completed and accepted.
The length will be determined as the difference between the top of shaft elevation as shown in
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the Plans and the final bottom of shaft elevation as authorized and accepted. When the
Contractor elects to provide outside diameter (O.D.) sized casing rather than inside diameter
(I.D.) sized casing as allowed in 455-15.7, the pay quantity measured as described above will be
multiplied by a factor (F) determined as follows:
2 F = D 2 D1
D2
where:
F= factor to adjust pay quantities to compensate for smaller shafts.
D1= casing inside diameter specified = shaft diameter specified.
D2= casing inside diameter provided (D2 = D1 minus twice the wall
thickness).
455-23.2 Drilled Shafts (Unreinforced): The quantity to be paid for will be the length,
in feet, of unreinforced concrete drilled shaft of the diameters shown in the Plans, completed and
accepted. The length will be determined as the difference between the top of shaft elevation as
shown in the Plans and the final bottom of shaft elevation as authorized and accepted. When the
Contractor elects to use O.D. casing, the quantity as determined above will be multiplied by the
factor F determined as described in 455-23.1.
455-23.3 Unclassified Shaft Excavation: The quantity to be paid for will be the length,
in feet, of unclassified shaft excavation of the diameter shown in the Plans, completed and
accepted, measured along the centerline of the shaft from the ground surface elevation after any
required excavation per 455-1.2 to the plan bottom of shaft elevation authorized and accepted
plus up to 15 feet or 3 shaft diameters, whichever is deeper, of additional excavation as
authorized by the Engineer. When drilled shafts are constructed through fills placed by the
Contractor, the original ground surface before the fill was placed will be used to determine the
quantity of unclassified shaft excavation. When the Contractor elects to use O.D. casing, the
quantity as determined above will be multiplied by the factor F determined as described in
455-23.1.
455-23.4 Unclassified Extra Depth Excavation: When excavation is required by the
Engineer to extend more than 15 feet or 3 shaft diameters, whichever is deeper, below the bottom
of the shaft elevation shown in the Plans, the work will be considered as Unforeseeable Work.
455-23.5 Test Holes: The cost of all test holes will be included in the cost of drilled
shafts.
455-23.6 Core (Shaft Excavation): The quantity to be paid for will be the length, in feet,
measured from the bottom of shaft elevation to the bottom of the core-hole, for each authorized
core drilled below the shaft excavation, completed and accepted. When the Engineer authorizes
pilot holes extending through part or all of the shaft, prior to excavation, to some depth below the
shaft bottom, the quantity paid as core (shaft excavation) will be the length in feet, measured
from the top elevation to the bottom elevation authorized by the Engineer, completed and
accepted. When SPT tests are substituted for coring or pilot holes as provided in 455-15.6, the
quantity will be determined as described above in this Section.
455-23.7 Casings: The quantity to be paid for will be the length, in feet, of each size
casing as directed and authorized to be used. The length will be measured along the casing from
the top of the shaft elevation or the top of casing whichever is lower to the bottom of the casing
580
at each shaft location where casing is authorized and used, except as described below when the
top of casing elevation is shown in the Plans. Casing will be paid for only when the Permanent
Casing Method is specified, when the Plans show a casing that becomes a permanent part of the
shaft, or when the Engineer directs the Contractor to leave a casing in place which then becomes
a permanent part of the shaft. No payment will be made for casings which become bound or
fouled during shaft construction and cannot be practically removed. The Contractor shall include
the cost of all temporary removable casings for methods of construction other than that of the
Permanent Casing Method in the bid price for unclassified shaft excavation item.
When the Permanent Casing Method and the top of casing elevation are specified,
the casing will be continuous from top to bottom. Authorization for temporary casing will not be
given unless the Contractor demonstrates that he can maintain alignment of the temporary upper
casing with the lower casing to be left in place during excavation and concreting operations.
When artesian conditions are or may be encountered, the Contractor shall also demonstrate that
he can maintain a positive water-tight seal between the two casings during excavation and
concreting operations.
When the top of casing elevation is shown in the Contract Documents, payment
will be from the elevation shown in the Plans or from the actual top of casing elevation,
whichever is lower, to the bottom of the casing. When the Contractor elects to use an approved
special temporary casing system in open water locations, the length to be paid for will be
measured as a single casing as provided above.
455-23.8 Protection of Existing Structures: The quantity to be paid for will be at the
lump sum price.
455-23.9 Load Tests: The quantity to be paid for will be the number and type of load
tests conducted.
455-23.10 Instrumentation and Data Collection: The quantity to be paid for will be at
the lump sum price.
455-23.11 Cross-Hole Sonic Logging: The quantity of the cross-hole sonic logging test
set-ups to be paid for will be the number of drilled shafts accepted based on cross-hole sonic
logging tests.
455-24 Basis of Payment.
455-24.1 Drilled Shafts: Price and payment will be full compensation for all drilled
shafts, including the cost of concrete, reinforcing steel and cross-hole sonic logging tubes,
including all labor, materials, equipment, and incidentals necessary to complete the drilled shaft.
The cost of the reinforcing steel, including lap lengths, to accommodate shaft lengths longer than
shown in the Plans is included in the cost of drilled shafts. Costs associated with repairing
defects found in the drilled shaft shall be included in the cost of the drilled shaft.
455-24.2 Drilled Shafts (Unreinforced): Price and payment will be full compensation
for all drilled shafts (unreinforced), including the cost of concrete and all labor, equipment,
materials, and incidentals necessary to complete the drilled shaft.
455-24.3 Unclassified Shaft Excavation: Price and payment will be full compensation
for the shaft excavation (except for the additional costs included under the associated pay items
for casing); removal from the site and disposal of excavated materials; restoring the site as
required; cleaning and inspecting shaft excavations; using slurry as necessary; using drilling
equipment; blasting procedures, special tools and special drilling equipment to excavate the shaft
to the depth indicated in the Plans; and furnishing all other labor, materials, and equipment
necessary to complete the work in an acceptable manner.
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455-24.4 Test Holes: No separate payment will be made for test hole (method shaft). All
cost of test holes will be included in the cost of drilled shafts.
455-24.5 Core (Shaft Excavation): Price and payment will be full compensation for
drilling and classifying the cores/pilot hole, delivering them to the Department, furnishing drilled
shaft concrete to fill the core/pilot hole, and all other expenses necessary to complete the work.
When SPT tests are substituted for cores/pilot holes as provided in 455-15.6, they will be paid
for at the price per foot for coring.
455-24.6 Casings: Price and payment will be full compensation for additional costs
necessary for furnishing and placing the permanent casing in the shaft excavation above the costs
attributable to the work paid for under associated pay items for unclassified shaft excavation.
455-24.7 Protection of Existing Structures: Price and payment will include all cost of
work shown in the Plans or described herein for protection of existing structures. When the
Contract Documents do not include an item for protection of existing structures, the cost of
settlement monitoring as required by these Specifications will be included in the cost of
unclassified shaft excavation; however, work in addition to settlement monitoring will be paid
for as Unforeseeable Work when such additional work is ordered by the Engineer.
455-24.8 Load Tests: Price and payment will include all costs related to the performance
of the load test.
455-24.9 Instrumentation and Data Collection: Price and payment will include all
labor, equipment, and materials incidental to the instrumentation and data collection, and, when
required, the load test report.
455-24.10 Cross-Hole Sonic Logging: Price and payment will include all costs related to
the performance of the CSL testing and incidentals to the cross-hole sonic test set-up.
455-24.11 Payment Items: Payment will be made under:
Item No. 455- 18Protection of Existing Structures - lump sum.
Item No. 455- 88Drilled Shaft - per foot.
Item No. 455-107Casing - per foot.
Item No. 455-111Core (Shaft Excavation) - per foot.
Item No. 455-119Test Loads - each.
Item No. 455-122Unclassified Shaft Excavation - per foot.
Item No. 455-129Instrumentation and Data Collection - lump sum.
Item No. 455-142Cross-Hole Sonic Logging - each.
D. SPREAD FOOTINGS
455-25 Description.
Construct reinforced concrete spread footing foundations, including dewatering when
necessary, excavating to the required limits, compacting the underlying soil as required, and
constructing seals when required.
455-26 General Requirements.
Meet the following requirements for all spread footings:
1. Perform excavations, including the removal of all material, of whatever nature,
necessary for the construction of spread footings. As used herein, the term soil shall constitute
any material, whether soil, rock, or other materials.
582
2. Slope excavations as required, or support them with sheeting, and shore them if
necessary, to provide a safe excavation that is adequate for construction purposes and that will
adequately protect any existing adjacent structures.
3. Ensure that the foundation soils are firm, stable, and, in the opinion of the
Engineer, meet or exceed the design bearing and compressibility requirements before
constructing the footings or any required seals. The Department may elect to use any type of
tests to evaluate the foundation soils that is appropriate in the opinion of the Engineer. Cooperate
with the Engineer in the evaluation of the foundation soils, and assist the Engineer as necessary
to provide access to the site.
4. The elevation of the bottom of footings or seals and/or the depth of
over-excavation shown in the Plans is approximate and the Engineer may order, in writing, such
changes as may be necessary to secure a satisfactory foundation.
5. Place all spread footing concrete in the dry.
455-27 Protection of Existing Structures.
Protect existing structures in accordance with 455-1.1. Also, if not otherwise provided in
the Plans, evaluate the need for, design, and provide all reasonable precautionary features to
prevent damage, including, but not limited to, the installation of sheet piling, shoring as
necessary, maintenance of the water table beneath such structures as nearly as practical to
existing conditions, and monitoring and controlling vibrations from construction activities
including driving of sheeting or from blasting.
455-28 Dewatering.
The Contractor is responsible for the design, installation, and operation of an adequate
dewatering system to dewater excavations for spread footings. Use a well point or well system.
Submit a dewatering plan to the Engineer for his records before beginning construction.
Use well points or wells where the piezometric water level is above an elevation 3 feet
below the bottom of the excavation. Maintain the water table 3 feet or more below the maximum
depth of excavation. Provide continuous dewatering until completing construction of the footing
and backfill the excavation at least 3 feet above the piezometric water table elevation. Continue
dewatering until the Engineer considers conditions safe to discontinue dewatering. In the event
of a dewatering failure, assist the Engineer as required in determining the effects of such a failure
on the foundation soils, and take whatever corrective measures are required at no additional
expense to the Department. When the Engineer approves the discontinuing of dewatering,
decrease the rate of pumping, allowing the water level to rise slowly. Use a rate, in feet per hour,
that the water table is allowed to rise equal to the total number of feet the water table was
lowered, divided by ten hours or a rate of 1 foot per hour, whichever is less.
Install one piezometer well approximately every 15 feet of footing perimeter. Provide a
minimum of two and a maximum of six piezometers at locations within 2 feet from the outside
of the footing perimeter. Install piezometer wells to a depth at least 10 feet below the bottom of
footing elevation or as directed by the Engineer. Measure water elevation in the piezometer wells
prior to excavation and at 12-hour intervals between excavation and discontinuation of
dewatering. Maintain the piezometers in working condition throughout the dewatering process,
and repair or replace them when damaged at no expense to the Department.
583
455-29 Excavations:
If the excavation must be carried deeper than shown in the Plans to obtain a satisfactory
foundation, the Engineer will revise the Plans in accordance with the following:
a. When the change in bottom elevation of the footing is 12 inches or less, the
Engineer will keep the top of the footing at the elevation shown in the original Plans and will
increase the thickness to obtain a satisfactory foundation.
b. When the change in elevation of the bottom of footing exceeds 12 inches, the
Engineer will revise the Plans and lower the footing, thereby increasing the height of stem, to
obtain a satisfactory foundation. Generally, the Engineer will also increase the thickness and
width of footing over that shown in the original Plans.
455-29.1 Dry Excavations: Dry excavations are excavations that can be completed
without the need to lower the piezometric water level. Perform dry excavations when the
piezometric water level at the time of construction is and, in the opinion of the Engineer, will
remain at least 3 feet below the bottom of the authorized excavation or over-excavation.
Demonstrate to the Engineer that a stable excavation can be made without dewatering. Make
adequate provisions to divert surface runoff and to collect and remove any water entering the
excavation.
Excavate to the bottom of footing, to the over-excavation limits shown in the
Plans, or as directed by the Engineer. Save any suitable materials for backfill. Provide areas for
the disposal of all unsuitable materials, and dispose of them in a satisfactory method. Compact
the foundation soils below the footing as shown in the Plans or described herein before
constructing the footing.
455-29.2 Dewatered Excavations: Dewatered excavations are excavations made after
first lowering the piezometric water level with wellpoints or wells. Perform dewatering as
described in 455-28. Excavate in the dry after lowering of the water table.
When dewatering is required, the Contractor may excavate within 3 feet of the
ground water table before dewatering begins if the dewatering system is operating and the
Contractor has demonstrated that the water level has been lowered to and maintained at
acceptable limits. Where large excavations require stage lowering of the water table (additional
wellpoint systems installed at lower elevations), the Contractor may continue excavating as long
as the water elevation is maintained at least 3 feet below the excavation.
Ensure that surface runoff is diverted from the excavation. Compact the
foundation soils as shown in the Plans or as described herein before constructing the footing.
455-29.3 Wet Excavations: Wet excavations are excavations made below the existing
water table without prior dewatering. When the Plans show a cofferdam and seal, perform the
excavation in the wet. Maintain the water level during excavation at or above the water level
outside the cofferdam.
Place the seal directly upon the foundation soils or rock when using wet
excavations. Do not compact foundation soils for wet excavations. Ensure that the foundation
soils or rock are disturbed as little as practical. Remove all materials that are determined by the
Engineer to be loose or disturbed before placing the seal concrete.
455-30 Fill or Backfill.
Only use fill or backfill, including over-excavations below the footing, that is clean
cohesionless material, free of rubble, debris, or rocks that would prevent uniform placement and
compaction. For backfill materials, use A-1, A-2, or A-3 materials, as shown in the Plans, or
materials approved by the Engineer.
584
455-31 Compaction and Density Requirements.
Compact the bottom of the excavation with suitable equipment. Compact the soil beneath
footing excavation (whether dug to the bottom of footing or over-excavated) to a density not less
than 95% of the maximum density as determined by AASHTO T180 for a minimum depth of
2 feet below the bottom of the excavation or to the depth shown in the Plans before backfilling
begins. Perform at least one density determination at each footing excavation at a depth of one to
2 feet below the bottom of the excavation. Compact the backfill in footing excavations which
have been over-excavated in 12 inches maximum loose lifts to a density not less than 95% of the
maximum density as determined by AASHTO T180 to the bottom of footing elevation. Perform
at least one density determination in each lift of backfill at each footing excavation.
For compaction, use an approved heavy vibratory roller with a static drum weight of at
least 4 tons. Compact each lift to the required density. Also, compact the final lift below the
footing with a suitable sled vibratory compactor to remove any upper disturbance caused by the
drum roller. When conditions require use of smaller compaction equipment, obtain the
Engineers approval for the equipment, and reduce the lift thickness to achieve the required
density.
Perform backfilling to the original ground surface, finished grade, or subgrade as required
by the Plans in the immediate vicinity by approved mechanical compactors weighing less than
1,000 pounds. The Contractor may compact backfill located more than 15 feet away from the
exterior periphery of the footing with heavier compactors. Do not place backfill on the footing
until the Engineer has given permission and until the concrete is at least seven days old.
455-32 Forming.
Form spread footings if it cannot be demonstrated that the natural soil or rock is strong
enough to prevent caving during construction. For forms, meet the applicable requirements of
400-5. When forms are not required, meet the requirements of 400-5.4.4.
455-33 Materials.
455-33.1 Concrete: Meet the requirements of Section 346.
455-33.2 Reinforcing Steel: Meet the requirements of Section 415. For spread footing
reinforcing steel, use Grade 60.
455-34 Reinforcing Steel Placement.
Place and fasten reinforcing steel for footings according to the applicable provisions of
415-5.
455-35 Concrete Placement.
455-35.1 Placement: Place all footing concrete in the dry and according to the applicable
provisions of Section 400. Do not construct joints in footings.
455-35.2 Finish: After placing and consolidating the concrete, strike-off the top surface
to the grades shown in the Contract Documents, leaving the surface smooth and free of
undesirable cavities and other defects. Do not provide a special finish unless the footing will be
visible after construction, in which case, meet the applicable provisions of Section 400.
455-35.3 Curing: Provide continuous-moisture-curing for footings. For cover materials,
use clean sand, sawdust, or other materials meeting the approval of the Engineer. Continuously
wet the cover materials for a period of 72 hours.
585
455-36 Method of Measurement.
455-36.1 Protection of Existing Structures: The quantity to be paid for, when included
in the Contract Documents, will be at the Contract lump sum price.
455-36.2 Dewatering: The quantity to be paid for will be at the Contract unit price for
each footing excavation, only at locations authorized by the Engineer and acceptably dewatered.
455-36.3 Excavation: No separate payment will be made for backfill or will separate
payment be made for excavation above bottom of footing elevation. The cost of this work will be
included in the Contract unit price for concrete (substructure). For footings with excavation
(over-excavation) below the bottom of the footing elevation shown in the Plans, the cost of this
excavation, backfilling, and compaction will be included in the Contract unit price for excavation
for structures. The pay quantity will be the volume in cubic yards bounded by vertical planes
12 inches outside of the limits of the footing and parallel thereto and extending from the bottom
of the footing elevation to the authorized bottom of over-excavation or within the pay limits
shown in the Plans. If the elevation of a footing as shown in the Plans is changed to a higher or
lower elevation, the Engineer will not consider such change as a material change to the original
Contract Documents, a waiver of any condition of the Contract, or an invalidation of any of the
provisions of the Contract.
455-36.4 Reinforcing Steel: The quantity to be paid for will be the total weight, in
pounds , determined as described in Section 415.
455-36.5 Concrete: The quantity to be paid for will be the volume of the classes shown
in the Plans, in cubic yards, determined as described in Section 400.
455-37 Basis of Payment.
455-37.1 Protection of Existing Structures: When separate payment for protection of
existing structures is provided, price and payment will be full compensation for all work
necessary to evaluate the need for, design of, and to provide the necessary features to protect
existing structures, including all cost of work shown in the Plans or described herein for
protection of existing structures.
When a separate payment for protection of existing structures is not provided, the
cost of this work will be included in the Contract unit prices for excavation for structures and/or
for concrete (substructure).
455-37.2 Dewatering: Price and payment will be full compensation for all work related
to the successful dewatering of footings, including installing, maintaining, and monitoring
piezometer wells. Dewatering will be considered Unforeseeable Work when the Engineer
determines that dewatering is required and the Plans do not include a dewatering item.
455-37.3 Excavation: Price and payment will be full compensation for all work related
to over-excavating below the bottom of footing elevation, backfill, and compaction as specified.
455-37.4 Reinforcing Steel: Price and payment will be full compensation for all work
required to furnish and place the steel as shown in the Plans and as specified herein.
455-37.5 Concrete: Price and payment will be full compensation for all work required to
construct footings and seals as shown in the Plans and described herein.
No separate payment will be made for sheeting and shoring required for
excavation and footing construction except when a separate pay item for sheeting and shoring is
included in the Plans. The cost of all work not specifically mentioned in the other footing items
will be included in the price per cubic yard for substructure concrete.
455-37.6 Payment Items: Payment will be made under:
Item No. 125- 1Excavation For Structures - per cubic yard.
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Item No. 400- 2Item No. 400- 3Item No. 400- 4Item No. 400- 91Item No. 415- 1Item No. 455- 18-
Class II Concrete - per cubic yard.
Class III Concrete - per cubic yard.
Class IV Concrete - per cubic yard.
Dewatering For Spread Footings - each.
Reinforcing Steel - per pound.
Protection of Existing Structures - lump sum.
E. STRUCTURES (OTHER THAN BRIDGE)
FOUNDATIONS-AUGER CAST PILES
455-38 Description.
Furnish and install auger cast piles used for structural support, other than bridge
foundations.
455-39 General Requirements.
455-39.1 Contractors Operations: Submit an Auger Cast Pile Installation Plan in
accordance with 455-47. Prior to the start of production piles, demonstrate to the satisfaction of
the Engineer, the dependability of the equipment, techniques, and source of materials by
construction of a demonstration pile.
455-39.2 Protection of Existing Structures: Protect existing structures in accordance
with 455-1.1.
455-40 Materials.
Meet the following material requirements:
(1) Portland Cement (Types I, II, III, IP, and IS)
............................................................................Section 921
(2) Fly Ash, Slag and other Pozzolanic Materials for
Portland Cement Concrete .................................Section 929
(3) Fine Aggregate (Sand)*................................Section 902
(4) Admixtures ...................................................Section 924
(5) Water ............................................................Section 923
(6) Fluidifier .................................................... ASTM C 937
* The Contractor may use any clean sand with 100% passing 3/8 inch sieve and
not more than 10% passing the 200 mesh sieve. The Engineer will only permit Silica Sand
except as provided in 902-5.2.3.
455-41 Grout Mix Proportions.
Use a grout mix consisting of a mixture of portland cement, fly ash, retarder, sand and
water proportioned and mixed to produce a mortar capable of maintaining the solids in
suspension without appreciable water gain and which may be pumped without difficulty and fill
open voids in the adjacent soils. The grout mix may also include a fluidifier if desired.
Proportion these materials to produce a hardened grout of the required strength shown in the
Plans.
455-42 Mixing and Pumping Cement Grout.
Meet the following requirements:
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1. Only use pumping equipment approved by the Engineer in the preparation and
handling of the grout. Before using the mixers, remove all oil or other rust inhibitors from the
mixing drums, stirring mechanisms, and other portions of the equipment in contact with the
grout.
2. Accurately measure all materials by volume or weight as they are fed to the
mixer. Place the materials in the mixer in the following order: 1) water, 2) fluidifier, 3) other
solids in order of increasing particle sizes. The fluidifier may be added at the option of the
Contractor.
3. Use a quantity of water and mixing time that will produce a homogenous grout
having a consistency of 21 seconds minimum, when tested with a flow cone in accordance with
ASTM C939 (3/4 inch diameter outlet), with a frequency at the discretion of the Engineer. Mix
the grout at least one minute. If agitated continuously, the grout may be held in the mixer or
agitator for a period not exceeding 2.5 hours at grout temperatures below 70F; two hours for
temperatures from 70Fto 100F. Do not place grout when its temperature exceeds 100F. If
there is a lapse in the operation of grout injection, recirculate the grout through the pump, or
through the mixer drum or agitator.
4. Use mixers capable of combining components of the cement grout into a
thoroughly mixed and uniform mass, free from balls or lumps of cementitious material and
capable of discharging the concrete with a satisfactory degree of uniformity. The Engineers
approval of grout mixers and all other equipment will be conditioned on proper performance
during construction of the demonstration pile and subsequent production work.
5. Use a screen no larger than 3/4 inch mesh between the mixer and pump to
remove large particles which might clog the injection system.
6. Use a positive displacement piston type grout pump capable of developing
displacing pressures at the pump up to 350 psi.
7. Use a grout pump/system equipped with a pressure gauge to accurately monitor
the volume and pressure of the grout flow. Test and calibrate the equipment during construction
of the demonstration pile to demonstrate flow volume measurement accuracy of plus or
minus 3% over the range of grouting pressures anticipated during this work. Provide a pump
stroke counter in good working condition on the grout pump. Also calibrate the equipment any
time the Engineer suspects that the grout pump performance has changed.
455-43 Testing Cement Grout.
The Engineer will cast four 4 inches x8 inches cylinders in accordance with ASTM C31
for each LOT, considered to be 50 cubic yard of cement grout placed, or one day of pile
placement. The Department will test two cylinders at seven days and two cylinders at 28 days, in
accordance with ASTM C39. The minimum required strength for the LOT will be specified in
the Plans. When a cement grout acceptance strength test falls more than 10% or 500 psi below
the specified minimum strength, whichever is less deviation from the specified minimum
strength, perform one of the following:
(a) Remove and replace the cement grout represented by the LOT in question at
no additional cost to the Department, or
(b) Submit a structural analysis performed by the Contractors Engineer of
Record. Use the lowest measured value of compressive strength in the analysis. The Department
may require the Contractor to take cores for additional testing or pile integrity test in the auger
cast piles in question. The Department will not accept LOTs or piles where an individual
compressive strength test is less than 3000 psi, the average strength is less than 3500 psi, or the
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integrity testing reveals a structural deficiency or a reduced section. If the results of the analysis,
approved by the Department, indicate adequate strength and the computed lateral deflections are
within the Department design requirements to serve the intended purpose with adequate
durability, the concrete may remain in place. Otherwise, remove and replace the LOT of concrete
in question at no additional cost to the Department. All low strength cement grout accepted by
the Engineer will be subject to reduced payment as follows: $0.80 per cubic yard for each 10 psi
of strength test value below the specified minimum strength. The Engineer will use the average
compressive strength of the LOT tests for the computation of this pay reduction.
The Engineer will compute the volume of grout for which the reduction will be applied as
115% of the theoretical volume of the auger cast pile diameter required in the Contract
Documents. Reduction in pay will be applied to the entire length of all piles containing low
strength cement grout, in any quantity. The quantity of cement grout affected by the price
reduction may exceed the quantity of cement grout contained in the LOT.
When separate payment for auger grouted piles is provided, the dollar reduction will be
equated to an equivalent length of pile not to exceed the total pile length constructed utilizing the
subject LOT based on the following formula:
PLR = RC/UC
Where: PLR = Equivalent Pile Length Reduction in feet
RC = Total Reduction in payment, dollars
UC = Unit Cost of pile, dollars /foot
455-44 Pile Installation.
Meet the following requirements:
1. Locate the piles as shown on the drawings.
2. Should soft, compressible muck, organics, clay or other unsuitable materials
(non A-1, A-3, A-2-4 or limestone materials) be encountered, remove the unsuitable material to a
maximum depth of 5 feet and a maximum diameter about the pile centerline, not to exceed 1/2 of
the distance to the adjacent pile. Backfill with clean granular backfill materials (A-1, A-3,
A-2-4), placed and compacted in maximum 12 inch lifts to at least 95% of maximum dry density
as determined by AASHTO T180. Complete this work to the Engineers satisfaction prior to
auger cast pile construction. Should more than 5 feet or excessive quantities of unsuitable
material be encountered, immediately advise the Engineer and proceed with the work as directed
by the Engineer.
3. Provide continuous auger flighting from the auger head to the top of auger with
no gaps or other breaks, uniform in diameter throughout its length, and of the diameter specified
for the piles less a maximum of 3%. Provide augers with a distance between flights of
approximately half the diameter of the auger.
4. Use augers with the grout injection hole located at the bottom of the auger head
below the bar containing the cutting teeth, and with pile auger leads containing a bottom guide.
5. Construct piles of the length and diameter shown on the drawings.
6. Clearly mark the auger leads to facilitate monitoring of the incremental drilling
and grout placement. Provide individual foot marks with 5 foot increments highlighted and
clearly visible. Provide a clear reference mark on the moving auger assembly to facilitate
accurately monitoring the vertical movement of the auger.
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7. Place piles by rotating a continuous flight hollow shaft auger into the ground at
a continuous rate that prevents removal of excess soil. Stop advancement after reaching the
predetermined depth.
8. Should auger penetration to the required depth prove difficult due to hard
materials/refusal, the pile location may be predrilled, upon approval of the Engineer, through the
obstruction using appropriate drilling equipment, to a diameter no larger than 1/2 the prescribed
finish diameter of the auger cast pile. Commence auger cast pile construction immediately upon
predrilling to minimize ground loss and soil relaxation. Should non-drillable material be
encountered preventing placement to the depth required, immediately advise the Engineer and
proceed with the work as directed by the Engineer. Refusal is defined as the depth where the
penetration of the standard auger equipment is less than 12 inches per minute.
9. Plug the hole in the bottom of the auger while being advanced into the ground.
Remove the plug by the grout or with the reinforcing bar.
10. Pump the grout with sufficient pressure as the auger is withdrawn to fill the
auger hole, preventing hole collapse and to cause the lateral penetration of the grout into soft or
porous zones of the surrounding soil. Prior to commencing withdrawal of the auger, establish a
head of at least 5 feet of grout by pumping a volume of grout equivalent to 5 feet of pile volume.
Maintain this head of at least 5 feet of grout above the injection point around the perimeter of the
auger to displace and remove any loose material from the hole. Maintain positive rotation of the
auger at least until placement of the grout.
11. Once the grout head has been established, greatly reduce the speed of rotation
of the auger and commence extraction at a rate consistent with the pump discharge. Maintain
extraction at a steady rate to prevent a locked-in auger, necking of the pile, or a substantially
reduced pile section. Ensure grout starts flowing out from the hole when the cutting head is at
least 5 feet below the ground surface. Place a minimum volume of grout in the hole of at least
115% of the column of the auger hole from a depth of 5 feet to the tip. Place a minimum volume
of grout in the hole of at least 105% of the column of the auger hole from the ground surface to a
depth of 5 feet. Do not include any grout needed to create surplus grout head in the volume of
grout placed into the hole. If the grout does not flow out from the hole when the cutting head is
at least 5 feet below the ground surface, redrill the pile under the direction of the Engineer. If
grouting is interrupted for any reason, reinsert the auger by drilling at least 5 feet below the tip of
the auger when the interruption occurred, and then regrout.
Use this method of placement at all times. Do not depend on the stability
of the hole without the earth filled auger. Place the required steel reinforcement while the grout
is still fluid, but no later than 1/2 hour after pulling of the auger.
12. Assume responsibility for the grout volume placed. If less than 115% of the
theoretical volume of grout is placed in any 5 foot increment (105% in the top 5 foot increment),
reinstall the pile by advancing the auger 10 feet or to the bottom of the pile if that is less,
followed by controlled removal and grout injection.
13. Furnish and install the reinforcing steel and anchoring bolts as shown in the
Contract drawings.
14. Use reinforcement that is without kinks or nonspecified bends, free of mud,
oil or other coatings that could adversely affect the bond. Make splices in reinforcement as
shown on the Contract drawings, unless otherwise approved by the Engineer.
15. Leave any temporary supports of/for items placed into a grouted pile
(reinforcement template, anchor bolt template, precast column supports, etc.) in place for a
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minimum of 12 hours after completion of the pile. Do not place wall panels or other significant
loads, before the grout has set a minimum of seven days or reached the 28 day strength.
455-45 Construction Tolerances.
Locate piles as shown on the drawings, or as otherwise directed by the Engineer. Locate
pile centers to an accuracy of plus or minus 3 inches. Ensure that the top of pile elevation is
within an accuracy of plus or minus 3 inches of the Plan elevation.
Locate all precast post, anchor bolts, etc. within the following tolerances unless otherwise
shown in the Plans: variation from plumb (plus or minus 1/4 inch/post height); specified
elevation (plus or minus 1/2 inch); and specified location (plus or minus 1/4 inch).
455-46 Unacceptable Piles.
Repair or replace unacceptable piles, as directed by the Engineer, at no cost to the
Department. Unacceptable piles are defined as piles that fail for any reason, including but not
limited to the following: piles placed out of position or to improper elevation; piles with reduced
cross section, contaminated grout, lack of grout consolidation (honeycombed), or deficient grout
strength; and piles with reinforcement, anchor devices or other components cast or placed into
the fluid grout out of position.
455-47 Auger Cast Pile Installation Plan.
At the preconstruction conference, but no later than 30 days before auger cast pile
construction begins, submit an auger cast pile installation plan for approval by the Engineer.
Provide the following detailed information on the plan:
1. Name and experience record of auger cast pile superintendent or foreman in
responsible charge of auger cast pile operations. Place a person in responsible charge of day to
day auger cast pile operations who possesses satisfactory prior experience constructing shafts
similar to those described in the Contract documents. The Engineer will give final approval
subject to satisfactory performance in the field.
2. List and size of the proposed equipment, including cranes, augers, concrete
pumps, mixing equipment etc., including details of proposed pump calibration procedures.
3. Details of pile installation methods.
4. Details of reinforcement placement and method of centering in pile, including
details of all temporary supports for reinforcement, anchor bolts, precast columns, etc.
5. Details of how and by whom the grout volumes will be determined, monitored
and documented.
6. Required submittals, including shop drawings and concrete grout design mixes.
7. Other information shown in the Plans or requested by the Engineer.
455-48 Inspection and Records.
The Engineer will monitor pile installation.
455-49 Method of Measurement.
455-49.1 Protection of Existing Structures: The quantity to be paid for, when included
in the Contract Documents, will be at the Contract lump sum price.
455-49.2 Auger Cast Pile: The quantity to be paid for will be at the Contract unit price
per foot between tip and required pile top elevations for all piles completed and accepted.
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455-50 Basis of Payment.
455-50.1 Protection of Existing Structures: When separate payment for protection of
existing structures is provided, price and payment will be full compensation for all work
necessary to evaluate the need for, design of, and to provide the necessary features to protect the
existing structures, including all cost of work shown in the Plans or described herein for
protection of existing structures.
When a separate payment for protection of existing structures is not provided, the
cost of settlement monitoring will be included in the cost of the structure. Work ordered by the
Engineer for protection of existing structures, other than settlement monitoring, will be paid for
as Unforeseeable Work.
455-50.2 Auger Cast Piles: Price and payment will be full compensation for all labor,
materials, and incidentals for construction of auger cast piles of the sizes and depths indicated on
the Contract drawings or otherwise required under this Contract. Price and payment will also
include the removal and proper disposal off site of all spoil from the auger operation and all
excess grout displaced from the auger hole, unless otherwise approved by the Engineer. Work to
remove and replace unsuitable material when necessary as specified in 455-44 will be considered
Unforeseeable Work.
455-50.3 Payment Items: Payment will be made under:
Item No. 455- 18Protection of Existing Structures - lump sum.
Item No. 455-112Auger Grouted Piles - per foot.
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SECTION 458
BRIDGE DECK JOINTS
458-1 Description.
Furnish and install bridge deck joints of the types and at the locations shown in the Plans.
This Section covers the following types of joints:
Poured Joint
Poured Joint with Backer Rod System
Strip Seal Joint System
458-2 Materials.
458-2.1 Poured Joint: Furnish joint sealer or a Type A, B, or C silicone sealant material
meeting the requirements of Section 932 that is listed on the Qualified Products List (QPL).
458-2.2 Poured Joint with Backer Rod System: Furnish poured joint with backer rod
systems consisting of Type D silicone sealant material, foam backer rods, sidewalk cover plates
(as required) and all associated miscellaneous components.
The Type D silicone sealant material used in the system shall be listed on the QPL
and meet the requirements of Section 932.
458-2.3 Strip Seal Joint System: Furnish strip seal joint systems in accordance with
ASTM D5973 and Design Standards, Index No. 21100 that are listed on the QPL. Manufacturers
seeking evaluation of their product for the QPL shall submit an application in accordance with
Section 6. Design documentation showing the expansion joint system shall include installation
details and temporary or sacrificial support brackets, bolts, clamps, etc. that are compatible with
decks constructed with or without block-outs. Furnish joint systems consisting of watertight steel
edge rails, elastomeric strip seals, sidewalk cover plates (as required) and all associated
miscellaneous components. Obtain the elastomeric strip seals from the edge rail manufacturer.
458-2.4 Sidewalk Cover Plates: Furnish 1/4 inch thick, slip resistant galvanized steel
sidewalk cover plates in accordance with ASTM A36 or ASTM A709, Grade 36 or 50 and
Design Standards, Index Nos. 21100 and 21110. Sidewalk cover plates shall be an anti-slip steel
surface consisting of a random hatch matrix or other suitable pattern. Do not use diamond plate
or surface applied slip resistant tapes, films, nonmetallic coatings or other similar materials.
Sidewalk cover plates shall have a minimum coefficient of friction on the top galvanized surface
of 0.8 in dry condition, and 0.65 in a wet condition, as determined by FM 3-C1028. After shop
fabrication, hot-dip galvanize in accordance with Section 962 and the cover plate manufacturers
recommendations. Furnish flat head stainless steel sleeve anchors in accordance with
ASTM F593 Group 1 Alloy 304 for attaching sidewalk cover plates. Install sleeve anchors in
accordance with the manufacturers instructions. Submit shop drawings for sidewalk cover plates
showing all materials, project specific details and dimensions. Provide certification from the
manufacturer that the sidewalk cover plates meet the minimum coefficient of friction
requirements.
458-3 Fabrication and Installation.
458-3.1 General: Install the joint in accordance with the specific requirements of this
Article, the plan details and the details shown on the Design Standards for the particular type of
expansion joint called for.
593
458-3.2 Poured Joint: Install the joint at the locations and in accordance with the details
shown in the Plans and the manufacturers recommendations.
458-3.3 Poured Joint with Backer Rod System:
458-3.3.1 Casting Expansion Joint Opening When casting the bridge deck,
approach slab or raised sidewalk adjacent to the expansion joint at temperatures other than 70F,
adjust the joint opening (Dim. A) as shown on Design Standards, Index No. 21110 at 70F by the
amount of the adjustment per 10F shown in the Structures Plans, Poured Expansion Joint Data
Table. For temperatures above 70F, decrease the opening. For temperatures below 70F,
increase the opening.
458-3.3.2 Installation of Poured Joint System: After deck profiling, grinding,
and grooving operations are complete, install poured joint with backer rod in accordance with the
manufacturers recommendations, when the joint opening is plus or minus 1/4 inch of the design
joint opening (Dim A at 70F) shown in the Structures Plans, Poured Expansion Joint Data
Table. The minimum opening must not be less than 1 inch at the time of installation. Place
poured joint material only when the ambient temperature is between 55F and 85F and is
expected to rise for the next three hours minimum to provide for adequate joint opening and
compression of the poured joint material during curing.
458-3.4 Strip Seal System:
458-3.4.1 Elastomeric Seal Fabrication: Furnish continuous heavy duty bridge
deck elastomeric seals sized in accordance with the manufacturers recommendations, to perform
satisfactorily for the opening range shown. Minimum movement classification is 4 inches. Shop
vulcanization is restricted to use on horizontal turns on skewed bridges at upturn ends where the
horizontal turn angle is greater than 35 degrees. Field vulcanization is not permitted.
458-3.4.2 Edge Rail Fabrication:
(a) Furnish extruded, hot rolled or machined solid steel edge rails in
accordance with ASTM A709, Grade 36, 50 or 50(W). Furnish edge rails with a minimum mass
of 19.2 lb/ft excluding studs, a minimum height of 8 inches, a minimum thickness of 1/2 inch
and a maximum top surface (riding surface) width of 2 inches. Edge rails manufactured from
bent plate or built up pieces are not acceptable.
(b) Furnish anchor studs in accordance with ASTM A108, and electric arc
end-weld anchor studs with complete fusion. Anchor studs may be piggy backed to achieve
required lengths.
(c) Perform all shop welding in accordance with the Bridge Welding Code
ANSI/AASHTO/AWS D1.5. Do not weld to surfaces in contact with the elastomeric seal or the
top surface (riding surface) except as shown in the shop splice detail. Do not weld inside seal
cavity.
(d) Fabricate edge rail assemblies in one piece including upturns, except
where the length or configuration prohibits shipping or proper installation or where phase
construction requires separate assemblies. Shop splice sections of edge rail to obtain the required
length by partial penetration double V-groove welds on prepared beveled edges and seal welds as
shown in the shop splice detail. Weld all around the joint as far as practical to achieve a
watertight seal. Do not use short pieces of edge rail less than 6-0 long unless required at curbs,
sidewalks or phase construction locations.
(e) After shop fabrication, hot-dip galvanize edge rail in accordance with
Section 962 and the manufacturers recommendations.
594
(f) Furnish temporary or sacrificial support brackets, bolts, clamps, etc.
that are capable of resisting shipping, handling and construction forces without damage to the
edge rail assemblies or galvanized coating and are adjustable to account for variable temperature
settings. Do not use temporary or sacrificial support brackets, bolts, clamps, etc. between the
faces of the edge rails.
(g) Clearly match mark corresponding edge rail assemblies with joint
location and direction of stationing.
(h) Submit shop drawings showing all joint materials and project specific
details and dimensions. Include name of manufacturer, seal model number, seal movement range
and the assigned QPL Number.
458-3.4.3 Installation:
(a) Install the edge rail assemblies at proper grade and alignment before or
after deck planing in accordance with the manufacturers instructions. When installed after deck
planing and grinding, install the edge rail assemblies in the block-outs on a profile tangent
between the ends of the deck and/or approach slab to within a plus 0 and minus 1/4 variation.
When installed before deck planing, install the edge rail assemblies 3/8, plus or minus 1/16,
below the top surface of the deck or approach slab to compensate for concrete removal during
planing and grinding.
(b) Bolt, weld or clamp edge rail assemblies in position using temporary
or sacrificial brackets as required. For phased construction, install edge rail assemblies in a given
subsequent phase to align with those installed in an adjacent prior phase after deflection and
rotation due to deck casting of adjoining spans has occurred.
(c) For installation of edge rail assemblies at temperatures other than 70F,
adjust the opening of the joint (Dim. A) as shown on Design Standards, Index No. 21100 by the
amount of the adjustment per 10F shown in the Structures Plans, Strip Seal Expansion Joint
Data Table. For temperatures above 70F decrease the opening. For temperatures below 70F,
increase the opening.
(d) After galvanizing, do not weld within 2 inches of edge rail surfaces
exposed in the completed structure. Do not weld expansion joint components to or electrically
ground to reinforcing steel or structural steel. Seal field butt joints and empty shipping and
erection holes with caulk before placing deck concrete.
(e) Protect galvanized edge rail assemblies during screeding operations per
the manufacturers recommendations. Provide temporary blocking material in the edge rail seal
cavities to prevent concrete intrusion during deck pour and finishing.
(f) Loosen any temporary or sacrificial support brackets, bolts, clamps,
etc. that span across the joint after initial set of concrete, but not more than two hours after
conclusion of concrete placement.
(g) Install elastomeric seal after completion of deck casting. Remove all
joint form material and blocking material prior to installing elastomeric seal. Field install
elastomeric seal in accordance with manufacturers recommendations. Thoroughly coat all
contact surfaces between the elastomeric seal and the edge rail seal cavities with an adhesive
lubricant before setting elastomeric seal in place.
458-4 Method of Measurement.
The poured joint without backer rod will be incidental to the concrete work and included
in the cost of the concrete. Poured joints with backer rod and strip seal joints will be the plan
quantity length of each type of joint constructed and accepted.
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458-5 Basis of Payment.
458-5.1 Basic Items of Joints. The Contract unit price per foot for joints will be full
compensation for all work and materials necessary for the complete installation. Such price and
payment will include, but not be limited to, the following specific incidental work:
(a) Any work required to clean and prepare the adjacent bridge deck, deck block
out or deck joint gap.
(b) Any repairs to the galvanizing on metallic joint components.
(c) Any additional work or materials required for non-standardized or special
construction or installation techniques.
(d) Any cost of erection and removal of any temporary supports which may be
necessary for ensuring proper alignment and positioning of the joint relative to the bridge deck.
458-5.2 Payment Items: Payment shall be made under:
Item No. 458 - 1Bridge Deck Expansion Joint - per foot.
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SECTION 459
BITUMEN COATING AND POLYETHYLENE SHEETING
ON CONCRETE PILES
459-1 Description.
Furnish and apply bituminous coating and primer, or install polyethylene sheeting and
lubricant to prestressed concrete piles.
459-2 Materials.
459-2.1 Bituminous Coating: Use an asphalt type bituminous coating meeting the
requirements of Section 916, with a minimum viscosity (at 140F) of 3,000 poises and a
maximum of 1,000 poises. Apply bituminous coating uniformly over an asphalt primer.
459-2.2 Primer: Meet the requirements of ASTM-D 41.
459-2.3 Polyethylene Sheeting: Use polyethylene sheeting that is 6 mils thick and is
clean, new and has a smooth surface.
459-2.4 Lubricant: Use a lubricant between the two layers of sheeting that is either a
vegetable oil or other approved environmentally and functionally acceptable lubricant.
459-3 Construction Requirements.
Before surfaces are coated with bitumen, dry and thoroughly clean them of dust and loose
materials. Do not apply primer or bitumen in wet weather or when the temperature is below
65F.
Apply the primer to the surfaces and allow it to dry completely before applying the
bituminous coating. Apply primer uniformly at the quantity of 1 gal/100 ft2 of surface.
Apply bitumen uniformly at a temperature of not less than 300F, or more than 350F,
and apply either by mopping, brushing, or spraying at the project site. Completely fill all holes or
depressions in the concrete surface with bitumen. Apply the bituminous coating to a minimum
dry thickness of 1/8 inch, but not less than 8 gal/100 ft2.
Store bitumen coated piles before driving, and protect piles from sunlight and heat.
Ensure that pile coatings are not damaged during storage, hauling, or handling. Take appropriate
measures to preserve and maintain the bitumen coating. At the time of pile driving, ensure that
the bitumen coating has a minimum dry thickness of 1/8 inch. If necessary, recoat the piles, at no
cost to the Department, to comply with the requirements of this Section.
Ensure that all surfaces to be wrapped with polyethylene sheeting are dry and thoroughly
cleaned of dust and loose materials.
Place the sheeting on the pile to the limits shown on the Plans. Wrap the pile with a
minimum of 2 1/4 wraps of sheeting. Apply a uniform coating of a lubricant between the first
and the second layers. Ensure that this coating fully covers the entire surface of the first layer of
sheeting. Once the pile has been wrapped with the minimum of two and one-quarter wraps of
sheeting, secure the sheeting with tape or other means that does not damage the sheeting or
restrict its movement. Do not place any tape or other material other than the lubricant between
the first and second layers of sheeting. Protect the sheeting from construction damage. Where
sheeting has been damaged, completely remove the damaged sheet of polyethylene and replace
it, at no cost to the Department, as directed by the Engineer.
Where the sheeting will not wrap the specified limits of the pile in one sheet, overlap the
previous sheet with each subsequent sheet by 12 inches.
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459-4 Method of Measurement.
459-4.1 Bitumen Coating: The quantity will be paid for by the square yard of coating in
place on concrete pile surfaces.
459-4.2 Polyethylene Sheeting: The quantity will be paid for by the square yard of
wrapped concrete pile surfaces.
459-5 Basis of Payment.
459-5.1 Bitumen Coating: Price and payment will be full compensation for all work
specified in this Section, including furnishing all labor, materials, tools, equipment, and
incidentals, and doing all the work involved in applying the bituminous coating and primer, as
specified in the Contract Documents.
459-5.2 Polyethylene Sheeting: Price and payment will be full compensation for
furnishing all labor, materials, including primer and lubricant, tools, equipment, and incidentals,
and for doing all the work involved in installing the polyethylene sheeting and lubricant, as
specified in the Contract Documents.
459-5.3 Payment Items: Payment will be made under:
Item No. 459- 70Bitumen Coating on Concrete Piles - per square yard.
Item No. 459- 71Polyethylene Sheeting on Concrete Piles - per square yard.
598
SECTION 460
STRUCTURAL STEEL AND MISCELLANEOUS METALS
460-1 Description.
460-1.1 General: Prepare, fabricate, assemble, erect, and perform all nondestructive
testing for structural steel or miscellaneous metal structures, or portions thereof in accordance
with the Contract Documents.
As used in this specification, the following terms shall apply:
Main or primary load-carrying member or component: This designation
refers to the following;
1. Longitudinal or transverse rolled beams or fabricated girders
(I or box, curved or straight)
2. All truss members not designated as cross frames
3. Cross frames, diaphragms and connection plates of horizontally
curved beams or girders
4. Rib members of steel arches
5. Bracing members subjected to and specifically designed for
traffic live load and/or other loads
6. Cross frames or diaphragms at pier and abutment supports of tub
or box girders (trapezoidal members) and their connection plates
7. Attachments and components of the above such as splice, cover,
cross frame and diaphragm connection and gusset plates, but not transverse and bearing
stiffeners (unless acting as a cross frame or diaphragm)
8. Cables, moment release pins and links, and hangers
9. All steel substructure members except those designated as
secondary in the Contract Documents
10. Other members as may be identified in the Contract
Documents
Miscellaneous components - This designation refers to, but is not limited
to, the following:
1. Ladders
2. Platforms
3. Bearings
4. Railings
5. End Wall Grates
6. Roadway Gratings
7. Metal Drainage Components
8. Steel Expansion Joint and Components
460-2 Materials.
Provide the materials specified in the Contract Documents in accordance with Sections 6,
105, ASTM A6, and AASHTO/AWS D1.5, Bridge Welding Code as supplemented by the
AASHTO Guide for Highway Bridge Fabrication with HPS70W Steel. Fabricate all unpainted
steel elements using steels with weathering characteristics as defined in ASTM A709 for grades
with a W suffix.
599
Structural components designated as fracture critical shall conform to the provisions of
the AASHTO/AWS D1.5, Bridge Welding Code, Section 12-AASHTO/AWS Fracture Critical
Control Plan for Non-Redundant Members, in additional to the requirements of the Contract
Documents.
Ensure that structural steel and miscellaneous metal components and products for use on
Department projects are obtained from a fabricator listed on the Departments list of Producers
with Accepted Quality Control Programs for Metal Fabricators and certified by the AISC Quality
Certification Program with the AISC categories modified as follows:
1. Standard for Steel Building Structures - required for miscellaneous components
or as approved by the Engineer.
2. Simple Steel Bridge Structures - Required for bolted highway sign, lighting and
traffic structures fabrication, bridge components such as cross-frames and diaphragms not
designated as main or primary load-carrying members, and unspliced rolled beam bridges.
Fabricators qualified under this category are also qualified to perform work as described under
the Conventional Steel Building Structures Category.
3. Major Steel Bridges - Required for all steel bridges (including welded or bolted
truss structures), welded truss and pole type highway sign, lighting and traffic structures, and
bridge elements not defined as miscellaneous components or covered by Simple Steel Bridge
Structures in 2 above. Fabricators qualified under this category are also qualified to perform
work as described under the Simple Steel Bridge and Conventional Steel Building Structures
Categories.
4. Fracture Critical Endorsement - Required for any fabrication conducted on
fracture critical structures or components.
Producers seeking inclusion on the list of Producers with Accepted Quality Control
Programs for Metal Fabricators shall meet the requirements of 105-3.
Meet the additional following requirements:
Steel and Miscellaneous Metal Items .................Section 962
Material Testing and Certifications ....................Section 962
Galvanizing .........................................................Section 962
Structural Coatings..............................................Section 560
Structural Coating Materials ...............................Section 975
460-3 Pre-Assembly Requirements.
460-3.1 Shop Drawings: Shop drawings are required for work items as specified in 51.4.2 of the Standard Specifications. When shop drawings are required, submit such drawings in
accordance with Section 5. For drawing presentation format, refer to the AASHTO/NSBA Steel
Bridge Collaboration Guidelines for Shop Detail Drawing Presentation.
460-3.2 Welding Procedures: Submit all welding procedures to the Engineer.
Such procedures shall contain a notation that they have been reviewed by a Certified Welding
Inspector, and shall be signed, dated and stamped accordingly.
Except as noted in the Contract Documents, perform all shop and field welding in
accordance with the AASHTO/AWS D1.5, Bridge Welding Code. Additional/alternate
requirements for hollow steel structural sections and non-dynamically loaded members or
components are noted in 460-6.
460-3.3 Quality Control Plan: Develop and implement a Contractor Quality Control
Plan to verify that all materials and workmanship meet the requirements of the Contract
Documents. Develop the plan in conformance with Section 105.
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Do not commence work until the Quality Control Plan is approved. Provide
sufficient detail in the plan to enable the Engineer to determine the adequacy of the plan. As a
minimum, provide the following information in the plan:
1. Name, address, and facility or site number of the fabricator.
2. A description of the fabricators organization including the following;
a. Clearly established lines of authority.
b. List of personnel showing their experience and qualifications.
c. Position, title and name of the individual assigned to the
position.
d. A list of function and duties assigned to the position.
e. Organizational Chart.
f. The fabricators AISC Certifications, indicating the facilities
appropriate certification levels for all work to be performed, and ASIC approved Quality System
Documentation.
g. A statement signed by management affirming the fabricators
commitment to achieving a quality product and implementation of this commitment through all
personnel.
h. Department, including lines of authority and position titles.
i. A detailed description of the responsibilities of the Quality
Control Department.
3. A description of the Contractor procedures that will ensure quality
materials and workmanship, clearly addressing the methods used, frequency of inspections or
tests, and personnel responsible as appropriate. Include forms or other documents as well.
Include procedures that explain how the following tasks will be performed that ensure
compliance with the requirements of the Contract documents:
a. Material traceability;
b. Hot and/or cold bending;
c. Cambering and heat-curving, including temperature
measurement, patterns and sequences, and supporting or loading positions with copies of the
design computations if other than restraining forces are applied;
d. Shop assembly/laydown, including drilling and/or punching;
e. Post heat and/or stress relieving procedures;
f. Heat straightening;
g. Installation of high strength bolts and rotational capacity (RC)
tests; and Direct Tension Indicator (DTI) Verification tests
h. Field welding;
i. Blast cleaning, painting, galvanizing and/or other applied
coatings;
j. Use of ASTM A490 bolts;
k. Horizontal jacking of substructure units;
l. Removal of lubricants from exposed surfaces of installed
fastener assemblies.
460-3.4 Pre-Assembly Meeting: Prior to commencing work, a meeting shall be held
between the Contractor and the Engineer. Representatives of the Fabricator, Suppliers or
subcontractors may attend the meeting if requested by the Engineer or Contractor. During this
601
meeting, the Engineer may review various aspects of the job, including but not limited to, any of
the following:
1. Plant and Personnel Certification.
2. Organizational Structure of Contractor personnel.
3. Traceability of Materials to Pre-Qualified Fabricator.
4. Shop Drawing requirements, submittal, review and approval process.
5. Fabrication Procedures, especially shop assembly, welding and painting.
6. Sampling and Testing Procedures.
7. Project specific areas of concern for fabrication, inspection and testing.
8. Handling of Material Test Reports.
9. Work Schedule.
10. Lines of Communication.
11. Availability of Quality Control and Verification Inspectors during specific
fabrication/erection operations.
12. Loading and Transporting.
13. Handling of non-conformance and repair issues.
14. Special Requirements.
15. Consistency between fabrication shop drawings and the erection plan,
specifically between the fabrication shop blocking diagrams and available site locations for
temporary support during erection.
460-3.5 Access to Fabrication Facilities: Provide the Engineer full access of facilities or
site where the work is being stored, fabricated, assembled or erected.
Provide and maintain office facilities at the fabrication facility for the
Departments inspectors that ensure a reasonable amount of privacy, are clean, properly
illuminated, heated or air-conditioned as necessary and are relatively free of noise, dust and
odors. Locate the office reasonably close to the work and provide access any time fabrication,
assembly or erection operations are in progress. Provide a desk, chair, and a four-drawer locking
file cabinet for the use by each inspector and the Engineer. Provide a telephone within the office
with an outside line suitable for modem communication. Provide ready access to adequate
parking, fax and copy machines, and clean, contractor-maintained restrooms within a reasonable
distance to the office.
The Engineer may observe any or all activities and perform nondestructive testing
of materials, components and the fabricated product to the extent considered necessary to
confirm the conformance with Contract Documents.
460-3.6 Notification Prior to Commencement of Assembly: Notify the Engineer at
least one week prior to beginning assembly, when conducted in-state, and at least two weeks
prior to beginning assembly, when conducted out-of-state.
460-4 Shop Workmanship and Assembly.
460-4.1 Handling, Transporting and Storage of Materials:
460-4.1.1 General: Handle, transport and store plates, shapes, assemblies,
fastener components and other parts in a manner that protects them from damage and facilitates
subsequent inspections in a safe manner.
Provide storage which will keep materials, assemblies, other components
and parts clean, and free from dirt, grease, other foreign matter, unacceptable corrosion or
coating deterioration, and any other adverse environmental conditions.
602
460-4.1.2 Bulk Materials: Ensure that all bulk materials, such as shear studs, are
stored together in individual LOTs and that the outside of each container has a list and
description of the contents. Maintain a separate list of the weights of all tools and erection
materials.
460-4.1.3 Fastener Assemblies (Bolts, Nuts and Washers): Transport and store
fastener assemblies in sealed, watertight containers. Label the side of each container with the
suppliers name and LOT identification number, and marked to identify the contents and size of
the fastener components. Ensure that all surfaces of the nuts are lubricated prior to their
placement in watertight containers. Provide containers for components that are capable of
protecting them from moisture and other harmful materials. Maintain containers in their sealed
conditions until they are opened for use at their assembly locations.
Do not remove more fastener assemblies from the protected area than can
be installed and tightened during a work shift. Leave the containers unopened until needed for
assembly. At the end of the work shift, return unused fastener assemblies to the protected storage
area for future use. Protect opened storage containers from contamination.
460-4.1.4 Coatings: Store coatings in accordance with Sections 962, and 975 and
the manufacturers recommendations. Notify the Engineer if the manufacturers
recommendations vary from that provided in the Contract Documents.
460-4.1.5 Anchor Rods and Nuts: Ship anchor rods and nuts as an assembly.
Washers may be shipped separate from the assembly.
460-4.2 Material Traceability:
460-4.2.1 General: All materials arriving at the shop shall be properly identified
in accordance the requirements of ASTM A6. Document all main load-carrying member
material, high-strength fastener assemblies, and weld materials incorporated into the work
through the entire fabrication process. Document this material traceability in a report type format
that correlates heat numbers to their respective locations in the completed members. Provide
diagrams and sketches as requested by the Engineer for clarity.
At the fabrication facility, maintain the records of the material testing and
certification processes and component/part identification as part of the fabricators permanent
project records for a period of not less than two years as measured from the last shipment of
materials from the fabricators facility. Provide a copy to the Engineer.
Mark the weight on members weighing more than three tons, in a visible
location.
460-4.2.2 Match Marking of Members and Assemblies: Match mark all
connecting members or parts that have been reamed or drilled while assembled. The fabricator
shall provide a diagram showing all marks and clearly indicate the location of all the marks on
the shop drawings.
Use painted marks, attached metal tags, other durable methods which do
not degrade the finish of the piece, or low-stress type steel die stamps to identify and match mark
pieces. If steel die stamps are used, they must be blunt nosed or interrupted dot dies,
manufactured to produce impressions that are rounded at the bottom of the impression and do not
exceed a depression of 0.030 inch and a maximum character height of 0.5 inch. Remark coated
type markings as necessary to maintain continuity in traceability.
Mark splice plates and girders so that upon erection, the mark on the splice
plate is located opposite a matching mark on the girder. Place the mark on web splice plates,
midway down the long side of the plate, on either the right or left side, to correspond with the
603
girder to which the splice plate will be temporarily attached for shipping to the erection site.
Make a matching stamp on the girder web opposite the mark on the splice plate.
Place the mark on top or bottom flange splice plates, on the right or left
end of the plate, corresponding to the girder to which the plate will be attached for shipment to
the erection site. Place a corresponding mark on the girder flange opposite the mark in the splice
plate.
As an alternate location for tub girder bottom flange splice plates, place
the mark midway down the long side of the plate, on either the right or left side, to correspond
with the girder to which the splice plate will be temporarily attached for shipping to the erection
site. Make a matching mark on the girder flange opposite the mark on the splice plate.
Mark girders and beams on the left end, according to the orientation
shown in the shop drawings, near the top flange. Mark diaphragms in the middle upper portion of
the web. Mark cross frames in the middle of the top or bottom horizontal member. Do not use die
stamps on fracture critical members or use die stamps near edges of members or components
subject to tensile stresses as specifically noted in the Contract Plans or as directed by the
Engineer.
Ensure that during fabrication, the heat number is maintained on each
primary load-carrying component by paint until the component is permanently joined into a
piece marked member or assembly.
460-4.3 Workmanship:
460-4.3.1 Cutting, Shearing and Machining: Cutting (including burning and
sawing), shearing, and machining shall be accomplished in accordance with the
AASHTO/AWS 1.5, Bridge Welding Code and the following requirements:
Plane, mill, grind or thermally cut the sheared edges of main load-carrying
member plate components greater than 5/8 inch thick to a depth of 1/4 inch.
Cut and fabricate steel plates so that the primary direction of rolling is
parallel to the direction of the member or component main stress. For flanges and webs, the
direction of rolling is parallel to the flanges unless noted otherwise in the Contract Documents.
Web splice plates may be rolled parallel to their length with the approval of the Engineer.
460-4.3.2 Cold Bending:
460-4.3.2.1 General: Submit cold bending procedures to the Engineer for
review. Perform cold bending in accordance with the AASHTO/AWS D1.5, Bridge Welding
Code and the provisions below. Do not cold bend fracture critical materials or main loadcarrying members or components. Visually inspect all load points. Large dents or upsets will be
cause for rejection. As a minimum, visually inspect all load points. Inspect any potentially
damaged areas discovered using magnetic particle examination or ultrasonic examination.
460-4.3.2.2 Minimum Bend Radii and Other Requirements: Remove
all sharp edges (including edges of holes if affected by the cold bending) by grinding to a
1/16 inch radius. Submit material preparation procedures to the Engineer for review.
Unless otherwise approved, the minimum bend radii for cold
bending (at room temperature), measured to the concave face of the plate, are given in
Table 460-1, Minimum Cold-Bending Radii. If a smaller radius is required, heat may need to be
a part of the bending procedure. Submit the heating procedure for the Engineers review. For
materials and grades not shown in Table 460-1, follow minimum bend radii recommendations of
the plate producer.
604
ASTM A 709
Grade and
thickness (t)
in inches
36
50
50S
50W
HPS 50W
HPS 70W
100
100W
Table 460-1 - Minimum Cold-Bending Radii
Up to 3/4 inch
Over 3/4 inch to
1 inch
Over 1 inch to
2 inches
Over 2 inches
1.5t
1.5t
1.5t
1.5t
1.5t
1.5t
1.75t
1.75t
1.5t
1.5t
1.5t
1.5t
1.5t
1.5t
2.25t
2.25t
1.5t
2.0t
2.0t
2.0t
2.0t
2.5t
4.5t
4.5t
2.0t
2.5t
2.5t
2.5t
2.5t
3.0t
5.5t
5.5t
The preferred orientation of bend lines is perpendicular to the direction of
final rolling of the plate. If the bend line is parallel to the direction of final rolling, multiply the
suggested minimum radii in Table 460-1 by 1.5.
460-4.3.3 Straightening: Member components, such as plates, angles or shapes,
are to be straightened before the parts are assembled. Perform straightening such that no cracking
or other damage occurs in the part. If heat is to be used for straightening, follow the provisions of
460-4.3.4.
460-4.3.4 Heat Application:
460-4.3.4.1 General: At various points during the fabrication of structural
steel, applications of heat may be necessary for hot-bending, cambering, curving or
straightening. Use the temperature limits and guidelines given in this Section, unless alternate
procedures have been approved by the Engineer. Routine straightening of material other than
quenched and tempered material shall be done in accordance with the temperature limits and
guidelines as specified herein, but do not require a submitted procedure.
Heat curving may be used in conjunction with a cut-curve
procedure, in which a portion of the curvature is obtained by cutting the plates to all or part of
the required radius, except as limited by 460-4.3.4.4.
460-4.3.4.2 Heating Process and Equipment:
460-4.3.4.2.1 Maximum Temperatures: The maximum allowable
temperature to which the material can be heated is given in Table 460-2, Maximum Temperature
Limits for Heat Applications.
Table 460-2, Maximum Temperature Limits for Heat Applications
ASTM A 709 Grade
Maximum Temperature, F
36, 50, 50S, & 50W
1,200
70W
1,050
HPS 70W
1,100
100 & 100W
1,100
460-4.3.4.2.2 Timing of Heat Applications: Conduct heating
operations prior to the application of coatings.
605
460-4.3.4.2.3 Allowable Preload Stresses: Preload compressive
stresses will be permitted up to 0.5 times the minimum specified yield strength (Fy) of the
material. This stress limit is applicable to all steels covered by this specification as listed in
Table 460-2. If jacks are used, energize and lock off prior to the application of heat.
460-4.3.4.2.4 Heating Tips: Apply heat using orifice tips only.
Select tip sizes proportional to the thickness of the heated material.
460-4.3.4.2.5 Torches: Manipulate the heating torches to guard
against general and surface overheating. In addition, place heat reflective sheet material against
the web before applying heat to the inside flange surface. When heating the inside flange surface,
point the torches to prevent applying heat directly to the web.
460-4.3.4.2.6 Heating Patterns: Fundamental heating patterns
(such as vee, line, edge, spot, and strip) may be used separately or in combination. Mark vee and
strip heat patterns on the material surfaces prior to heating. When heating, bring the steel within
the planned pattern to the specified heating temperature as rapidly as possible without
overheating the steel. Apply heat in accordance with the approved procedure.
460-4.3.4.2.7 Thin Wide Plates: Prevent buckling of thin wide
plates by not applying excessive heat.
460-4.3.4.2.8 Verification of Temperatures: Use temperaturesensitive crayons, pyrometers, or infrared non-contact thermometers for verifying temperatures
during heating operations. When heating patterns are used, make regular verifications of the
temperatures throughout the pattern. Remove the heating flame from the material before taking
measurements.
460-4.3.4.2.9 Cooling: Prior to the use of any artificial cooling,
allow steel to cool below 600F. Use only dry compressed air. Do not quench with water or a
water and air mixture.
460-4.3.4.2.10 Reheating: Reheat only after the material has
cooled below 250F.
460-4.3.4.2.11 Over Heating: The Engineer will reject the
product, if any portion of the material is exposed to heating higher than the allowable
temperature.
460-4.3.4.3 Heat-Curving of Bridge Members (Weak Axis Shaping):
460-4.3.4.3.1 General: Rolled beams and girders may be heatcurved at the job site, provided that the heating is performed in accordance with the Engineers
approval.
460-4.3.4.3.2 Sequence of Operations: Heat curve members prior
to the attachment of longitudinal stiffeners.
460-4.3.4.3.3 Web Position: When the radius is less than
1,000 feet, heat curve members with the web in the horizontal position or preloaded to induce
stress prior to heating. Otherwise, members may be heat-curved with the web in either the
vertical or horizontal position.
When heat-curving with the web in the horizontal position,
provide intermediate safety catch blocks between supports of the member and not more than
2 inches below the flanges to catch the member in case of a sudden sag.
When heat-curving with the web in the vertical position,
the member shall be braced or supported in such a manner that the tendency of the member to
deflect laterally during the heat-curving process will not cause the member to overturn.
606
460-4.3.4.3.4 Subsequent Heats: If multiple locations are to be
heated, do not reheat the same location until after at least three heats at other locations.
460-4.3.4.3.5 Locating Heating Patterns: Space the heating
patterns along the full length of each flange to produce a circular (not parabolic) curvature.
Adjust the heating patterns to produce the necessary curvature. Compensate for differences in
flange thickness and width as necessary. Use enough heating patterns in each piece to eliminate
chording effects.
460-4.3.4.4 Minimum Radius for Heat-Curving: Heat-curving of beams
and girders is allowed when the horizontal radius of curvature measured to the centerline of the
member web is greater than both values calculated by Equations 4.1 and 4.2 below, and greater
than 150 feet at any and all cross sections throughout the length of the member. Do not heat
curve steels manufactured to a yield strength greater than 50.0 ksi, other than ASTM A709,
Grade HPS 70W.
R=
R=
where:
14bD
F yt
7500b
Fy
in.
(Equation 4.1)
in.
(Equation 4.2)
Fy = specified minimum yield point of member web, ksi;
= ratio of the total cross section area to the cross-sectional area of both flanges;
b = width of the widest flange, inch;
D = clear distance between flanges, inch;
t = web thickness, inch;
R = radius, inch.
In addition to the above requirements, do not heat curve if the radius is
less than 1,000 feet when the flange thickness exceeds 3 inches or the flange width exceeds
30 inches.
460-4.3.4.5 Heat-Cambering (Strong Axis Shaping):
460-4.3.4.5.1 General: Procedures for cambering of built-up plate
girders shall be submitted as a part of the Quality Control Plan. In the procedures, address any
proposed preloading and heat application and control. Minor heat adjustments in camber at the
finishing stage of the girder do not require approval if the patterns and temperatures are followed
in accordance with the approved procedures.
Do not utilize heat-cambering as the primary source of
vertical camber in horizontally curved main load-carrying members; cut the web plate to the
required position. Only use heat-cambering on horizontally curved main members to adjust cut
cambering with the approval of the Engineer.
460-4.3.4.5.2 Web Position: Support members to be heatcambered with the web vertical. Space supports to take maximum advantage of dead load in the
member prior to the application of heat.
607
460-4.3.4.5.3 Subsequent Heats: If multiple locations are to be
heated, do not reheat the same location until after at least three heats at other locations.
460-4.3.4.5.4 Rolled Beams: Rolled beams may be heat-cambered
to provide the required curvature at the producing mill. Attach all detail material, such as
connection plates, bearing stiffeners and gusset plates, after the beam has been heat-cambered.
460-4.3.4.6 Heat-Straightening Damaged Structural Steel:
460-4.3.4.6.1 General: Submit procedures for heat-straightening
for the Engineers review prior to beginning the work. Describe in detail the distortion to be
corrected and all details for preloading, heating, cooling, verifying final dimensions, and
nondestructive testing.
460-4.3.4.6.2 Cracking: As a minimum, visually inspect all heatstraightened areas. Notify the Engineer when suspected areas of cracking are found. Inspect
these areas by one or more of the following methods, as directed by the Engineer:
1. Visual inspection;
2. Liquid penetrant examination as described in
ASTM E165;
3. Magnetic particle examination as described in
ASTM E709;
4. Ultrasonic examination as described in Section 6, Part C
of the AASHTO/AWS D1.5, Bridge Welding Code;
5. Radiographic examination as described in Section 6,
Part B of the AASHTO/AWS D1.5, Bridge Welding Code.
460-4.3.4.6.3 Restraining Forces: Restraining forces (usually
jacks) shall be set to restrain the steel during heating, but allow free contraction during cooling.
In addition, apply the restraining forces in a direction tending to restore the member and limit the
magnitude so that the material is not overstressed during heating.
460-4.3.4.6.4 Heating: Heat the steel in a single pass following the
specified pattern and allow it to cool to below 250F prior to reheating. Select heating patterns
and sequences appropriate for the type of damage and shape of the cross section. Simultaneous
vee heats may be used provided the clear spacing between vees is greater than the width of the
plate element.
460-4.3.4.6.5 Subsequent Repair: Heat cambered members
damaged after cambering may be repaired. However, do not repair previously heat-straightened
members in the same region of damage without the approval of the Engineer.
460-4.3.4.7 Hot Bending: Where a smaller radius than that allowed in
460-4.3.2 is required, non-primary load-carrying components may be bent using heating together
with mechanical force in accordance with the guidelines provided in 460-4.3.4.2 Apply heat
uniformly through the thickness of the plate. Provide the hot bending procedures to the Engineer
for review.
460-4.3.4.8 Heat Treatment:
460-4.3.4.8.1 General: When any special form of heat treatment is
required, it will be described in the Contract Documents. Perform heat treatments following any
boring, machining and/or straightening operations.
460-4.3.4.8.2 Stress Relief: Where required, perform thermal
stress relief in accordance with the procedure outlined in the AASHTO/AWS D1.5, Bridge
Welding Code. Provide welding materials consistent with the stress relieving process utilized.
608
460-4.3.4.8.3 Normalizing and Annealing: Where required by the
Contract Documents, perform normalizing and annealing as defined in ASTM A941. Maintain
temperatures uniformly throughout the furnace during heating and cooling so that the
temperatures at any points on the member do not differ by more than 130F.
460-4.3.4.9 Bolt Holes:
460-4.3.4.9.1 General: Unless shown otherwise in the Contract
Documents, the bolt (and anchor rod) hole geometry is to be as shown in Table 460-3, Bolt Hole
Geometry.
Table 460-3, Bolt Hole Geometry
Short-Slotted
Bolt Diameter
Standard
Oversize
(Width, inch by
(d), inch
(Diameter, inch) (Diameter, inch)
Length, inch)
1/2
9/16
5/8
9/16 x 11/16
5/8
11/16
13/16
11/16 x 7/8
3/4
13/16
15/16
13/16 x 1
7/8
15/16
1 1/16
15/16 x 1 1/8
1
1 1/16
1 1/4
1 1/16 x 1 5/16
(d + 1/16) x (d +
> 1 1/8
d + 1/16
D + 5/16
3/8)
Long-Slotted
(Width, inch by
Length, inch)
9/16 x 1 1/4
11/16 x 1 9/16
13/16 x 1 7/8
15/16 x 2 3/16
1 1/16 x 2 1/2
(d + 1/16) x
(2.5 x d)
Note: Except as shown elsewhere in the Contract Documents, bolt holes in the connections of primary members are to be
standard size unless.
460-4.3.4.9.2 Holes, Tolerances and Quality: Make bolt (and
anchor rod) holes using any method suitable to the Fabricator and as specified below; except
holes for high strength fasteners in main or primary load-carrying members which are not to be
punched full size, but may be thermally cut in accordance with 460-4.3.4.9.4 and ground smooth
with the approval of the Engineer.
The misalignment of holes in a bolt group relative to the
same holes in the component or components it is joined to in a connection, shall not exceed
1/32 inch for 85% of the bolt holes in that group. Bolt holes are to be normal to the work and
have no tears, cracks, fins, dirt, loose rust, burrs or other anomalies, and the surface is to be flat
within a slope of 1/20. Bolt holes are to be round within plus or minus 1/32 inch and within plus
or minus 1/32 inch of the specified size. For subsize holes, a pin 1/8 inch smaller than the
subsize holes must be able to pass through all assembled plies in at least 75% of the locations
prior to reaming. Holes inclined more than 3 degrees to a surface in any direction must have a
hardened beveled washer provided at that face. Unless specified elsewhere in the Contract
Documents, it is not required to coat the inside of the bolt holes.
460-4.3.4.9.3 Slotted Holes: Slots may be made by a single punch,
or by joining two adjacent drilled or punched holes when punching is permitted. When joining
holes, thermal cutting is to follow the common tangent to the two holes, and this cut is to be
ground. Do not make slotted holes more than 1/32 inch in width nor 1/16 inch greater in length
than specified. Grind smooth any flame cut portions of the slot to ANSI 1000 micro-inches.
460-4.3.4.9.4 Holes in Plates Not Subjected to Tensile Stress:
Large diameter holes in heavy plates not subjected to tensile stress (such as bearing plates) and
slotted holes in materials not subject to tensile stress may be thermally cut, followed by
609
appropriate grinding to smooth the periphery. Stop the practice if gouges or other defects occur,
or if directed by the Engineer. These holes are to meet the following criteria:
Do not thermally cut holes in ASTM A 709, Grades 100 or
100W steels. Provide hole centerlines aligned within plus or minus 1/16 inch of theoretical. The
inside (cut) faces of the hole are to be perpendicular to the plane of the plate. Eighty-five percent
of the (open) hole diameter is not to exceed that specified in the Contract Documents, plus or
minus 1/16 inch. Local notches, gouges or the maximum diameter shall not exceed that specified
in the Contract Documents plus or minus 3/32 inch.
460-4.3.4.9.5 Punching: Punch holes only under the following
conditions:
1. Final members that contain no more than five
thicknesses (plies) of material.
2. ASTM A709, Grade 36 material less than 3/4 inch in
thickness.
3. ASTM A709, Grades 50, 50S, 50W or HPS 50W
materials less than 5/8 inch in thickness.
4. ASTM A709, Grade HPS 70W and Grade 100 or 100W
materials less than 1/2 inch in thickness.
460-4.3.4.9.6 Edge Distance: Provide minimum as-fabricated
distance from the center of a bolt hole to an edge as given in Table 460-4, Edge Distances.
Fastener Size, Inch
Sheared Edge, Inch
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
1 3/4
Rolled Edges of Plates or Shapes
or Gas Cut Edges Inch
7/8
1
1 1/8
1 1/4
460-4.3.4.9.7 Bolted Splice Gaps: Unless shown elsewhere in the
Contract Documents, the tolerance for bolted splice gaps (open distance face-of-web/flange to
face-of-web/flange) shall be from zero (no gap between faces) to a maximum of 1/8 inch greater
than the gap shown on the Contract Plans. If no gap is shown in the Contract Plans, assume that a
nominal gap of 3/8 inch is required. In addition, meet the edge distance requirements, provided
above.
460-4.3.4.9.8 Maximum Edge Distance: Unless otherwise
specified in the Contract Documents, the maximum fabricated distance from any edge to the
center of the hole shall be 8 times the thickness of the thinnest outside plate, not to exceed
5 inches with no additional tolerance allowed.
460-4.3.4.9.9 Spacing of Bolt Holes: Space bolt holes within plus
or minus 1/8 inch of that shown in the Contract Documents.
460-4.3.4.9.10 Holding of Plies: When drilling or reaming is
accomplished through multiple plies of material, do not hold the materials together by welds not
specified in the Contract Drawings.
460-4.3.4.10 Contact and Bearing Surfaces: Provide surface finishes of
bearings, base plates, and other contact surfaces in accordance with the ANSI surface roughness
610
requirements as defined in ANSI B46.1, Surface Roughness, Waviness and Lay, Part I, given in
Table 460-5, ANSI Surface Roughness Requirements.
Table 460-5, ANSI Surface Roughness Requirements
Steel slabs
ANSI 2000 micro-inch
Heavy plates in contact with shoes to be welded
ANSI 1000 micro-inch
Milled ends to compression members, milled or
ANSI 500 micro-inch
ground ends of stiffeners or rockers
Bridge rollers and rockers
ANSI 250 micro-inch
Sliding bearings
ANSI 125 micro-inch
Pins and pin holes
ANSI 125 micro-inch
460-4.3.4.11 Cleaning and Coating (Including Galvanizing):
460-4.3.4.11.1 General: Clean and coat the work in accordance
with Sections 560, and 562, 460-2 and/or 460-7.2.
460-4.3.4.11.2 Removal of Lubricants: Remove lubricants from
the exposed surfaces of installed fastener assemblies and other surfaces in accordance with the
approved Quality Control Plan or the paint manufacturers recommendations prior to painting.
Demonstrate the procedures to the Engineer prior to preparations for painting. Bring to the
Engineers attention any Manufacturers processes or procedures that conflict with those
specified in the Contract Documents.
460-4.4 Member Geometry:
460-4.4.1 General:
460-4.4.1.1 Tolerances: Provide dimensional tolerances as follows:
1. Rolled shapes, plates, bars, wide flange sections and
miscellaneous steel in accordance with ASTM A6;
2. Fabricate girders in accordance with the AASHTO/AWS D1.5,
Bridge Welding Code and as described below;
3. For built-up members not specifically covered by
AASHTO/AWS D1.5, apply AASHTO/AWS D1.5, Bridge Welding Code, except as noted
below or as directed by the Engineer.
460-4.4.1.2 Camber and Sweep: Tolerances for camber and sweep of
continuous and simply supported girders of any shape shall be as described in the
AASHTO/AWS D1.5, Bridge Welding Code. The camber and sweep tolerances for steel pier
caps shall be the same as those specified for girders. Measure sweep for horizontally curved
members from the theoretical centerline for comparison to the aforementioned requirements.
460-4.4.1.3 Alternate Sections: Rolled sections or fabricated sections of
equal or slightly greater dimensions than the section specified may be proposed for the
Engineers approval. Changes that reduce fatigue resistance or significantly affect splice design
or deflection will require complete design calculations.
460-4.4.1.4 Web Flatness: Maximum deviation from flatness for webs of
curved and/or cambered sections shall be the same as for straight built-up girders. Measure
curved girder web flatness using a straightedge oriented perpendicular to the flanges (vertical,
flange to flange).
460-4.4.1.5 Girder Length: If measuring girder length with a device that
is free of thermal effects, appropriately adjust the measurements to the reference temperature
611
shown in the Contract Documents. Measure the length of horizontally curved girders along the
arc.
460-4.4.2 Specialty Structures:
460-4.4.2.1 Box Members as Bent Caps:
460-4.4.2.1.1 Tolerances: Unless otherwise shown in the Contract
Documents, submit tolerances for bearing planes and box twist to the Engineer for review and
approval. Prior to submitting these tolerance values for approval, coordinate between the Erector
and the Fabricator.
460-4.4.2.1.2 Bearings: Unless otherwise specified in the Contract
Documents, each bearing is to be true to a tolerance of 1/32 inch across its entire width in either
direction.
460-4.4.2.1.3 Beam Trueness: Unless otherwise specified in the
Contract Documents, the plane of beam supports on the box girder (the bearing area specifically
attached to the box girder) is to be true to the box girder bearing within 1/16 inch in the short
direction and true to the vertical axis of the nesting girders (those girders attached to or resting
on the box girder) within 1/16 inch.
460-4.4.2.2 Trapezoidal Bridge Members: As a minimum, trapezoidal
bridge members (tub or box girders) shall meet AASHTO/AWS D1.5, Bridge Welding Code
dimensional tolerances. Camber may be verified with the girder in its upright position, supported
to avoid dead load deflections.
460-4.4.2.3 Pinholes: Unless shown elsewhere in the Contract
Documents, bore pinholes:
1. True to the specified diameter;
2. Smooth to ANSI 3 (125 micro-inches);
3. At right angles with the axis of the member;
4. Parallel with each other; and
5. With a diameter of the pinhole not exceeding that of the pin by
more than 0.015 inch for pins 5 inches or less in diameter, or 1/32 inch for larger pins.
460-4.4.2.4 Truss Chord Joints: Abutting joints in truss chords not
specified to be mill-to-bear, shall have openings of 1/4 inch plus or minus 1/8 inch.
Abutting joints in truss chords specified to be mill-to-bear, shall be
faced and brought into bearing. When assembled, provide 85% or more of the abutting surfaces
in full contact. Allowable visible gaps shall not exceed 1/64 inch.
460-4.4.2.5 Horizontally Curved Beams and/or Skewed Steel Girders:
Account for torsion induced deflections for horizontally curved beams and/or skewed steel
girders. Unless otherwise defined in the Contract Documents, a horizontally curved beam or
girder is a longitudinal or transverse bridge component with a radius less than 10,000 feet
anywhere along its continuous length.
460-4.5 Shop Assembly:
460-4.5.1 General: Ensure the fit of all connections and the geometry of
all components. Unless specified elsewhere in the Contract Documents, check the fit of all
longitudinal girder/beam lines in accordance with 460-4.5.1.1. Perform this prior to transporting
the pieces in question to the site for erection.
460-4.5.1.1 Progressive Girder or Truss Assembly: Assemble
the structure for a minimum of three spans, panels, field sections, segments or longitudinal
chords of the structure. Successive assemblies shall consist of at least one longitudinal segment
612
of the previous assembly, repositioned as necessary for accurate alignment, plus two or more
longitudinal segments added at the advancing end. For entire structures less than 150 feet in
length or less than three segments, assemble the entire longitudinal line. Meet the requirements
of 460-4.5.1.4 when utilizing computer-numerically-controlled drilling equipment.
When a transverse structural steel member or members is
required for the continuation of the uninterrupted girder or beam line, truss, arch rib, bent tower
face or rigid frame, and is designated elsewhere in the Contract Documents to be shop
assembled, the Fabricator may include this member or component in a separate subassembly and
not the three segment longitudinal assembly (discussed above). If combined in a different
subassembly, include the longitudinal member(s) or component(s), as designated elsewhere in
the Contract Documents to be shop assembled, that frame directly into the transverse structural
member. Do not include the transverse member(s) in the longitudinal assembly unless directed so
elsewhere in the Contract Documents or by the Engineer. Account for end rotations and
deflections as necessary, and submit the procedure to the Engineer for review.
460-4.5.1.2 Progressive Chord Assembly: When specified
elsewhere in the Contract Documents, assemble the truss chords for a minimum of three panels
or longitudinal segments of the structure. Successive assemblies shall consist of at least one
longitudinal segment of the previous assembly, repositioned as necessary for accurate alignment,
plus two or more longitudinal segments added at the advancing end. For entire structures less
than 150 feet in length or less than three segments, assemble the entire longitudinal line. Meet
the requirements of 460-4.5.1.4 when using computer-numerically-controlled drilling equipment.
Account for transverse members indicted elsewhere in the
Contract Documents to be included in the shop assembly as in 460-4.5.1.1.
When assembled in accordance with this subsection, the
holes of the connections will be so located that they will be drilled to the final geometric angles.
This will require that the truss members, when erected under the no load (or practically no load
or stress) condition, must be bent and forced to fit the end conditions. This condition will
introduce an initial reverse secondary stress that will theoretically wane when the structure
assumes the loading for which it is cambered. Submit the procedure to the Engineer for review.
460-4.5.1.3 Special Complete Structure Assembly: When
specified elsewhere in the Contract Documents, this type of shop assembly will include
assembling the entire structure including the diaphragms, cross frames, integral steel substructure
and floor components. Miscellaneous components are not included unless directed elsewhere in
the Contract Documents. Establish procedures for each structure or structure type including
consideration of incremental erection, temporary field support locations, stage construction and
final tightening of field connections. Submit the procedures for review by the Engineer.
460-4.5.1.4 Computer-Numerically-Controlled (CNC) Drilling
Associated with Progressive Girder, Truss or Chord Assembly: If the Fabricator chooses to
drill the holes in all plies of all connections of the continuous main girder or beam line, truss,
arch rib, bent, tower face or rigid frame and any intersecting (transverse) members utilizing
computer-controlled-numerical drilling procedures, piece-wise assembly of the entire continuous
girder or beam line, truss, arch rib, bent, tower face or rigid frame is not required if the following
requirements are met:
Prior to transporting to the site, perform a check fit of the
first three spans, panels, field sections, segments or longitudinal chords; or entire first bent, tower
face or rigid frame of the structure to ensure the accuracy of the CNC procedures and equipment.
613
As selected by and at the discretion of the Engineer and
prior to transporting to the site, perform another check fit of a different assembly of three spans,
panels, field sections, segments or longitudinal chords; or another entire bent, tower face or rigid
frame of the structure to ensure that the accuracy of the CNC procedures and equipment is
maintained. If either of the above fails to meet the Contract requirements, assemble the entire
girder or beam line, truss, arch rib, bent, tower face or rigid frame as originally prescribed in
460-4.5.1.1 or 460-4.5.1.2 as prescribed elsewhere in the Contract Documents. Account for
transverse members indicated elsewhere in the Contract Documents to be included in the shop
assembly as in 460-4.5.1.1.
460-4.6 Evaluation of Work: The Engineer will evaluate and accept materials
and work conforming to the Contract Documents. These evaluations may take place prior to or
following delivery of the materials to the site of the structure. Materials or work that fails to meet
Contract requirements will be rejected.
The Engineer may, at his sole discretion, permit further inspections and
testing of materials or work that fail to meet Contract requirements for acceptance. The cost of
such inspections and tests shall be borne by the Contractor.
Bring to the attention of the Engineer, all nonconforming work and or
materials that cannot be brought into conformance with the Contract Documents using preestablished procedures as outlined in the Department approved Quality Control Plan. Submit the
following information to the Engineer:
A cover letter prepared on the Contractors letterhead and addressed to the
Engineer briefly describing the nonconforming work and the proposed credit to the Contract
proportionate to the nonconformance. For each fabricating facility and for each project within
that fabrication facility, submittals must be numbered consecutively beginning with the number
1, at the start of each project. Erectors will start with one for each individual project.
A completed Department Nonconforming Structural Steel and
Miscellaneous Metal Component Data Sheet prepared by the Contractor and countersigned by
the Engineers designated representative to indicate agreement between the Contractor and the
Department regarding the nonconformance, not any solution, resolution or credit. If the
Contractor and the Engineers designated representative are not in agreement regarding the
nonconformance, the Engineers designated representative will either reject the submittal
indicating the reason(s) for the rejection or modify the submittal and forward to the Engineer. In
the event of modification, the Contractor will initial the submittal before being forwarded to the
Engineer, thereby indicating the Contractors concurrence with the modification.
A list of supporting information such as sketches, documentation,
calculations, pictures, etc., must be included in the appropriate space on the Nonconforming
Component Data Sheet. Supporting information regarding Contract Document noncompliance in
the form of separate documents is only necessary when space on the Department Nonconforming
Structural Steel and Miscellaneous Metal Component Data Sheet is inadequate for the required
data. All of the supporting information required for the form must be prepared by, or under the
supervision of, the Specialty Engineer who will sign and seal one (1) complete copy of the
supporting information.
If requested by the Engineer, submit a structural and durability evaluation
of the proposed repair and/or remediation. This evaluation must be conducted under the
supervision of a Specialty Engineer and the submittal is to bear the Specialty Engineers
signature and seal.
614
460-4.7 Member or Component Certification: Coordinate with the
Engineer to schedule final inspection of the completed work within two weeks prior to shipment
or erection to verify that all Contract Document requirements have been met. After verification
that all Contract Document requirements have been met and all necessary repairs have been
satisfactorily completed, the Quality Control Manager shall certify, by initials and/or signature,
such materials, components or members. The record shall include certification for:
A. items being shipped or stored prior to final assembly. Affix a
certification in the form of a stamp or tag in accordance with 460-4.2 and as indicated in the
Quality Control Plan, and with a copy of the certification placed in the Contractors permanent
project records,
B. work being placed into its final position. Document as indicated
in the approved Quality Control Plan, in the Contractors permanent project records.
Submit a summary certification at the least once a month or with each
payment request that includes the following or similar wording. The undersigned, being a
responsible official of (insert Contractor identification) certifies that the materials, components
or members listed herein have been produced under strict quality control and meet the
requirements of the Contract Documents. Include a positive identification in the certification
such that the applicable materials, components and/or members can be uniquely identified
utilizing just the summary certification document. The Quality Control Manager shall sign this
summary certification.
460-5 Bolted Connections.
460-5.1 General: Use bolts as follows:
1. Use galvanized ASTM A325 Type 1 bolts in all field installed bolted structural
steel connections for painted steel.
2. Use either black or galvanized ASTM A 25 Type 1 bolts in all shop installed
bolted structural steel connections that will be shop painted.
3. Use black ASTM A325 Type 3 bolts in all bolted structural steel connections
for weathering steel that is to remain unpainted.
4. Use the bolts as specified for connected assemblies or parts that are designated
as miscellaneous components where the fastener type is specified elsewhere in the Contract
Documents.
Tighten ASTM A325 bolts in accordance with the procedures specified below for
turn-of-nut or direct-tension-indicator (DTI) tightening.
Lubricate and maintain consistency in lubrication of fastener assembly during
Rotational Capacity (RC) testing and installation. Assemblies that exhibit a loss of lubrication, as
determined by the Engineer, may be re-lubricated and retested prior to installation.
Use ASTM A490 bolts only with the approval of the Engineer. Provide
procedures in accordance with for the handling, lubrication, installation, tightening and testing of
ASTM A490 bolts. Do not install ASTM A490 bolts without prior approval of the procedures by
the Engineer.
When the Engineer approves ASTM A307 bolts for use in miscellaneous
components, tighten them such that the plies of the joint are in firm contact. Use three to five
impacts of an impact wrench or the full effort of a person using an ordinary spud wrench to
obtain a snug connection.
Fasten aluminum, other materials or assemblies of dissimilar materials in
accordance with the Contract Documents.
615
Install ordinary rough or machine bolts and nuts in accordance with the Contract
Documents.
460-5.2 Testing:
460-5.2.1 Rotational Capacity (RC) Tests: At the location of and prior to
installation of permanent high-strength fasteners in main or primary load-carrying member
connections, perform RC tests in accordance with Florida Method FM 5-581 (for long bolts) or
FM 5-582 (for short bolts) to ensure that the fasteners are capable of developing the specified
strength and that the fasteners are properly lubricated. As a minimum, test two assemblies per
LOT designation. The bolt, nut and washer shall come from the same LOT and be packed in the
same container (or group of containers assigned the same LOT), except in special cases where
nuts and washers have only one production LOT number for each size.
Short bolts may also be tested using FM 5-583 with DTIs calibrated with
long bolts installed in a Tension Measuring Device.
Washers are required for RC tests even though they may not be required
for jobsite installation. Where washers are not required for jobsite installation, LOT
identification is not required. The washer coating shall be the same as that for the bolt and nut.
Perform the RC test in a manner that replicates the anticipated fastener
installation the technique (e.g. If a spud wrench is to be used as a part of the installation process,
use the wrench similarly for the RC test).
If any of the required tests fails, the entire LOT will be rejected.
460-5.2.2 Verification of Direct Tension Indicator (DTI) Device Performance:
On a daily basis (when DTI devices are being installed) and at the location of installation,
perform DTI Verification tests in accordance with Florida Method FM 5-583. Perform this test
on a minimum of two high-strength fastener assemblies from each fastener assembly LOT and
position of the DTI prior to production installation. If either assembly fails, test additional
fastener assembly LOT/DTI combinations as requested by the Engineer to verify that the
Requirements of the Contract Documents have been satisfied. These two tests are in addition to
the RC tests required in 460-5.2.1. If, after additional testing, the DTI fails to meet the
requirements of FM 5-583, the LOT will be rejected by the Engineer.
460-5.3 Reuse and Retightening: Do not reuse ASTM A490 bolts or galvanized
ASTM A325 bolts. Black ASTM A325 bolts with free spinning nuts may be reused one time
with the Engineers approval. Previously tightened bolts that may have been loosened by the
tightening of adjacent bolts can be further tightened from the original position. Ensure proper
lubrication prior to retightening. Discard and replace fractured or damaged bolts.
460-5.4 Assembly of Bolted Connections:
460-5.4.1 General: Verify that the faying surfaces are in accordance with the
Contract Documents, are free of dirt or other foreign materials, and that the geometry of the bolt
holes and the connection meets the requirements of 460-4.3.4.9.
Install fastener assembly components of the same LOT and of the size and
quality specified in the Contract Documents. Provide final bolts, cylindrical erection pins or
other fit-up bolts as indicated in the Erection Plan.
When it is impractical to turn the nut, tighten the fastener by turning the
bolt while preventing the nut from rotating. During this tightening operation, do not allow the
rotation of the part of the fastener assembly not turned by the wrench.
616
460-5.4.2 Preparation of Faying Surfaces: Provide coated and non-coated
faying surfaces in accordance with the Contract Documents. Faying surfaces specified as blastcleaned must satisfy SSPC SP-10 Near-White Blast Cleaning.
When painting of the slip-critical faying surface of bolted connections is
required, use only the prime coat. Prepare and coat the faying surfaces prior to installation of the
fasteners. Provide certification of the slip critical classification required in the Contract
Documents.
Provide certification to the Engineer that galvanized faying surfaces meet
or exceed a Class C slip critical classification, unless a different classification is required
elsewhere in the Contract Documents. Mechanically roughen galvanized faying surfaces in
accordance with the galvanizers recommendations.
460-5.4.3 Reaming: Do not over size bolt holes by reaming (or any other
method) without the approval of the Engineer.
460-5.4.4 Drifting: Do not over size, stretch or otherwise damage bolt holes by
improper and excessive drifting.
460-5.4.5 Splice Plate Filler Material: Unless otherwise specified in the
Contract Documents, provide filler material edges within 1/8 inch of the adjacent splice material
edge.
460-5.4.6 Installation of Fastener Assemblies: Unless shown otherwise in the
Erection Plan, install the bolts of the connection by progressing systematically from the most
rigid part of the connection to the free edges. Install bolts in all holes of the connection and bring
them to a snug tight condition. Following the sequence indicated in the Erection Plan, further
tighten all the bolts in the connection.
For ASTM A325 bolts, obtain the required bolt tension as shown in Table
460-6, Minimum Required Fastener Tension in accordance with the turn-of-nut method specified
in 460-5.4.8, or when DTIs are used, the DTI tightening method specified in 460-5.4.9.
For connections (such as large main load-carrying members or truss joints)
in which previously tightened high strength bolts become loose and require retightening upon the
tensioning of others, install into a minimum of ten percent of the holes fully tensioned bolts prior
to final tensioning of the permanent bolts. Distribute these first bolts randomly throughout the
connection. If directed by the Engineer, remove the initial bolts and install permanent bolts at
each location, otherwise retighten in accordance with 460-5.3.
Table 460-6, Minimum Required Fastener Tension
Bolt Size,
Tension ASTM A 325 bolts,
inch
kips
5/8
19
3/4
28
7/8
39
1
51
1 1/8
56
1 1/4
71
1 3/8
85
1 1/2
103
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460-5.4.7 Bolt Tension: Provide a Skidmore-Wilhelm Calibrator, or other
equivalent bolt tension measuring device, wherever final connections are being made. Confirm
the accuracy of the tension measuring device by having it calibrated by an approved testing
agency once a year.
460-5.4.8 Turn-of-Nut Tightening: For each work shift, perform tests utilizing a
representative sample of five fastener assemblies, from each LOT to be installed that shift.
Perform the tests using the tension measuring device, following the same procedure to be used
for actual installation of the fastener assemblies, to a snug-tight tension and corresponding
torque, which, when the additional turns required in Table 460-7, Nut Rotation from the SnugTight Condition are added, will result in at least 1.05 times the minimum required fastener
installation tension as shown in Table 460-6. Place a washer under the part turned in the
tightening of the bolt. Consider the job inspection snug-tight torque as the average of three test
values determined after rejecting the high and low-test values.
For fastener assemblies too short to fit in the tension measuring device,
modify the determination of the job inspection snug-tight torque in accordance with FM 5-582.
460-5.4.8.1 Snug-Tight Condition: In the turn-of-nut method, first bring
all the fastener assemblies of the connection to a snug-tight condition to ensure that all parts of
the connection are in firm contact with each other. For the purposes of this specification, firm
contact shall mean the condition that exists on a faying surface when the plies are solidly seated
against each other, but not necessarily in continuous contact. Regard snug-tight as the tightness
required to produce the bolt tension, which following the final applied rotation, produces at least
1.05 times the minimum required bolt tension in accordance with Table 460-6, Minimum
Required Fastener Tension. In the presence of the Engineer, and on a daily basis, determine the
job inspection snug-tight torque as specified herein.
460-5.4.8.2 Final Tightening: After verification of the snug-tight
condition in accordance with 460-5.4.11 by the Engineer, tighten all fastener assemblies in the
joint by applying the applicable amount of nut rotation specified in Table 460-7, Nut Rotation
from the Snug-Tight Condition. Once snug-tight, bring all fasteners to the required tension
within the same work shift.
Table 460-7, Nut Rotation from the Snug-Tight Condition
Both Faces Sloped Not
One Face Normal to Bolt
Bolt Length Measured from Both Faces
More than 20:1 from
Axis and Other Face Sloped
Underside of Head to End of Normal to
Normal to Bolt Axis.
Not More than 20:1.Bevel
Bolt
Bevel Washers not
Bolt Axis
Washer not Used.
Used.
Up to and Including Four (4)
1/3 turn
1/2 turn
2/3 turn
Diameters
Over Four (4) Diameters but
not Exceeding Eight (8)
1/2 turn
2/3 turn
5/6 turn
Diameters
Over Eight (8) Diameters but
Not Exceeding Twelve (12)
2/3 turn
5/6 turn
1 turn
Diameters
Notes:
1. Nut rotation is relative to the bolt, regardless of the element being turned.
2. Tolerance for bolts installed by 1/2 turn or less is 30 degrees. For bolts installed by 2/3 turn or more, the tolerance is 45
618
Table 460-7, Nut Rotation from the Snug-Tight Condition
degrees.
3. Nut rotations given are only applicable to connections in which all material within the grip of the bolt is steel.
4. For bolt lengths exceeding 12 diameters, establish the required rotation by performing actual tests in a suitable tension device
simulating the actual conditions. Submit procedures to the Engineer for review.
460-5.4.9 Direct-Tension-Indicator (DTI) Tightening: After complying with
the requirements of 460-5.2.2, install and tighten DTI devices following the procedures
described in the DTI Verification Test. Do not permit the DTI to turn during installation and
tightening. Provide washers in accordance with 460-5.4.10.
460-5.4.9.1 Snug-Tight Condition: Install the bolts as specified through
Step 3 (Snug-Tight Condition) of the DTI Verification test. If the 0.005 inch feeler gage is
refused in more gaps than shown in the Table in Step 3.5 of the test, or the DTI device becomes
loose and can be spun by hand, remove the bolt and DTI device, discarding the DTI device.
Provide a new DTI device and reinstall the assembly and bring to the snug-tight condition.
460-5.4.9.2 Final Tightening: After verification by the Engineer that the
snug-tight condition for all bolts has been met, tighten all fastener assemblies in the joint such
that the number of spaces in which the 0.005 inch thickness gauge is refused is equal to or
greater than the number shown in Table 460-8, DTI Device Tightening Criteria. Once snug-tight,
bring all fasteners to the required tension within the same work shift.
Table 460-8, DTI Device Tightening Criteria
Number of Spaces in DTI
Minimum Spaces in which Gage is Refused
Do not tighten the assembly beyond the smallest gap permitted in
Step 3.5 of FM 5-583. Remove and replace bolts, discarding the DTI, which have a DTI with a
smaller gap or no gap.
460-5.4.10 Washers:
460-5.4.10.1 General: Provide ASTM F436 hardened steel washers as
follows:
1. For connections (and all associated testing) using ASTM A490
bolts, use a hardened washer under each element.
2. For connections using ASTM A325 bolts, use hardened washers
under the turned element.
3. Use hardened steel washers as part of the Rotational Capacity
tests.
4. Where the outer face of the bolted parts has a slope of greater
than 20:1 with respect to a plane normal to the bolt axis, use a hardened, beveled washer to
compensate for the lack of parallelism.
5. Where bolts are to be installed in a oversized or slotted hole in
an outer ply, provide a single washer satisfying ASTM F436, or continuous bar satisfying
ASTM A709: for ASTM A325 bolts, provide a thickness of at least 5/16 inch; and for
ASTM A490 bolts, provide a thickness of 3/8 inch. Provide these washers or bars to completely
cover the slot after installation. Provide a finish consistent with the bolt specified.
619
6. In non-Direct-Tension-Indicator (DTI) applications, clip
washers on one side to a point not closer than 7/8 of the bolt diameter from the center of the
washer, if necessary.
460-5.4.10.2 Use of Washers with Direct-Tension-Indicators (DTIs)
Devices: When DTIs are used; use ASTM F436 hardened washers as follows:
1. When the nut is turned and the DTI is located under the bolt
head, a hardened washer is to be located under the nut.
2. When the nut is turned and the DTI is located under the nut, a
hardened washer is to be located between the nut and the DTI.
3. When the bolt head is turned and the DTI is located under the
nut, a hardened washer is to be located under the bolt head.
4. When the bolt head is turned and the DTI is located under the
bolt head, a hardened washer is to be located between the bolt head and the DTI.
460-5.4.11 Inspection:
460-5.4.11.1 Turn-of-Nut Tightening:
1. Once the snug-tight condition is achieved for all of the fastener
assemblies of the connection, within 24 hours of snugging the first bolt in the connection and in
the presence of the Engineer, verify for a minimum of three (3) bolts [two (2) for two bolt
connections] or 10% of the fastener assemblies, that the job inspection snug-tight torque has
been attained. These fasteners are to have a snug-tight torque equal to or exceeding that specified
in 460-5.4.8. Perform this check using the same torque wrench used in 460-5.4.8. For bolts tested
in accordance with FM 5-583 or when multiple torque wrenches are required, provide a
calibrated torque wrench or wrenches.
2. If the tested fasteners do not obtain the job inspection snug-tight
torque, test all remaining untested fastener assemblies using the torque wrench in the connection
in question. Following testing of all assemblies, bring to snug-tight all assemblies and retest as
stated above. Re-snug and retest as necessary using the calibrated torque wrench until the
minimum testing stated above is performed favorably.
3. Following confirmation of the snug-tight condition as performed
by the Contractor, and in the presence of the Engineer, match mark the fastener assemblies on
the end of the bolt thread and on the nut, and then tighten the nut the amount of rotation specified
in Table 460-7, Nut Rotation from the Snug-Tight Condition. The Engineer will accept the
connection as fully tightened when all of the following conditions are met:
a. the rotation specified in Table 460-7 has been achieved,
b. there are no loose assemblies in the connection,
c. all plies of the connection are in firm contact,
d. there are no indications that excessive stretching or
yielding has occurred in the fastener assembly,
e. bolt stick-through is consistent per LOT.
460-5.4.11.2 Direct-Tension-Indicator (DTI) Tightening: Prior to
bringing the connection to a snug-tight condition, verify in the presence of the Engineer that the
dimples of the DTI are not deformed or damaged. Bring the connection to a snug-tight
condition and tighten in accordance with the requirements of 460-5.4.9. The Engineer will accept
the connection as fully tightened when all of the following conditions are met:
a. the requirements of 460-5.4.9 have been achieved,
b. there are no loose assemblies in the connection,
620
c. all plies of the connection are in firm contact,
d. there are no indications that excessive stretching or yielding has
occurred in the fastener assembly,
e. Bolt stick-through is consistent per LOT.
460-6 Welding.
460-6.1 General: Except as noted in the Contract Documents, perform all shop and field
welding in accordance with the AASHTO/AWS D1.5, Bridge Welding Code. Additional or
alternate requirements for hollow steel structural sections and non-dynamically loaded members
or components are listed below.
460-6.2 Welding on Non-Dynamically Loaded Elements: Perform welding on
miscellaneous components and other statically (non-dynamically, non-cyclically, etc.) loaded
structural elements in accordance with the AWS D1.1, Structural Welding Code, or the
AASHTO/AWS D1.5, Bridge Welding Code. Unless otherwise specified in the Contract
Documents or as approved by the Engineer, follow the Bridge Welding Code for weld inspection
and welder certifications.
460-6.3 Electroslag Welding: Use Narrow-Gap Improved Electroslag Welding
(NGI-ESW) for joining non-fracture critical members or components up to 3 inches thick. These
members or components may be subjected to tension, compression or stress reversal. Inspect
100% of all NGI-ESW welds subject to tension stresses or reversal of stress by both UT
(ultrasonic examination as described in Section 6, Part C of the AASHTO/AWS D1.5, Bridge
Welding Code) and RT (radiographic examination as described in Section 6, Part B of the
AASHTO/AWS D1.5, Bridge Welding Code).
Perform NGI-ESW welding in accordance with the AASHTO/AWS D1.5,
Bridge Welding Code. Supplemented by the recommendations from the following references:
1. Report No. FHWA-SA-96-053, Technical Information Guide
for Narrow.Gap Improved Electroslag Welding.
2. Report No. FHWA-SA-96-052, Process Operational Guide for
Narrow.Gap Improved Electroslag Welding.
460-6.4 Welding of Hollow Structural Steel Sections (Pipes and Tubes): Except as
noted in the Contract Documents, perform all shop and field welding of Hollow Structural
Shapes in accordance with the AWS D1.1, Structural Welding Code as amended herein.
460-6.4.1 Highway Signs, Luminaires and Traffic Signals: For structural steel
sign structures, lighting poles, and traffic signal poles, comply with the additional requirements
of AASHTO Standard Specification for Structural Supports for Highway Signs, Luminaires and
Traffic Signals, Section 5.15, Welded Connections.
460-6.4.2 Bridge Structures: For tubular bridge structures including pedestrian
bridges, comply with the requirements of the AWS D1.1 Structural Welding Code as amended
by the following:
1. Qualify all welding processes in accordance with the
AASHTO/AWS D1.5, Bridge Welding Code. Comply with all qualification criteria including
production thickness and position limitations. Use ASTM A709 Grade 50 for this test.
2. UT NDE technicians performing inspection of TKY welds are to be
qualified to the requirements and recommendations for operator qualification specified in API
Recommended Practice 2X, Third Edition, 1996, including a practical test with mockup tubular
welds containing built-in flaws,
621
3. Perform nondestructive testing of all tubular complete joint penetration
groove welds in main members using Ultrasonic Testing in accordance with the AWS D1.1,
Structural Welding Code.
Perform ultrasonic testing at the following frequency:
1. One hundred percent of each joint subject to tension or reversal
of stress.
2. Twenty-five percent of each joint subject to compression or
shear.
If unacceptable discontinuities are found in the joint, the remainder
of the joint shall be tested.
Perform Magnetic Particle Testing on 12 inches in every 10 feet on
each fillet and partial penetration groove welds in main members but no less than 12 inches on
welds less than 10 feet.
460-6.5 Field Welding: Field weld only with the approval of the Engineer. Provide any
additional field welding procedures as requested by the Engineer for review.
460-6.6 Tack Welds: Do not weld or tack any fill plates, brackets, clips, shipping
devices, or other materials not required by the Contract Documents or allowed by the
AASHTO/AWS D1.5 Bridge Welding Code.
460-7 Erection.
460-7.1 Pre-erection Requirements:
460-7.1.1 Quality Control Plan: Develop an Erection Quality Control Plan for
review and approval of the Engineer.
460-7.1.2 Submittals: Meet the requirements of Sections 5 and 103 for any
required submittals. Provide submittals to the Engineer for review by the Department in
accordance with Section 5 and the Contract Documents.
460-7.1.3 Erection Plan: Submit, for the Engineers review, an Erection Plan
locating all primary members, lifting equipment and temporary supports or braces, and bolting
pattern tightening procedures not considered routine. Ensure that the plan includes the Specialty
Engineers signature and stamp. Include supporting calculations indicating that the design unit
stresses indicated in the Contract Documents have not been exceeded. Provide this Plan or Plans
to the Engineer three weeks before erecting the piece or pieces.
Include the following information in the Erection Plan:
1. A plan of the work area showing all substructure units and
foundations; surface roads and railroads; all streams, creeks and rivers; and all overhead and
underground utilities.
2. The erection sequence for all primary load-carrying members
and all primary load-carrying member bracing. Note any and all permanent or temporary support
and/or bracing locations, including crane-holding positions.
3. The center of gravity locations, pick weight and delivery
orientation for all primary load-carrying members and pick weight.
4. Identify any bolting requirements not considered routine.
5. Locate all pick crane work points.
6. Identify all temporary works and staging areas such as barges,
mats and temporary excavation support.
7. Provide capacity charts on the drawings for each crane
configuration and boom extension utilized.
622
8. Details of all temporary bracing, falsework, towers and shoring.
9. Provide any procedures requested by the Engineer and not
contained in the Quality Control Plan.
460-7.2 Special Requirements for Uncoated Weathering Steel:
460-7.2.1 General: Do not use marking materials (grease sticks, crayons) that
leave behind a residual film that may affect the weathering process of the steel. Store the girders
as required for non-weathering steels.
460-7.2.2 Steel Preparations: Prior to erection, perform the following as
appropriate:
Blast clean the exposed fascia of the exterior girders (both I and box) to
meet SSPC-SP10 criteria; blast clean the remaining exposed surfaces of steel trapezoidal girders,
not required to be prepared otherwise, to meet SSPC-SP6 criteria; for steel I-girders, if a nonuniform mill scale finish has developed, as determined by the Engineer, blast clean all remaining
exposed surfaces, not required to be prepared otherwise, to an SSPC-SP6 criteria; coat the inside
of box members including, but not limited to, all bracing members, cross frames and diaphragms
in accordance with Section 560. Coat the exterior face of box girder end diaphragms and all
interior surfaces of box girders extending beyond the end diaphragm with an inorganic zinc
coating system in accordance with Section 560.
460-7.2.3 Concrete Substructure Preparations:
460-7.2.3.1 Substructure Areas Not Receiving Class 5 Finish: Prior to
erection of the girders, cover all exposed substructure concrete surfaces to protect them against
staining from the weathering steel components. Leave the covering in place until after placement
of the concrete deck. As directed by the Engineer, clean all visible stains on concrete in areas not
receiving a Class 5 Finish by sandblasting and follow-on cleaning using a stain remover or
commercial cleaner after completion of the structure in accordance with Section 400.
460-7.2.3.2 Substructure Areas Receiving a Class 5 Finish: If the
Class 5 Finish is to be applied prior to the placement of the concrete deck, cover all finish
concrete surfaces after application and curing of the Class 5 Finish to protect them from staining
from the weathering steel components. Leave the covering in place until after placement of the
concrete deck. Upon removal of the covering, reapply the Class 5 Finish to cover any stains
which may be present.
If the Class 5 Finish is to be applied after placement of the
concrete deck, no substructure covering will be required.
460-7.2.4 Structure and Site Clean Up: Upon the completion of construction,
remove all oil, dirt, grease or other foreign material, including excessive or uneven mill scale
from the steel. Remove lubricants from the exposed surfaces of installed fastener assemblies and
other surfaces in accordance with the manufacturers recommendations. Follow procedures
specified in Section 560 as appropriate. Final surface finish is to be an even mill scale as
approved by the Engineer.
460-7.3 Coordination with Substructure: Prior to the erection of primary load-carrying
members, conduct a survey to document the vertical, longitudinal and transverse position of all
substructure units and anchor rod locations. Appropriately account for ambient temperature in
the survey.
Should a discrepancy be identified with the Contract Documents, submit the
necessary details to the Engineer for resolution.
623
460-7.4 Placing Anchor Rods: Locate and place anchor rods within the tolerance shown
in the Contract Documents or within 1/4 inch of the theoretical location shown. If anchor rods
cannot be located to the specified tolerance, place only with the approval of the Engineer. Unless
shown otherwise in the Contract Documents, provide galvanized anchor rods, nuts and washers
as follows:
1. Set the anchor rods in preformed holes vertical to the plane of the bridge seat.
2. Provide 4 inch diameter holes.
3. Provide non-shrink grout/mortar of a strength greater than or equal to that of
the substructure concrete strength, or as shown elsewhere in the Contract Documents.
4. Install the rods in accordance with the grout/mortar manufacturers
recommendations.
5. Clean the threads of the anchor rods as necessary without damaging the
coating.
460-7.5 Preparation of Bearing Areas and Setting of Bearings: Prior to placing
superstructure bearing units (including but not limited to neoprene pads and masonry plates),
prepare the top of concrete pad (bearing area) in accordance with Section 400. If a discrepancy is
identified, report it to the Engineer for resolution.
For expansion bearings with slotted holes for anchor rods, which allow movement
of the superstructure with respect to the substructure, vary the location of the slotted plate in
relation to the anchor rods, in accordance with the prevailing temperature at the time of setting.
For fixed bearings at multiple adjacent piers, if necessary, horizontally jack the
substructure units to correctly set the centerline of bearing. Adequately account for temperature.
Unless specified elsewhere in the Contract Documents, locate the theoretical
centerline of bearings to within 1/16 inch transverse to longitudinal girder lines; and in the
direction parallel to the longitudinal girder line locate the theoretical centerline of bearing within
1/4 inch of the theoretical centerline of bearing.
After setting the bearings and installing anchor rod nuts, washers and any other
associated hardware specified in the Contract Documents, clean the protruding/exposed surfaces
of the assembly of all deleterious material. Finish-coat metal parts in accordance with 4604.3.4.11.
460-7.6 Tightening of Anchor Bolt/Rod Nuts:
460-7.6.1 Fixed and Expansion Pot Bearing: Tighten anchor bolts or rod nuts to
a snug tight condition such that the different mating surfaces (such as the top of concrete,
neoprene and steel) are in firm contact. The nut or bolt is to be tight enough to develop friction
between surfaces to prevent sliding, but not over-tightened that bulging or damage occurs in any
of the mating materials.
460-7.6.2 Fixed and Expansion Bearings with Elastomeric Bearing Pads:
Draw down the lower nut such that a total gap of 1/2 inch exists between the nut and bearing
plate. Tighten a second nut of the same specification to a snug tight condition against the lower
nut maintaining the required gap.
460-7.7 Final Position of Girder Webs: Unless shown elsewhere in the Contract
Documents, detail the girders and cross frames as directed by the Engineer. The final condition is
to be defined as with the deck and parapets cast, but without any future wearing surface. A web
will be considered plumb if it is within a tolerance horizontally between the top and bottom of
the web of 3/32 inch per foot of web depth compared against the theoretical position as required
in the Contract Documents. Measure the out-of-plumb perpendicular to the face of the web. Erect
624
trapezoidal girders to the geometry shown in the Contract Documents to the same 3/32 inch per
foot of web depth tolerance.
460-7.8 Inspection and Final Acceptance:
460-7.8.1 General: Perform Quality Control inspections of all phases of the
work. The inspection frequency and depth shall be sufficient to ensure that all materials and
workmanship incorporated into the work meet the requirements of the Contract Documents and
that the processes are controlled to ensure that the final finished product(s) conform to the
physical characteristics and dimensions required by the Contract Documents. The Quality
Control Manager shall be responsible for all inspection operations. An adequate number of
Quality Control Inspectors shall be available to ensure review of all materials and fabrication
processes are preformed in accordance with the Quality Control Plan. Weekly meetings shall be
held with the Engineer to review inspection findings. The review of this information is to
identify any refinements and/or improvements in the process being utilized in the work. The
frequency of the meetings may be altered by the Engineer.
460-7.8.2 Inspection/Final Acceptance: Ensure the final alignment, profile and
fastening of the erected steel is in accordance with the Contract Documents.
460-8 Method of Measurement.
460-8.1 General: The quantities to be paid for will be the items covered by this Section,
following acceptance by the Engineer. Partial payments may be made for fabricated components
yet to be assembled into larger components, members and assemblies as allowed for elsewhere in
the Contract Documents.
460-8.2 Deductions and Allowances: No deductions from the computed weight of rolled
or fabricated structural steel or miscellaneous components will be made for sheared edges,
punchings, holes, milling, plaining or other items of waste associated with the finished
components or parts.
460-8.3 Weights of Structural Steel and Miscellaneous Materials: The weights of
structural steel will be taken as nominal weights as reported in the AASHTO LRFD Bridge
Construction Specifications and ASTM Specifications, in that order of precedence, using the
dimensions shown in the Contract Documents.
460-8.4 Structural Steel: The quantity of structural steel and miscellaneous metals
becoming part of the completed structure and accepted by the Engineer will be paid for at the
quantity shown in the Contract Documents, or as modified by the Engineer, measured in pounds,
or by the Contract lump sum price for Structural Steel.
460-8.5 High-Strength Fastener Assemblies: The weight of high-strength fastener
assemblies (including nuts and washers) installed by the Contractor and accepted by the
Engineer will be computed on the basis of an average length in accordance with Table 460-9:
Table 460-9, Weights of High-Strength Fastener Assemblies
Diameter of HighStrength
3/4 inch
7/8 inch
1 inch
1 1/8 inch
Fasteners, inch
Weight per 100,
52
100
135
182
pounds
625
1 1/4 inch
238
The weight of high-strength fastener assemblies will be included in the
determination of the weight of the completed structure in determining the quantity paid when
payment is not by Lump Sum. The Engineer will determine values for sizes of high-strength
fastener assemblies not shown.
460-8.6 Welding and Welds; Fasteners Not Designated as High-Strength; Anchor
Rods, Nuts, Bolts and Associated Washers; Transporting; Handling; and Erection:
Welding and welds; fastener assemblies not designated as high-strength; anchor rods, nuts, bolts
and associated washers; transporting; handling; and erection are considered incidental to the
work and will not be paid for separately.
460-8.7 Shims and Fill Plates: The quantity of shims and fill plates will be included in
the determination of the weight of the completed structure in determining the quantity paid when
payment is not by Lump Sum.
460-8.8 Coatings: The preparation, application, clean-up and the consumables used in
the coatings process are considered incidental to the work and will not be paid for separately.
460-8.9 Weathering Steel Preparation, Handling and/or Clean-up: The preparation,
handling, and/or clean-up of weathering steel or the rust marks on other items (concrete units,
etc.) caused by the development of the patina are considered incidental to the work and will not
be paid for separately.
460-8.10 Shear Connectors: Shear connectors are considered incidental to the work and
will not be paid for separately.
460-8.11 Span Jacking (Fixed Bridge): Jacking of substructure units of adjacent fixed
piers required to set bearing in accordance with the Contract Documents is considered incidental
to the work and will not be paid for separately.
460-9 Basis of Payment.
460-9.1 General: Prices and payments will be for full compensation for all work
specified in this Section completed and accepted, including but not limited to testing, bolting,
welding, cleaning and coating, temporary works and erection. No separate payment will be made
for falsework or other erection expense.
460-9.2 Payment Items: Payment will be made under:
Item No. 460- 1Structural Steel - Rehab - per pound.
Item No. 460- 2Structural Steel - New/Widening - lump sum.
Item No. 460- 6Ladders & Platforms - lump sum.
Item No. 460- 13Structural Steel Rehab - Sandwich Plate System - per
square yard.
Item No. 460- 70Aluminum Bullet Railings - per foot.
Item No. 460- 71Metal Traffic Railing - per foot.
Item No. 460- 81Rivet or High-Strength Bolt Replacement - each.
Item No. 460- 95Structural Steel Repair - per pound.
Item No. 460- 98Pipe Hanger - each.
Item No. 460-112Anchor Bolt Replacement - each.
626
SECTION 461
MULTIROTATIONAL BEARINGS
461-1 Description.
Furnish and install multirotational bearings in accordance with the recommendations of
the manufacturer and details shown in the Plans. Submit for the Engineers approval, shop
drawings and design calculations prepared, signed and sealed by a Specialty Engineer prior to
fabrication of bearings.
461-2 Materials.
Provide materials in accordance with the AASHTO LRFD Bridge Design Specifications
and as follows. Furnish structural steel conforming to ASTM A709 Grade 50W. Coat all exposed
steel surfaces with a thermal sprayed coating (metalization). Blast clean surfaces with grit
abrasive in accordance with Steel Structures Painting Council Surface Preparation Specification
No. 10, SSPC-SP10, Near-White Blast Cleaning, to a surface profile of .002-.004 inch. Use the
electric arc spraying process. Provide wire material for the metalized primer consisting of 85%
zinc and 15% aluminum, each being 99.9% pure metal. Apply the metalized primer to obtain a
thickness of 0.01 inch minimum and 0.02 inch maximum. Do not apply when the surface
temperature of the steel is less than 5F above the dew point. Prepare a sample coupon using the
same processes used to prepare the surface and apply the coating to the bearing. Test the coating
bond strength on the coupon in accordance with ASTM-D4541. The bond strength must be a
minimum of 700 psi. If the bond strength of the coating on the coupon is deficient, test the
coating on the bearing. If the required bond strength is achieved, repair the coating. Provide the
Engineer with a certified statement that the coating applicator has performed successful thermal
spray operations within the last 12 months.
Perform any required touchup repair and field metalizing after any field welding with
materials and procedures in accordance with Section 975.
Use stainless steel sheet meeting ASTM-A240, Type 316.
Use a stainless steel sheet in the expansion multirotational bearings at least 1/16 inch
thick and polished to a surface finish of less than 10 micro inches root mean square on the side of
contact with the PTFE.
Blast clean the surface of plates to which the stainless steel sheet is to be attached to near
white, SSPC-SP10. Abrade the back of the stainless steel sheet that is to be in contact with the
steel plate using emery cloth. Position the stainless steel sheet on the steel plate, clamp and bond
firmly in place using a quick-set epoxy applied in the center portion only. Apply the stainless
steel sheet to the blast cleaned surface of the steel plate as soon as possible after blasting and
before any visible oxidation of the blast cleaned surface occurs. Ensure that the epoxy conforms
to Federal Specification MMM-A-134 Type I. Weld the stainless steel sheet to the steel plate
continuously around its perimeter using a tungsten inert gas welder. Weld in a controlled manner
using multiple passes or stitch welding techniques to control heat build-up. As a mating surface
for the stainless steel sheet, use an unfilled virgin PTFE sheet (recessed) or a glass-fiber filled
PTFE sheet (recessed). Obtain the PTFE sheet by skiving fillets formed under hydraulic pressure
and heat. The resin shall meet the requirements for ASTM-D1457.Bond the PTFE and the piston
using a heat cured, high temperature epoxy capable of withstanding temperatures of minus 40oF
to 250oF
627
461-3 Design.
Design all bearings to be replaceable without removing the masonry plate or sole plate.
Ensure that multirotational bearings are designed by the manufacturer for the loads and
movements shown on the contract drawings. Obtain all multirotational bearings from the same
manufacturer.
Design guided multirotational bearings for a lateral load equal to 10% of the vertical load
capacity of the bearing or the lateral load indicated in the Plans, whichever is greater.
For projects designed with the AASHTO LRFD Bridge Design Specifications, use
multirotational pot or disc bearings designed and fabricated by the manufacturer in accordance
with AASHTO LRFD Bridge Design Specifications for the loads and movements designated in
the Plans.
For projects designed using the AASHTO Standard Specifications for Highway Bridges,
use multirotational pot or disc bearings designed by the manufacturer in accordance with FHWA
Structural Bearing Specification SBS-1010-93 for the loads and movements designated in the
Plans and fabricated in accordance with this specification.
461-4 Testing and Certification.
Ensure the manufacturer verifies the adequacy of the bearings by testing random samples
manufactured for this project for the following conditions:
(a) Test the bearings for a period of 24 hours under the maximum vertical load
with the maximum rotational displacements applied. The maximum reactions, rotations and
movements are shown in the Plans for each type of bearing.
(b) In addition, test expansion bearings under maximum vertical load during six
cycles of maximum longitudinal movement (One cycle shall consist of starting with the bearing
elements centered, moving the maximum distance (half the total longitudinal movement) in one
direction, then moving back through the center point to the maximum distance in the opposite
direction and then back to the starting point).
(c) In addition test the lateral capacity of bearings with laterally restricted
movement by applying the maximum vertical load and the required lateral load. Apply and
release the lateral load six times in a direction 90 degrees from the bearings unrestricted
longitudinal movement direction. Apply and release the required lateral load 6 times in a
direction 180 degrees from the initial lateral load direction.
Based on the maximum loads and movements shown in the Plans, group the bearings into
common design types for both fixed and expansion bearings. Clearly indicate this grouping on
the shop drawing for approval by the Engineer. One bearing of each type and size so designated
must be tested. All test results must comply with the manufacturers design data as shown in the
approved shop drawings; the bearings tested must show no visible deficiencies including
extrusion of the elastomer between the piston and the base plate cylinder and the PTFE surfaces
shall show no deterioration. Prior to shipment to the project site, submit the test data for the
bearings tested to the Engineer with the manufacturers certification of specification compliance
for all bearings. Unsatisfactory test results will be cause for rejection of all multirotational
bearings represented by the test. Any observed separation between the rotational element and the
bearing plate will be cause for rejection.
Provide written certification from the manufacturer that the multirotational bearings have
been fabricated and installed in accordance with the specification requirements and
manufacturers requirements prior to acceptance by the Department.
628
461-5 Construction.
Store multirotational bearings delivered to the bridge site under cover on a platform
above the ground surface. Protect bearings at all times from damage and ensure they are clean,
dry and free from dirt, oil, grease or other foreign substances before placement. Install the
bearings in accordance with the recommendations of the manufacturer, contract drawings, and as
may be directed by the Engineer. If there is any discrepancy between the recommendations of
the manufacturer, these Specifications, and contract drawings, the Engineer will be the sole
judge in reconciling any such discrepancy.
Obtain the services of a representative, employed by the manufacturer of the bearings, to
supervise the installation of the bearings. Do not install the bearings until the representative is on
the job site. Assume this responsibility at no further expense to the Department.
461-6 Basis of Payment.
Prices and payments will be full compensation for furnishing all labor, materials, tools,
equipment, testing, manufacturers installation supervision, and incidentals to complete the work
in accordance with the Contract drawings, the manufacturers requirements, and these
Specifications.
Payment will be made under:
Item No. 461-113Multirotational Bearing Assembly - Fixed - each.
Item No. 461-114Multirotational Bearing Assembly - Expansion - each.
629
SECTION 462
POST-TENSIONING
462-1 Description.
(a) Furnish, transport, store, handle, and install Post-Tensioning (PT) systems, all
constituent components of PT systems, as well as, all other related items, according to
requirements of this Section and component manufacturers recommendations, required for
successful installation of the PT application defined in the Contract Documents. Constituent
components of PT systems include, but are not necessarily limited to, anchorage assembly, grout
containment assembly, and related steel reinforcement. Use the most stringent requirements, as
determined by the Engineer, of those specified in this Section or the component manufacturers
recommendations for protecting components from damage due to environmental exposure,
improper handling, or improper installation.
(b) Furnish all PT system components, including steel pipes, from a single supplier.
Obtain prestressing steel and local zone mild reinforcement from any supplier.
(1) Use only approved PT systems meeting the requirements of Section 960 and
selected from the Structures Design Office (SDO) website for Approved Post-Tensioning
Systems.
(2) Use only PT systems of appropriate type and size required to construct
tendons shown in the Contract Documents.
(3) Substitution, modification, or deletion of components of approved PT systems,
excluding local zone reinforcement, is not permitted. Inclusion of all possible subcomponents is
required for PT system and component testing; however, subcomponents of approved systems
may be eliminated from final installations based on project-specific requirements, provided all
component-to-component interface hardware are included as necessary to maintain connections
and PT system integrity.
(c) Install PT steel (e.g., strands or bars) through ducts, either embedded in concrete,
referred to as internal, or external to the concrete member. Stress PT steel to a predetermined
load and anchor ends directly against hardened concrete. After anchoring PT steel, grout ducts to
completely fill voids, and install protection at end anchorages.
(d) Submit all required documents in accordance with this Section and Section 5 to the
Engineer for review and written approval.
(e) Cable stays are not covered by this Specification.
462-2 Materials.
462-2.1 General:
Approval of any material by the Engineer will not preclude subsequent rejection if
material is damaged or otherwise found to not meet the requirements of this Section or
Section 960.
462-2.2 Steel Reinforcing:
462-2.2.1 Mild:
(a) Provide reinforcing steel per Section 931.
(b) Final design and details of local zone reinforcement are project
specific and are the responsibility of PT system supplier. Design project specific local zone
reinforcement for the number of strands a particular approved PT system can accommodate at
maximum allowable strand force; do not design project specific local zone reinforcement for a
reduced system capacity.
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(c) Submit signed and sealed project specific local zone reinforcement
details to the Engineer for review and written approval.
462-2.2.2 Prestressing:
462-2.2.2.1 Strand:
(a) Provide prestressing strands per Section 960.
(b) Strand couplers are not permitted.
462-2.2.2.2 Bar:
(a) Provide prestressing bars per Section 960.
(b) For permanent applications, use and location of bar couplers is
subject to written approval by the Engineer.
462-2.3 Grout:
(a) Use only approved grouts meeting requirements of Section 938 found on
Departments Qualified Products List (QPL).
(b) Select grout for use in PT system by application: repair, horizontal, or vertical.
(c) Mix grout per manufacturers instructions with potable water meeting
requirements of Section 923.
462-2.4 Other Material References:
Meet the requirements of this Section, as well as, the following:
Class 5 Applied Coating ............................................Section 975
Elastomeric Coating System ......................................Section 975
Epoxy Compound ......................................................Section 926
Magnesium Ammonium Phosphate Concrete ...........Section 930
Methacrylate ..............................................................Section 413
Water ..........................................................................Section 923
462-2.5 Component Samples:
462-2.5.1 Prestressing Steel:
(a) Furnish samples per Section 933 from each manufacturer of
prestressing strand and bar to be used on project.
(b) The Engineer will collect sample materials from prestressing steel used
for PT operations on the Project.
(c) Samples, properly identified and tagged per 462-6, will be stored by
the Engineer.
462-2.5.2 Grout:
(a) The Engineer may sample grout packages at random, not to exceed a
total quantity of one bag per LOT or shipment.
(b) Grout sample may be virgin package mix, liquefied state, or solid state;
Engineer will determine at what frequency, interval, sample phase (powder, liquid or solid) and
location those samples will be recovered from the project.
(c) Sample, properly identified and tagged per 462-6, will be stored by the
Engineer.
462-3 Alternate PT System Designs.
Designs using a PT scheme different from that shown in the Contract Documents may be
submitted for the Engineers approval provided proposed scheme fulfills, and the Contractor
demonstrates, compliance with these requirements:
(a) PT system type and size meets all requirements of this Section.
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(b) Net compressive stress in the concrete after all prestress losses is equivalent to
or greater than that provided by the PT scheme shown in original Contract Documents.
(c) Distribution of individual tendons at each cross section generally conform to
the distribution shown in original Contract Documents.
(d) Proposed PT scheme meets the ultimate strength requirements of the
American Association of State Highway and Transportation Officials Load and Resistance
Factor Design, AASHTO LRFD Bridge Design Specifications Section 5, and is equivalent to or
greater than service and strength limit states provided in original Contract Documents.
(e) Stresses in concrete and PT steel at all sections and at all stages of
construction meet requirements of the Design Criteria shown in original Contract Documents.
(f) All Design Criteria provisions noted in original Contract Documents are
satisfied.
(g) Show complete design and detail of all elements for proposed locations of
alternate PT scheme.
(h) Submit: (1) design calculations including short and long term prestress losses
and (2) complete shop drawings including PT scheme and system, reinforcing steel, and concrete
cover, for the Engineers approval.
(i) Any alternate PT system approved by the Engineer resulting in a change in
quantity from that shown in the Contract Documents is paid based on comparison of (1) quantity
actually used and accepted or original plan quantity, whichever is less, and (2) unit bid price. If
approved alternate PT scheme or system is under a Cost Savings Initiative Proposal (CSIP),
method of payment will be in compliance with CSIP agreement.
(j) Submit alternate PT scheme signed and sealed by the Contractors Engineer of
Record.
462-4 Qualifications.
Provide all project personnel and crew foreman in accordance with Section 105.
462-5 Submittals.
462-5.1 Shop and Working Drawings:
(a) Submit to the Engineer all necessary information, Plans, shop and working
drawings, and manuals in accordance with this Section and Section 5. Submit to the Engineer
signed and sealed PT related shop drawings designed by the Contractors Engineer of Record.
(b) Prepare shop drawings addressing all requirements stated in the Contract
Documents and requirements of this Section. Indicate pre-approved PT systems to be used as
shown on the SDO website for Approved Post-Tensioning Systems. Show details of tendon
geometry and locations complying with the Contract Documents and limitations of selected PT
system. Include all inlets, outlets, high point outlet inspection details, anchorage inspection
details, permanent anchorage caps, protection system materials, and application limits.
462-6 Transport, Handling and Storage.
462-6.1 General:
Store all materials in a weatherproof building, shed, covering, or container until
time of use.
462-6.2 LOT Identification:
(a) Assign an individual LOT number and tag items shipped to project in a
manner that allows each LOT to be clearly identified at project site for all PT system
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components, grouting materials, bars of each size from each mill heat of steel, and all strands
from each manufactured reel.
(b) Submit records to the Engineer identifying assigned LOT numbers with heat
or reel of material represented if applicable.
(c) All unidentified prestressing components, strands, bars, or grouting material
received at the site will be rejected.
(d) Loss of positive identification of these items at any time will be cause for
rejection.
(e) Provide a copy of grout Quality Control Data Sheet received from the
manufacturer, to the Engineer for each LOT on the project.
(f) Material with a total time from manufacture in excess of six months must be
retested and certified by supplier before use or be removed from project and replaced with new
material.
462-6.3 Prestressing Steel:
(a) Protect all prestressing steel against physical damage and corrosion at all
times.
(1) Package prestressing steel in containers for protection against physical
damage and corrosion during shipping and storage.
(2) Place a corrosion inhibitor, which prevents rust, in package or
incorporate it into a corrosion inhibitor carrier type packaging material.
(3) Corrosion inhibitor must have no deleterious effect on steel or concrete
or bond strength of steel to concrete.
(4) Inhibitor carrier type packaging material must conform to provisions of
Federal Specification MIL-P-3420.
(5) Immediately replace or restore damaged packaging to original
condition.
(6) Clearly mark shipping package with a statement that package contains
high-strength prestressing steel, care to be used in handling, include type, kind, and amount of
corrosion inhibitor used, date when placed, safety orders, and instructions for use.
(b) The Engineer will reject prestressing steel that has sustained physical damage.
(c) Remove and discard lengths of strand found to contain broken wires.
(d) Wire must be bright and uniformly colored, with no foreign matter or pitting
on its surface.
462-6.4 Grout:
(a) Maintain grout in environmental exposure conditions (e.g., temperature,
humidity) in strict conformance with manufacturers recommendations at all times from
manufacture to installation.
(b) Storage in the open must be on a raised platform and with adequate waterproof
covering to protect the material.
(c) On site storage is limited to a maximum period of one month.
462-6.5 Duct and Pipe:
(a) Protect ducts against ultraviolet degradation, crushing, excessive bending, dirt
contamination, corrosive elements, or any other damage or contamination during transport,
storage, and handling.
(b) Furnish ducts with end caps to prevent contamination inside duct. Do not
remove duct end caps until duct is incorporated into the bridge component.
(c) Ship capped duct in bundles that are covered during transport and storage.
(d) Store on a raised platform and completely covered to prevent contamination.
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(e) If contamination is discovered, immediately flush duct with potable water per
462-7.2.4 before use.
462-7 Construction.
462-7.1 General:
(a) Furnish the Engineer with written certification from PT supplier (vendor) that
PT system chosen for the project meets requirement of this Section, Section 960, and is a
Department approved PT system prior to installing any PT hardware.
(b) Provide a list of PT system components and reference drawings to the
Engineer.
(c) Use methods to place and consolidate concrete that will not displace or
damage any PT ducts, anchorage assemblies, splices and connections, reinforcement, or other
embedded items.
(d) Conduct all stressing and grouting operations in the presence of the Engineer.
462-7.2 System Installation:
Accurately and securely fasten all PT anchorages, ducts, inlet and outlet pipes,
miscellaneous hardware, reinforcing bars, and other embedded items at locations shown in the
Contract Documents or on approved shop or working drawings or as otherwise approved by the
Engineer in writing.
462-7.2.1 Ducts:
(a) Construct tendon ducts using the minimum number of splices possible.
(b) Accurately position and align ducts at locations shown in the Contract
Documents, or according to approved shop or working drawings, or as approved in writing by
the Engineer.
(c) Securely fasten all internal ducts at regular intervals not exceeding
30 inches for steel pipes, 24 inches for round plastic ducts, and 12 inches for flat ducts to prevent
movement, displacement, or damage from concrete placement and consolidation operations.
(d) Show method and spacing of duct supports on appropriate shop
drawings.
(e) Ensure external tendon ducts are straight between connections to
internal ducts at anchorages, diaphragms, and deviation saddles and are supported at intermediate
locations according to the Contract Documents including approved shop drawings.
(f) Ensure all alignments, including curves and straight portions, are
smooth and continuous with no lips, kinks, or dents. This also applies to curves in pre-bent steel
pipe.
(g) Check and repair all ducts in accordance with 462-7.5 as necessary
before placing any concrete.
(h) Ensure ducts, at end connections to anchorages, splices, inlets, outlets,
and all other duct openings are sealed at all times after installing ducts and until tendon
installation is complete; open low point outlets just prior to strand installation.
(i) Provide an absolute seal of anchorage and duct termination locations
per the pre-approved system drawings.
(j) Use of tape is not permitted to make connections for any reason.
(k) Use heat welding techniques, in accordance with duct manufacturers
instructions, to make splices between sections of smooth plastic duct or make connection with
electrofusion duct coupler or other mechanical duct couplers meeting material requirements of
Section 960 and approved system drawings.
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(l) When connecting steel pipe to plastic pipe with a boot, use a 3/8 inches
wide power seated band and clamps in accordance with 960-2.2 on each end of a duct boot to
seal against grout leakage. Install band per manufacturers instructions.
(m) Ducts for prestressing used exclusively for temporary erection where
PT will be removed from structure are not required to be coupled across segment joints.
462-7.2.1.1 Installation Tolerances.
(a) Ensure final position of PT ducts is within the tolerances in the
following table:
Table 7.2.1.1-1 Duct Installation Tolerances
Type
Horizontal tendons in slabs or in slab regions
of larger members
Longitudinal draped superstructure tendons in
webs: Tendon over supports or in middle third
of span
Tendon in middle half of web depth
Longitudinal, generally horizontal,
superstructure tendons usually in top or bottom
of member
Horizontal tendons in substructures and
foundations
Vertical tendons in web
Vertical tendons in pier shafts
All other cases
Vertical Position
(inches)
Horizontal Position
(inches)
1/4
1/2
1/4
1/4
1/2
1/4
1/4
1/4
1/2
1/2
Longitudinal
Position 1
1/2
1/4
Transverse
Position 1/4
1/4
1/4
(b) Ensure entrance and exit angles of tendon paths at anchorages,
duct joints, and/or at faces of concrete are within plus or minus 3 degrees of desired angle
measured in any direction.
(c) Accomplish any deviations in alignment with smooth unkinked
transitions.
(d) Locate anchorages within plus or minus 1/4 inches of desired
position laterally and plus or minus 1 inch along tendon except that minimum cover requirements
must be maintained.
(e) Position anchorage confinement reinforcement in the form of
spirals, multiple U-shaped bars, or links centered around duct and starting within 1/2 inches of
the back of the main anchor plate.
(f) If conflicts exist between reinforcement and a PT duct, position
of duct prevails. Adjust local reinforcement with the Engineers written approval.
462-7.2.2 Splices and Joints:
(a) All splices, joints, couplings, connections (inlet and outlet), and valves
are part of approved PT system.
(b) Fabricate all duct splices to prevent duct kinks during concrete
placement.
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(c) Use mandrels as needed to maintain duct alignment and shape.
462-7.2.3 Inlets and Outlets:
(a) Place grout inlets/outlets at locations shown in the Contract Documents
including approved shop drawings.
(b) Equip all grout inlets/outlets with approved positive shut-off devices
(e.g., valves).
(c) At a minimum, place grout inlets/outlets in the following positions and
those shown in Design Standards, Index No. 21801:
(1) Top of tendon anchorage;
(2) Top of anchorage cap;
(3) At high points of duct when vertical distance between highest
and lowest point is more than 20 inches;
(4) At location three feet past high points of duct on downstream
side opposite direction of grouting;
(5) At all low points;
(6) At major change in duct cross section; and,
(7) At other locations required by the Engineer.
(d) Extend grout tubes a sufficient distance out of concrete member to
allow for proper closing of valve.
462-7.2.4 Tendons:
(a) Do not exceed 14 calendar days between first installation of
prestressing steel within duct and completion of the stressing and grouting operation for PT bars
located in superstructure and all strands regardless of location.
(b) Do not exceed 21 calendar days between the first installation of
prestressing steel within duct and completion of the stressing and grouting operations for PT bars
located in substructure.
(c) Any light surface corrosion forming during the period of time
described in (a) or (b) will not be cause for rejection of prestressing steel.
(d) Failure to grout tendons within the number of calendar days specified,
will result in stoppage of work, except when waived by the Engineer in writing.
(e) Flushing of grout is not permitted without written approval of the
Engineer and is only permitted as defined in this Article.
(f) Vacuum grouting is required to repair all voids and blockages as
subject to provisions of 462-8.3.2.
(g) For tendon ducts subjected to contamination with chlorides (e.g.,
uncapped ducts that have been subjected to salt spray), flush duct with potable water containing
slack lime (i.e., calcium hydroxide) or quicklime (i.e., calcium oxide) in the amount of
0.17 pounds per gallon.
1. Test for presence of chlorides and oils in discharged water
before placing prestressing strands.
2. If chloride levels in flush water outflow exceed 600 ppm,
continue to flush duct until chloride level in flush water outflow is below 250 ppm.
3. Dry duct interior by blowing oil-free compressed air, by
vacuuming, or by other means deemed acceptable to the Engineer. Remove excess water trapped
in duct corrugations. The Engineer may require use of a boroscope or other visual inspection
means, at no additional cost to the Department, to ensure duct interior is water free.
(h) Push or pull PT strands through ducts to make up a tendon using
methods that will not snag on any lips or joints in ducts.
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(i) Round off end of strands that are pushed or fit advancing end with
smooth protective cap.
(j) Do not intentionally rotate strand by any mechanical means during
installation of PT strand into duct.
(k) Provide sufficient strand length beyond dead end anchorages to allow
for second end stressing as needed for reconciliation of jacking force versus measured
elongation.
(l) Alternatively, tendons may be pulled through duct using a special steel
wire sock or other device attached to advancing end. Strands may be brazed together for pulling
as long as one foot of strand from the brazed end is removed by cutting after installation. Do not
electric arc weld strand ends together for this purpose.
(m) Cut strands in accordance with 462-7.3.2.7.
(n) Strand installation aids (i.e. wire/nylon ties around strand bundle,
strand spacers, etc.) must be removed prior to stressing
(o)Do not install permanent tendons before completion of testing as
required by this Section or the Contract Documents. The only two exceptions are:
(1) Tendon to be tested by Theoretical Elongation Verification
may be installed for test; and,
(2) Transverse tendons may be pre-installed in precast segmental
boxes prior to concrete casting such that they meet 462-8.3.1.
(p) Time limit between initial strand placement and grouting of stressed
tendon, as defined in 462-7.2.4, begins when strand is first placed in duct.
462-7.3 Post-Tensioning Operations:
(a) Do not apply PT forces until concrete has attained compressive strength
specified in the Contract Documents.
(b) Conduct all stressing operations in presence of the Engineer.
(c) With the written approval of the Engineer, revise PT operations so final tendon
force is in agreement with the Contract Documents.
462-7.3.1 Stressing Equipment:
Only use equipment furnished by supplier of PT system.
462-7.3.1.1 Jacks and Gauges:
Equip each jack with pressure gauge for determining jacking
pressure that has a minimum dial diameter of six inches.
462-7.3.1.2 Calibration:
(a) Calibrate each jack and its gauges as a unit.
(b) Calibration must consist of three test cycles with cylinder
extension of jack in various positions (e.g., two-inch, four-inch, eight-inch stroke).
(c) At each pressure increment, average forces from each test cycle
to obtain an average force.
(d) Perform calibration with equipment (e.g., jack, pump, hoses,
etc.) setup in same configuration intended for use on Project.
(e) Jack and gauge calibration is to be initially performed by PT
supplier or an independent laboratory.
(f) Use load cells calibrated within the past 12 months to calibrate
stressing equipment.
(g) Supply documentation denoting the load cells calibration date
and tractability to National Institute of Standards and Technology (NIST) along with jack/gauge
calibration.
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(h) Provide the Engineer with certified calibration charts and
curves for each jack and gauge unit used on the project prior to start of work and every six
months thereafter or as requested by the Engineer.
(i) Calibrations subsequent to initial calibration with a load cell
may be accomplished with use of a master gauge. Supply master gauge to the Engineer in a
protective waterproof container capable of protecting calibration of gauge during shipment to a
laboratory. Provide a quick-attach hydraulic manifold to enable quick and easy installation of
master gauge to verify permanent readings. Master gauge will remain in the possession of the
Engineer for duration of project and will be returned to the Contractor after final acceptance of
project by the Engineer.
(j) Any jack repair, such as replacing seals or changing length of
hydraulic lines, requires recalibration using a load cell.
(k) No extra compensation will be allowed for initial or any
subsequent calibrations or use of master gauge required by the Engineer.
462-7.3.2 Stressing Tendons:
(a) Tension all PT steel so PT force is not less than that required by the
Contract Documents or as otherwise approved by the Engineer in writing.
(b) Do not use monostrand jacks to stress tendons with five or more
strands.
(c) Use of curved stressing noses or chairs is not permitted.
462-7.3.2.1 Jacking Maximum Stress:
Maximum temporary stress (i.e., jacking stress) in PT steel must
not exceed 80% of Guaranteed Ultimate Tensile Strength (GUTS).
462-7.3.2.2 Initial and Permanent Stresses:
(a) PT steel must be anchored at initial stresses resulting in long
term retention of permanent stresses or forces of no less than those shown in the Contract
Documents.
(b) Unless otherwise approved by the Engineer in writing, initial
stress after anchor set must not exceed 70% of GUTS.
(c) Permanent stress and permanent force are stress and force
remaining in PT steel after all losses, including long term creep and shrinkage of concrete, elastic
shortening of concrete, relaxation of steel, losses in PT steel from sequence of stressing, friction,
and unintended wobble of ducts, anchor set, friction in anchorages, and all other losses particular
to the specific PT system.
462-7.3.2.3 Stressing Sequence:
(a) Permanent PT tendons must be stressed from both ends, except
as noted in the Contract Documents.
(b) Required force may be applied at one end and subsequently at
other end or simultaneously at both ends.
462-7.3.2.4 Elongation:
(a) Ensure forces being applied to tendon and resulting elongation
of tendon can be measured at all times.
(b) Measure elongations to nearest 1/16 inch.
(c) For required tendon force, observed elongation must agree
within 7% of theoretical elongation or entire operation must be halted, checked, and source of
error determined and remedied to satisfaction of the Engineer before proceeding.
(d) Do not overstress tendon to achieve theoretical elongation.
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(e) In event that agreement between observed and theoretical
elongations at required force falls outside acceptable tolerances, the Engineer may, at his
discretion and without additional compensation to the Contractor, require additional tests for
Tendon Modulus of Elasticity and/or In Place Wobble and Friction Test.
462-7.3.2.5 Friction:
(a) Provide actual expected friction and wobble coefficients and
anchor set in the shop drawings; submit calculations and show a typical tendon force diagram on
shop drawings based upon expected actual coefficients and values for the PT system to be used.
(b) Graphite may be used as a lubricant when friction must be
reduced, subject to written approval of the Engineer.
462-7.3.2.6 Tendon Wire Failure:
(a) Multi-strand PT tendons with wires which fail by breaking or
slipping during stressing may be accepted provided these conditions are met:
(1) Completed structure has a final PT force of at least 98%
of original total design PT force;
(2) PT force across a mating joint is at least 98% of PT
force required by the Contract Documents for that mating joint for that stage of construction for
precast or cast-in-place segmental construction. This 98% minimum PT force requirement
applies to segmental construction, or any similar construction, that has members post-tensioned
together across a common joint face at any stage of construction; and,
(3) Any single tendon must have no more than a 5%
reduction in cross-sectional area of PT steel due to wire failure.
(b) When conditions permit the Contractor to propose acceptable
alternative means of restoring PT force lost due to wire failure, any of the above conditions may
be waived at discretion of and with approval of the Engineer in writing.
462-7.3.2.7 Cutting of PT Steel:
(a) Cut PT steel using an abrasive saw or plasma torch within
3/4 inches to 1-1/2 inches away from anchoring device.
(b) Flame cutting of PT steel is not permitted.
(c) Do not cut tendon to final length prior to acceptance.
462-7.3.2.8 Post-Tensioning Operations Record:
(a) Keep a record of these PT operations for each tendon installed:
(1) Project name, Financial Project ID (FPID);
(2) Contractor and/or subcontractor;
(3) Tendon location, size, and type;
(4) Date tendon was first installed in duct;
(5) Reel number for strands and heat number for bars;
(6) Tendon cross-sectional area;
(7) Modulus of elasticity;
(8) Date stressed;
(9) Jack and Gauge numbers per tendon end;
(10) Required jacking force;
(11) Gauge pressures;
(12) Elongations (theoretical and actual);
(13) Anchor sets (anticipated and actual);
(14) Stressing sequence (i.e., sequential order of tendon
stressing by number);
(15) Stressing mode (single-end, dual-end, simultaneous);
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(16) Witnesses to stressing operations (Contractor and
Inspector);
(17) Any other relevant information.
(b) Provide the Engineer with a complete copy of all stressing
operation records within five days of completed tendon installation.
462-7.3.3 System Protection:
462-7.3.3.1 Tendon:
(a) Install anchorage caps and seal all other duct openings within
four hours after stressing.
(b) Seal all openings and temporarily weatherproof open ends of
anchorage if acceptance of tendon is delayed.
(c) If tendon contamination occurs and if directed by the Engineer,
remove tendon, flush duct with potable water per 462-7.2.4, and replace with new tendon.
462-7.3.3.2 Anchorage:
(a) Protect PT bar and strand anchorages as indicated in the
Contract Documents within seven days of completing grouting operations (see 462-7.4 for
grouting operations).
(b) Cap all grout inlets/outlets with plugs meeting the requirements
of Section 960.
(c) Construct anchorage pour-backs with a Type Q epoxy grout per
Section 926 within 28 days of permanently affixing all anchorage caps within each individual
pour-back.
(1) Remove all laitance, grease, curing compounds, surface
treatments, coatings, and oils by grit blasting or water blasting. Flush surface with water and
blow dry. Surfaces must be clean, sound, and without any standing water. Test substrate at all
pour-back locations using ACI 503 and develop a minimum of 175 psi tension (e.g., pull-off
value). Testing frequency may be reduced, as determined by the Engineer, after the Contractor
has demonstrated an ability to prepare substrate surfaces for bonding as indicated by the result of
the ACI 503 test.
(2) Mix and apply epoxy grout in accordance with the
manufacturers current standard technical guidelines. Construct all pour-backs in leak proof
forms creating neat lines. Epoxy grout may require pumping for proper installation. Construct
forms to maintain a liquid head to ensure intimate contact with concrete surface. Use vents as
needed to provide for escape of air to ensure complete filling of forms.
(d) Coat exposed surfaces of all pour-backs and anchorage caps
with an elastomeric coating system meeting requirements of Section 975 and having a thickness
of 30 mils to 45 mils. Assure concrete, anchorage caps, or other substrates are structurally sound,
clean, and dry. Concrete must be a minimum of 28 days old. Remove all laitance, grease, curing
compounds, surface treatments, coatings, and oils by grit blasting or water blasting using a
minimum 10,000 psi nozzle pressure. Blow surface with compressed air to remove dust or water.
Apply the elastomeric coating within 90 days of tendon grouting. Apply a manufacturers
approved primer over the elastomeric coating before applying Class 5 coating, if required.
(e) Prior to application of elastomeric coating, construct a 2 foot x
4 foot concrete test block with a similar surface texture to surfaces to be coated. Coat a vertical
face with chosen elastomeric coating system. Determine number of coats required to achieve the
specified thickness without runs and drips. Mix and apply elastomeric coating as per
manufacturers current standard technical specifications. Spray application is preferred; roller
application is permitted. Have coating manufacturer representative on site to supervise and
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comment on application of elastomeric coating onto test block. Apply coating using approved
and experienced personnel with a minimum of three years experience applying similar
polyurethane systems. Submit credentials of these persons to the Engineer for review and
consideration for approval.
462-7.4 Grouting Operations:
Conduct all grouting operations in the presence of the Engineer.
462-7.4.1 Plan:
(a) Submit a Grouting Operations Plan to the Engineer for approval at
least six weeks in advance of any scheduled grouting operation.
(b) Written approval of Grouting Operations Plan by the Engineer is
required before any grouting of permanent structure takes place.
(c) At minimum, Grouting Operations Plan will address and provide:
(1) Names and proof of training for grouting crew and crew
supervisor in conformance with this Specification;
(2) Type, quantity, and brand of materials to be used in grouting
that conform to Section 938 including all required certifications;
(3) Type of equipment to be used, including capacity in relation to
demand and working conditions, as well as, standby equipment and spare parts;
(4) General grouting procedure;
(5) Duct pressure test and repair procedures;
(6) Method to be used to control rate of flow within ducts;
(7) Theoretical grout volume calculations;
(8) Mixing and pumping procedures in accordance with the
manufacturers recommendations;
(9) Direction of grouting;
(10) Sequence of inlet and outlet pipes use;
(11) Procedures for handling blockages;
(12) Procedures for possible post grouting repair.
(d) Conduct a joint meeting of the Contractor, grouting crew, and the
Engineer before grouting operations begin. Discuss Grouting Operations Plan, required testing,
corrective procedures, and any other relevant issues at the meeting.
(e) Demonstrate, to the Engineers satisfaction, grouting of a longitudinal
tendon by constructing a full-scale mockup with all associated PT system components of a
typical longitudinal tendon profile on the project. Utilize clear duct for the mockup to facilitate
visual inspection and verification that no voids or bleed are present in the tendon mockup after
grouting. Place a non-stressed PT strand equivalent to the typical longitudinal tendon size inside
the duct to simulate in-place PT strand.
462-7.4.2 Inlets and Outlets:
(a) Ensure connections from grout pump hose to inlets are free of dirt and
are air-tight.
(b) Inspect valves to ensure they can open and close properly.
462-7.4.3 Supplies:
Provide an adequate supply of water and compressed air for clearing and
testing ducts, as well as, mixing and pumping grout before grouting operations start.
462-7.4.4 Equipment:
(a) Provide grouting equipment consisting of measuring devices for water,
a high-speed shear colloidal mixer, a storage hopper (e.g., holding reservoir) and pump with all
necessary connecting hoses, valves, and pressure gauge.
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(b) Provide pumping equipment with sufficient capacity to ensure PT
ducts can be filled and vented in not more than 30 minutes without interruption.
(c) Provide an air compressor and hoses with sufficient output to perform
required functions.
(d) Have available vacuum grouting equipment (i.e., volumetric measuring
type) and experienced operators within 48 hours notice.
462-7.4.4.1 Mixer and Storage Hopper:
(a) Provide colloidal grout machinery with a charging tank for
blending and a holding tank. Blending tank must be equipped with a high speed shear colloidal
mixer capable of continuous mechanical mixing producing a homogeneous and stable grout free
of lumps and un-dispersed cement. Holding tank must be kept agitated and at least 10% full at all
times during pumping operations to prevent air from being drawn into duct.
(b) Add water during primary mixing phase in the colloidal mixer
by use of a flow meter or calibrated water reservoir with measuring accuracy equal to 1% of total
water volume.
462-7.4.4.2 Pumps:
(a) Provide pumping equipment capable of (1) continuous
operation which includes a system for circulating and agitating grout when actual grouting is not
in progress and (2) maintaining pressure on grouted ducts and (3) fitted with a valve that can be
closed off without loss or pressure in duct.
(b) Grout pumps will (1) be positive displacement type, (2) provide
a continuous grout flow, and (3) be able to maintain a discharge pressure of at least 145 psi.
(c) Use pumps constructed with seals to prevent oil, air, or other
foreign substances from contaminating grout and prevent loss of grout or water.
(d) Specify pump capacity adequate to maintain the specified
grouting rate.
(e) Place pressure gauge with full scale reading of no more than
300 psi at duct inlet. If long hoses (in excess of 100 feet) are used, provide two gauges: one at
pump and one at inlet.
(f) Grout hoses to be compatible with pump output (diameter and
pressure rating).
462-7.4.4.3 Vacuum Grouting:
Provide vacuum grouting equipment meeting these minimum
requirements:
(1) Volumeter for measurement of void volume;
(2) Vacuum pump with a minimum capacity of ten cubic
feet per minute and equipped with flow-meter capable of measuring amount of grout being
injected.
(3) Manual colloidal mixers and/or dissolvers (e.g., manual
high speed shear mixers) for voids less than five gallons in volume;
(4) Standard colloidal mixers for voids five gallons and
greater in volume.
462-7.4.4.4 Standby Equipment:
Provide a standby colloidal grout mixer and pump during grouting
operations.
462-7.4.5 Grouting:
(a) Maintain grout fluidity in strict compliance with grout manufacturers
recommendations.
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(b) In the presence of the Engineer, perform test to confirm accuracy of
grouting equipment volume-measuring components each day of use before performing any
grouting operations. Use either water or grout for testing using standard testing devices with
volumes of 0.5 gallon and 6.5 gallon and an accuracy of equal to or less than four ounces.
Perform one test with each device. Results must verify accuracy of grouting equipment void
volume-measuring component within 1% of test device volume and must verify accuracy of
grouting equipment grout volume component within 5% of test device volume.
(c) Do not use grout that tests outside allowable flow rates.
(d) Perform grouting in accordance with procedures set forth in approved
Grouting Operations Plan.
(e) Grout all ducts.
462-7.4.5.1 Temperature:
(a) At inlet end of grout hose, the maximum limit for grout
temperature is 90F for normal grouting procedures and 85F when performing repair operations
with vacuum grouting.
(b) Condition grout material to maintain mixed grout temperature
below maximum limit.
(c) Grouting operations are not permitted when ambient
temperature is below 40F or is expected to fall below 40F within one day subsequent to
grouting.
(d) Postpone grouting operations if freezing temperatures are
forecasted within two days subsequent to grouting.
462-7.4.5.2 Mixing and Pumping:
(a) Mix grout with a metered amount of water.
(b) Mix materials to produce a homogeneous grout.
(c) Continuously agitate grout until grouting operations are
complete.
(d) Reject bags of grout containing clumps.
462-7.4.5.3 Production Test:
(a) Test grout fluidity to verify it is within limits established by
grout manufacturer during grouting operations. Target fluidity rate is established by
manufacturers representative based on ambient weather conditions.
(b) Determine grout fluidity in accordance with Section 938.
(1) Perform a fluidity test using flow cone on grout
discharged from anchorage cap outlet immediately after uncontaminated uniform consistency
discharge begins for each tendon greater than 50 feet in length. For tendons 50 feet or less,
perform a fluidity test on a per batch basis. For fluidity tests done on a per batch basis, perform
test after new batch has been transferred from mixing tank to holding tank and thoroughly mixed
with remains of the previous batch to produce a new homogenous mixture. During mixing
process, continually re-circulate grout from hose into holding tank. Ensure measured grout efflux
time is not less than efflux time measured at injection end of grout hose.
(2) Alternately, check grout fluidity using Wet Density
method contained in Section 938. Density at discharge outlet must not be less than grout density
at inlet. Continuously discharge grout until density requirements are met. Discard grout used for
testing fluidity.
(c) Perform fluidity test for each tendon to be grouted without
modifying water-cement ratio.
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(d) Check temperature of grout at inlet end of grout hose hourly to
verify conformance to this Section.
(e) Obtain a sample from first production batch of grout and
perform a wick induced bleed test on this sample in accordance with Section 938 at beginning of
each days grouting operation. Begin grouting operations after sample is obtained.
(f) Once grouting has begun, if zero bleed requirement is found to
not have been achieved in the wick induced bleed test at any time during required test time
period, complete grouting of any partially grouted tendons currently being grouted but do not
begin grouting any new or additional tendons. Immediately inform the Engineer when grouting
operations have ceased due to non-compliance of the wick induced bleed test.
(g) Do not re-start grouting operations until such time that testing
shows grout meets specified requirements.
462-7.4.5.4 Operations:
(a) Open all grout outlets before starting grouting operation.
(b) Grout tendons in accordance with approved Grouting
Operations Plan.
(c) Pump grout at the lowest possible pressure practical.
(d) Conduct normal grouting operations at a pressure range of
10 psi to 50 psi measured at grout inlet.
(e) Do not exceed maximum pumping pressure of 145 psi at grout
inlet for round ducts and 75 psi for flat ducts.
(f) Use grout pumping methods that ensure complete filling of
ducts and complete encasement of steel.
(g) Grout must flow from first and subsequent outlets until any
residual water or entrapped air has been removed prior to closing outlet.
(h) Pump grout through duct and continuously discharge it at
anchorage and anchorage cap outlets until all free water and air are discharged and consistency
of grout is equivalent to that of grout being pumped into inlet. Close anchorage outlet and
discharge a minimum of two gallons of grout from anchorage cap into a clean receptacle. Close
anchorage cap outlet.
(i) Elevate grout pressure to the equivalent realized pumping
pressure while grouting the tendon, seal inlet valve, and wait two minutes to determine if any
leaks exist after all outlets have been bled and sealed. If leaks are present repair all identified
leaks using methods pre-approved by the Engineer and repeat steps until no leaks are present.
Bleed pressure to 5 psi and wait a minimum of ten minutes for any entrapped air to flow to high
points if no leaks are present. Increase pumping pressure not to exceed actual realized pumping
pressure of tendon and discharge grout at each high point outlet to eliminate any entrapped air or
water after specified ten minute period has expired. Complete process by locking a pressure of
30 psi into tendon duct.
(j) If actual grouting pressure exceeds maximum allowed, close
inlet and pump grout at next outlet which has just been closed or is ready to be closed as long as
a one-way flow is maintained. Do not pump grout into a succeeding outlet from which grout has
not yet flowed. Fit outlet/inlet to be used for pumping with a positive shut-off valve as shown in
the approved system drawings and pressure gauge if this procedure is used.
(k) Stop grouting operation if complete grouting of tendon cannot
be achieved by the steps stated and in compliance with the approved Grouting Operations Plan.
After waiting 48 hours, vacuum grout duct in accordance with this Section.
462-7.4.5.5 Vertical Grouting:
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(a) Provide a reservoir, equivalent to a minimum of 2% of the total
anticipated grout volume used on a particular tendon, at upper end of tendon to store bleed water
and grout; maintain grout level above level of prestressing plate and anchorage for all vertical
tendons. Design and size this device to maintain level grout at an elevation that ensures potential
bleed will not drop below the highest point of upper anchorage device. Design reservoir to allow
all bleed water, if any, to rise into reservoir.
(b) Discharge grout and check grout fluidity as described in this
Section. Immediately add grout if level of grout begins to drop, potentially allowing bleed water
into the upper anchorage device and tendon duct. Remove reservoir after grout has hardened.
Visually inspect for voids using an endoscope or probe in presence of the Engineer. Fill all voids
found in duct using volumetric measuring vacuum grouting process in accordance with this
Section.
(c) Allow grout to flow from each outlet until all air and water
have been purged prior to using a higher elevation outlet for pumping. Pump grout at
increasingly higher outlets which have been or are ready to be closed, as long as one-way grout
flow is maintained for vertical tendons within allowable grouting pressures.
462-7.4.5.6 Grouting Operations Report:
(a) Provide grouting report signed by the grouting Contractor
within five days of each grouting operation for review by the Engineer.
(b) Record theoretical quantity of grout anticipated as compared to
actual quantity of grout used to fill duct. Notify the Engineer immediately of shortages or
overages.
(c) Information to be noted in this report must include at a
minimum, but not necessarily be limited to: (1) identification of tendon; (2) date grouted; (3)
number of days from tendon installation to grouting; (4) type of grout; (5) injection end and
applied grouting pressure; (6) ratio of actual to theoretical grout quantity; (7) number of grout
bags mixed; (8) total quantity of water used to mix grout; (9) summary of any problems
encountered; and, (10) corrective action taken, (11) description and results of the post grouting
operations and inspection.
462-7.5 Repair:
Perform no remedial or repair work without the Engineers approval in writing.
462-7.5.1 Lifting and Access Holes:
(a) Repair all holes with magnesium ammonium phosphate concrete
meeting requirements of Section 930 or Type Q Epoxy grout meeting requirements of
Section 926. Immediately before casting concrete (i.e., within 24 hrs), mechanically clean and
roughen the mating concrete surfaces to remove any laitance and expose small aggregate. Use
grit blasting or water blasting using a minimum 10,000 psi nozzle pressure. Flush surface with
water and blow dry. Form, mix, place, and cure material in strict compliance with manufacturers
recommendations.
(b) Coat repaired holes, block-outs, and an area extending six inches
outside perimeter of repair with a high molecular weight methacrylate (HMWM) listed on the
QPL upon completion of deck grooving. Prepare surface to be coated and apply HMWM in
accordance with Section 413. Friction (skid) test per Section 413 are not required.
462-7.5.2 Inlets and Outlets:
(a) Place threaded plastic plugs in all inlet/outlet locations required in the
Contract Documents.
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(b) Repair inlets/outlets as shown in the Contract Documents using a
Type Q epoxy compound, Type E epoxy compound, or Type F-1 epoxy compound meeting
requirements of Section 926.
(c) Prepare surface to receive epoxy compounds in compliance with
manufacturers recommendations.
462-7.5.3 Duct:
(a) Heat-shrink wrap material designed for duct repair may be used with
approval of the Engineer in writing.
(b) Use approved heat-shrink sleeve material to repair ducts. Install in
accordance with manufacturers instructions.
462-8 Acceptance and Testing.
462-8.1 Contractor Material Testing:
(a) The following tests are not required on post-tensioned, precast flat slab
bridges, and double-tee bridges but are required on all other PT applications.
(b) Include cost for Contractor Tendon Modulus of Elasticity Test and In-Place
Wobble and Friction Test in price of PT system.
462-8.1.1 Tendon Modulus of Elasticity Test:
Perform a tendon modulus of elasticity test in accordance with the
following procedure if required in the Contract Documents or ordered by the Engineer.
(a) Bench test two samples of each size tendon prior to stressing tendons
to determine modulus of elasticity for purpose of accurately determining tendon elongations
while stressing.
(b) Bench length between anchorages must be at least 40 feet and tendon
duct at least two inches clear of tendon all around for purpose of this test.
(c) Test procedure must consist of stressing tendon at an anchor assembly
with a load cell at dead end.
(d) Tension test specimen 80% of GUTS in ten increments and then
detention from 80% of GUTS to zero in ten decrements.
(e) Record gauge pressure, elongations, and load cell forces for each
increment and decrement.
(f) Note elongations of tendon for both ends and the central 30 feet,
measured to an accuracy of plus or minus 1/32 inches.
(g) Correct elongations for actual anchorage set of dead end.
(h) Calculate modulus of elasticity as follows:
E = PL/Adl
where,
P = force in tendon
L = distance between pulling wedges and dead end wedges or
exact length in the center 30 feet of tendon
A = cross sectional area of tendon
dl = strand elongation within length, L, for load, P
(i) Submit revisions to theoretical elongations to the Engineer for approval
if bench test varies from modulus of elasticity used for shop or working drawings by more than
1%.
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(j) Additional Tendon Modulus of Elasticity Tests may be required when
observed tendon elongations in erected structure fall outside acceptable tolerances or to
otherwise settle disputes to satisfaction of the Engineer.
(k) Additional test series of substantiation from previous projects, not to
exceed two per source, will be required if source of prestressing steel changes during project.
(l) Apparatus and methods used to perform the test must be submitted to
the Engineer for approval in writing.
(m) Tests must be conducted in the Engineers presence.
462-8.1.2 In-Place Wobble and Friction Test:
(a) Test in-place a minimum of one tendon per tendon group performing
the same function for tendons in excess of 100 feet long.
(b) Functional tendon groups are cantilever tendons, continuity tendons,
draped external tendons, or continuous profiled tendons passing through one or more spans.
(c) Selected tendon will represent the size and length of tendon group
being tested.
(d) In-place test is not required on projects with straight tendons used in
flat slabs or precast voided slabs.
(e) Test procedure consists of stressing tendon at an anchor assembly with
a load cell or a second certified jack at dead end.
(f) Stress test specimen to 80% of GUTS in eight equal increments.
(g) For each increment, record gauge pressure, elongations, and load cell
force.
(h) Take into account any wedge seating in both live end (i.e., back of
jack) and dead end (i.e., back of load cell) and any friction within anchorages, wedge plates, and
jack as a result of slight deviations of strands through these assemblies.
(i) Keep an accurate account of elongation at jacking end allowing for
intermediate wedge seating and slip of the jacks wedges for long tendons requiring multiple jack
pulls with intermediate temporary anchoring.
(j) If elongations fall outside the plus or minus 7% range compared to
anticipate elongations, investigate reason and make detailed calculations confirming final tendon
forces are in agreement with requirements of the approved Contract Documents.
(k) Do not vary value of expected friction and wobble coefficients by
more than plus or minus 10% in reconciling theoretical and actual elongations.
(l) Submit for written approval by the Engineer a plan to correct or
compensate for elongation discrepancies if necessary.
(m) The Engineer will require one successful test for each tendon group
for the project.
(n) The Engineer may require additional in-place tests if there are
irreconcilable differences between forces and elongations or other difficulties during the course
of routine stressing operations.
(o) Submit apparatus and methods used to perform test to the Engineer for
approval in writing.
(p) Conduct all in-place tests in the Engineers presence.
462-8.1.3 Required Reports:
(a) Submit two copies of the test report for Tendon Modulus of Elasticity
Test to the Engineer at least 30 days before installing tendon.
(b) Submit two copies of the test report for In-Place Wobble and Friction
Test to the Engineer within two weeks after successful installation of tested tendon.
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462-8.1.4 Test Results Application:
(a) Reevaluate theoretical elongations shown on PT shop or working
drawings using results of Tendon Modulus of Elasticity Test and In-Place Wobble and
Friction Test, as appropriate, and correct calculations as necessary.
(b) Submit revisions to theoretical elongations to the Engineer for
approval in writing.
462-8.2 Contractor Field Tests:
462-8.2.1 Prior to Concrete Placement:
(a) Types of systems to be tested include all PT system components
utilized on the project for, but not limited to, transversely post-tensioned slabs, longitudinally
post-tensioned girders, transverse post-tensioning in box girder segments, pier and bent caps, and
columns. Longitudinal tendons in box-girder segments (internal tendons) are exempt from this
testing.
(b) In the formwork, pressure test each different type and size of duct
assemblies with all assemblies used in a single structural component (e.g. segment, beam, etc.)
constructed for first time on project.
(c) One system per group, but not less than a total of two per project, will
be randomly chosen by the Engineer for testing.
(d) When required by the Engineer, test assemblies in their final position
just prior to concrete placement by sealing them at their anchorages or construction joint termini
and then applying compressed air in accordance with this Section to determine if assembly
connections are pressure tight.
(1) In presence of the Engineer, pressurize duct to 1.5 psi and lockoff outside air source.
(2) Record pressure loss for one minute.
(3) If pressure loss exceeds 0.15 psi, or 10%, find and repair leaks
in duct assembly using repair methods approved by the Engineer and retest.
462-8.2.2 Post Concrete Placement:
(a) After stressing and before grouting internal or external tendons, install
all anchorage caps, inlets and outlets and test the tendon with compressed air in accordance with
this Section to determine if duct connections require repair.
(b) In the presence of the Engineer, pressurize tendon to 50 psi and lockoff outside air source. Record pressure loss for one minute. A pressure loss less than 25 psi, or
50%, is acceptable for tendons with a length of equal to or less than 150 feet and a pressure loss
less than 15 psi is acceptable for tendons longer than 150 feet.
(c) If the pressure loss exceeds allowable, repair leaking connections using
methods approved by the Engineer and retest.
462-8.3 Contractor Inspections:
462-8.3.1 Post Concrete Placement / Prior to Grouting Operations:
(a) Upon completion of concrete placement and except as otherwise
described, prove PT ducts are free and clear of any obstructions or damage and are able to accept
intended PT tendons by passing a torpedo through ducts.
(b) Use a torpedo having same cross-sectional shape as duct that is
1/4 inches smaller all around than clear, nominal inside dimensions of duct. Make no deductions
to torpedo section dimensions for tolerances allowed in manufacture or fixing of ducts. For
straight ducts, use a torpedo at least two feet long. For curved ducts, determine length so that
when both ends touch outermost wall of duct, torpedo is 1/4 inches clear of innermost wall. The
Engineer will reject member if torpedo will not travel completely through duct and workable
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repair cannot be made to clear duct. Torpedo must pass through duct easily when pushed through
by hand, without resorting to excessive effort or mechanical assistance.
(c) Alternatively, four strand tendons in flat ducts used for transverse PT
of segmental box-girders may be preplaced prior to concrete casting. Prove PT ducts are free and
clear of any obstructions or damage by moving the group of strands back and forth in duct for a
minimum distance of one foot in each direction. Move strands easily, by hand, without resorting
to excessive effort or mechanical assistance.
462-8.3.2 Post Grouting Operations:
(a) Inspect all tendons.
(b) Do not open or remove inlets and outlets until grout has cured for a
minimum of 24 hours.
(c) Perform inspections within one hour after removal of all inlets/outlets
located at anchorages and high points along the tendon.
(d) Drill into existing grout ports at all high points along tendon as well as
inlets or outlets located at anchorages for inspection. Drill through hardened grout to penetrate
full-length of grout port access piping to top of trumpet or duct. If drilling of inlets or outlets is
not feasible with conventional equipment, propose an alternative method of tendon inspection for
approval by the Engineer in writing. Use drilling equipment that will automatically shut-off
when steel is encountered. Do not drill into anchorage cap unless anchorage caps are determined
to have voids by sounding.
(e) Perform all inspections using endoscopes or probes and in presence of
the Engineer.
(f) Fill voids using volumetric measuring vacuum grouting process within
48 hours if voids are detected in tendon ducts or anchorages during inspection.
(g) Seal and repair all anchorage and inlet/outlet voids that are produced
by drilling for inspection purposes as specified within four hours of completion of inspections if
no additional voids are detected in tendon ducts or anchorages.
(h) Remove inlet/outlet to a minimum depth of two inches below face of
concrete and seal the surface as specified within 4 hours of inlet/outlet removal. Use an injection
tube to extend to bottom of holes for backfilling with epoxy compound.
(i) Drill into duct and explore voided areas with an endoscope if tendon
grouting operation were prematurely terminated prior to completely filling tendon. Probing is not
allowed. Determine location and extent of all voided areas. Fill voids using volumetric
measuring vacuum grouting equipment in accordance with this Section.
462-9 Method of Measurement.
(a) Quantity of PT tendons to be paid for under this Section will be computed weight, in
pounds, of permanent PT steel tendons installed in the completed structure and accepted.
(b) Quantity is determined by theoretical plan length measured from anchorage to
anchorage (measured from front face of bearing plate) with no allowance made for waste or
extension past bearing faces.
(c) No measurement will be made for temporary PT which is considered incidental to Pay
Item 462-2, Post Tensioning Tendons.
(d) Use these unit weights for quantity determination:
Table 9-1 PT Strand Weight per Unit Length
Prestressing System
Weight per Unit Length, Lb/Ft
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1/2 inch diameter 7-wire strand
0.52
0.6 inch diameter 7-wire strand
0.74
1 inch high strength deformed bar
3.01
1-1/4 inch high strength deformed bar
4.39
1-3/8 inch high strength deformed bar
5.56
1-3/4 inch high strength deformed bar
9.23
462-10 Basis of Payment.
462-10.1 General:
(a) PT tendons will be paid for at the Contract unit price per pound of steel
tendon, completed and accepted.
(b) Payment will be full compensation for furnishing, installing, stressing, and
grouting of all temporary and permanent, internal and external PT tendons. Payment also
includes anchorage assemblies and associated supplemental reinforcing steel required by
supplier, PT system hardware not embedded in concrete, ducts grout and grouting operations, all
testing, including Tendon Modulus of Elasticity Test and In-Place Wobble and Friction Test,
protection of PT anchorages, vents, inlets, outlets, and all labor, materials, tools, equipment, and
incidentals necessary for completing the work in accordance with the Contract Documents. This
payment also includes lubricants in tendon ducts for friction control and flushing lubricants or
contaminants from ducts.
(c) Anchorage components, ducts, and similar items of PT system hardware
embedded within precast components or cast-in-place concrete will be deemed to be included in
cost of precast component or cast-in-place concrete in which it is embedded.
(d) Payment is based on unit price bid extended by either quantities shown in the
Contract Documents or actual quantities used and accepted, whichever is less, if the Contractor
constructs structure with an accepted alternate not detailed in the Contract Documents.
(e) Permanent PT strand or bar tendons which are an integral part of individual
precast concrete segments or units will be measured and paid for under this item and will not be
considered incidental to cost of those precast concrete segments or units.
(f) Payment for PT will be made following successful placement, stressing,
grouting, inspection, repair, protection, and written approval by the Engineer.
(g) Full payment for PT tendons within precast segmental concrete structure units
may occur prior to erection of segments into final position when ducts have been grouted and
anchorage protection system applied and the segmental unit otherwise approved in writing for
placement by the Engineer.
462-10.2 Pay Items:
Payment will be made under:
(a) Item No. 462- 2 Post-tensioning Tendons - Per Pound
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SECTION 470
TIMBER STRUCTURES
470-1 Description.
Furnish and erect treated timber into various structures.
470-2 Materials.
Meet the following requirements:
Timber ................................................................ Section 952
Preservative ........................................................ Section 955
Use timber as specified in the Plans.
470-3 Timber Handling.
Handle treated timber with rope slings, without sudden dropping, breaking of outer
fibers, bruising, or penetration of the surface with tools. Do not use cant dogs, hooks, or pike
poles.
470-4 Cutting and Framing.
Before treatment, cut and frame all timbers which are shown by the Plans to be furnished
in special lengths or framed to detailed dimensions. Limit the cutting of treated timber to minor
fitting which might be necessary and that is authorized by the Engineer. For all places where the
surface is broken, by cutting or otherwise, thoroughly coat with the preservatives and by the
methods specified in AWPA M4.
470-5 Bolt Holes.
The Contractor may drill holes in the field. For timbers originally treated with
pentachlorophenol, creosote, creosote solutions, or waterborne preservatives, field treat all cuts,
abrasions, bolt holes, and recesses that occur after treatment with two liberal applications of a
compatible preservative in accordance with the requirements specified in AWPA Standard M4,
Standard for the Care of Pressure-Treated Wood Products.
470-6 Pile Caps.
Ensure that pile caps have full even bearing on all piles in the bent, and secure them to
each pile by a 3/4 inch diameter drift bolt extending at least 9 inches into the pile. Where so
shown in the Plans, cover the tops and ends of pile caps with 10 ounce, minimum weight, copper
sheet meeting the requirements of ASTM B370.
470-7 Floors.
Attach the planks to each joist or nailing strip with at least two 8 inch nails for 3 inch
planks, or two 10 inch nails for 4 inch planks. Use nails that are at least 1/4 inch in diameter. For
treated timber floors where a bituminous wearing surface is to be applied, lay the planks with the
best side up and with adjacent edges in contact. Grade the planks as to thickness before laying,
and lay the planks so that no two adjacent planks vary in thickness more than 1/8 inch. Cut the
floor to straight lines along the side of the roadway and walkway.
651
470-8 Framing.
Cut and frame truss and bent timbers to a close fit in such manner that they will have
even bearing over the entire contact surface of the joint. Do not perform blocking or shimming of
any kind in making the joints. The Engineer will not accept open joints.
470-9 Holes for Bolts, Dowels, Rods, and Lag Screws.
Bore holes to the diameters shown in the following table:
Hole use
Drift Bolts and Dowels
Machine Bolts
Rods
Lag Screws
Hole diameter
1/16 inch less in diameter than the bolt or dowel to be used
same diameter as the bolt
1/16 inch greater in diameter than the rod
not larger than the body of the screw at the base of the thread
470-10 Stringers.
The Contractor may use butt joints for outside stringers, but shall frame interior stringers
to bear over the full width of floor beam or cap at each end. Separate the ends at least 1/2 inch to
allow circulation of air, and securely fasten the ends to the timber on which they rest.
470-11 Railings.
Construct railings of treated dressed lumber.
470-12 Hardware.
470-12.1 General: Use hardware, including bolts, drift pins, dowels, rods, nuts, washers,
spikes, nails and all similar incidental metal items, necessary to complete the work in accordance
with the details shown in the Plans. Use common wire nails as commercially manufactured. Use
ogee washers of cast or malleable iron. The Contractor may use other hardware of steel, iron, or
any similar material ordinarily used in the manufacture of such articles.
470-12.2 CCA, ACQ-D, CA-B, and CA-C, Treated Timber Structures: Use the
fasteners and connectors as described in the following table:
TABLE HARDWARE REQUIREMENTS FOR TREATED TIMBER
Environmental condition where
Fasteners
Connectors
structure will be located
Permanent wood foundations
and/or where salt spray if
304 or 316 Stainless Steel
04 or 316 Stainless Steel
prevalent
Structures that will be exposed
304 or 316 Stainless Steel
304 or 316 Stainless Steel
to standing water or rainwater
304 or 316 Stainless Steel
304 or 316 Stainless Steel
Structures that will be situated
Hot-dipped galvanized
indoors and remain dry in Hot-dipped galvanized fasteners
connectors meeting the
service
meeting ASTM A-153
requirements of ASTM A-653
requirements
Class G185 sheet or better
Do not use aluminum in direct contact with treated wood.
652
470-12.3 Bolts: Use bolts of the sizes shown in the Plans with square heads and nuts and
with screw threads that make close fits in the nuts. Upon completion of the installation, check all
nuts for tightness, and cut off protruding bolt ends so that not more than 1/4 inch extends beyond
the nut.
470-12.4 Inspection: The Engineer will inspect the hardware for quality of manufacture
and accuracy of size prior to use on wood structures.
470-13 Countersinking.
Perform countersinking wherever the heads of screws or bolts would otherwise interfere
with the assembly of the work. Fill recesses formed by countersinking with hot asphalt.
470-14 Method of Measurement.
470-14.1 General: The quantity to be paid for will be the plan quantity, in feet board
measure, of such timber actually incorporated in and forming a part of the completed structure.
470-14.2 Method of Calculation: For calculating the quantity of timber, the width and
thickness will be taken as the actual sizes shown in the Plans or ordered by the Engineer. Where
special sizing is required, the width and thickness to be used will be that of the smallest
commercial size from which the special piece could be cut. Lengths to be used in the
calculations will be the overall lengths of the pieces as shown in the Plans, except that, where the
lengths actually incorporated in the structure are less than the lengths shown in the Plans, the
lengths actually incorporated will be used in the calculations. Deductions will not be made for
copes, scarfs, or crownings.
470-15 Basis of Payment.
Prices and payments will be full compensation for all the work specified in this Section,
including all copper covering over pile heads, caps, etc., as shown in the Plans, all hardware
except such plates, lag screws, and other metal parts as may be shown in the Plans to be paid for
as structural steel and all paint materials and all excavation, painting, and incidentals necessary
to complete the work.
Payment will be made under:
Item No. 470- 1Treated Structural Timber - per Thousand Board Measure.
653
SECTION 471
POLYMERIC FENDER SYSTEMS
471-1 Description.
Construct fender systems using components in accordance with this Section, the Plans,
Design Standards and the Qualified Products List (QPL) drawings.
471-2 Materials.
Meet the following requirements:
Fiberglass fiber reinforced lumber (Dimensional Lumber)
....................................Section 973
Fiberglass structurally reinforced composite lumber (Wales)
................................................................Section 973
Concrete used to fill hollow piles ......................Section 347
471-3 Polymeric Pile Product Acceptance.
Use polymeric pile configurations listed on the Departments QPL.
Manufacturers seeking evaluation of products for inclusion on the QPL must submit an
application in accordance with Section 6, independently certified test reports, written
certification that the piling configuration meets the requirements of this Section, and the
following:
1. Design:
a. Design fender piling configurations and connections in accordance with
the latest edition of the FDOT Structures Design Guidelines and applicable Structures Design
Bulletins based on the desired energy capacity rating.
b. All design calculations and design details must be signed and sealed by
a Professional Engineer licensed in the State of Florida.
2. Submittals:
a. Signed and sealed design calculations. Design calculations may be
either by hand or by a computer program with hand calculations verifying the program output.
b. Report from an independent lab verifying the flexural properties of the
piling as derived from ASTM D-6109 with the following modification. Supports shall be located
to provide a minimum span to depth ratio of 20:1.
c. For pile sections remaining hollow under service conditions, a report
from an independent lab verifying a minimum bolt pull-through and crushing resistance of 10 kip
when equipped with manufacturers detailed connection hardware at a maximum distance of two
feet from the end of a pile with a minimum length of four feet.
d. Signed and sealed pile configuration drawings in 11 inches x 17 inches
PDF format depicting information required by the latest edition of the FDOT Structures Design
Guidelines and applicable Structures Design Bulletins.
e. Detailed material specifications showing material type, quality,
certifications, acceptance and rejection criteria and placement procedures.
f. Other information pertinent to the design and performance of the pile
configuration as necessary.
654
g. A field construction manual describing in detail, with illustrations,
construction requirements and the step-by-step construction sequence for the pile handling and
installation. Submit manual in 8.5 inches x 11 inches PDF format.
471-4 Construction Details.
Unless otherwise shown in the manufacturers approved field construction manual, use
the following construction details.
Protect materials at all times against exposure to extreme heat or impact. Transport
products in a manner that will minimize scratching or damage to the outer surfaces, stack on
dunnage above ground so that it may be easily inspected and store in a manner that will avoid
damage. Handle and lift products with nylon slings. Do not use sharp instruments in handling the
product. Products damaged in shipping or handling will be rejected.
Products containing cracks in the reinforcing rods or cracks, partial or full depth, across
the section or splits will be rejected.
Cut, bevel, drill, countersink and otherwise install products in accordance with the
manufacturers recommendations. Set all material accurately to required levels and lines, with
members plumb and true and accurately cut and fitted. Securely attach all materials to substrate
by anchoring and fastening as shown in the Plans. Perform all cutting and drilling in a manner
that allows for the collection of all debris and dispose of properly.
Install piles in accordance with Section 455.
471-5 Method of Measurement.
The quantity of dimensional fiberglass fiber reinforced lumber and fiberglass structurally
reinforced composite lumber to be paid for will be the plan quantity, in feet board measure,
computed based upon the dimensions shown in the Plans.
The quantity of polymeric piles to be paid will be lump sum.
471-6 Basis of Payment.
Price and payment for plastic marine lumber will be full compensation for the work
specified in this Section including all material, storage costs, disposal of unused material and
waste, transportation costs, labor, equipment, fasteners and other necessary items required for
completing the work. No separate payment will be made for plates, bolts, screws or other
hardware necessary to complete the work.
Price and payment for polymeric piles will be full compensation for all labor, equipment
and materials required to furnish and install the piles to the pile cut-off elevations shown in the
Plans.
Payment will be made under:
Item No. 471-1
Fender System, Plastic Marine Lumber - MB.
Item No. 471-2
Fender System, Polymeric Piles - LS
655
INCIDENTAL CONSTRUCTION
SECTION 502
SHEAR CONNECTORS
502-1 Description.
Furnish and install welded shear connectors on steel beams and girders at locations
shown in the Contract Documents. Field weld shear connectors located on the top flange only
after the deck forms are in place. Installation of shear connectors in the fabrication plant is not
permitted.
502-2 General Requirements.
502-2.1 Design: Provide shear connector studs of a design suitable for end-welding to
steel beams and girders, with automatically timed stud welding equipment. Provide the type, size
or diameter, and length of stud as specified by the Contract Documents, and as approved by the
Engineer. Meet the allowable tolerances on dimensions as specified in 502-7.
502-2.2 Arc-Shield: Furnish an arc-shield (ferrule), of heat-resistant ceramic or other
suitable material, with each stud. Use material that is not detrimental to the welds, does not cause
excessive slag, and has sufficient strength not to crumble or break due to thermal or structure
shock before the weld is completed.
502-2.3 Flux: Furnish flux for welding with each stud, either attached to the end of the
stud or combined with the arc-shield for automatic application in the welding operation.
502-2.4 Coatings: Do not paint or galvanize studs.
502-2.5 Qualification: Use only qualified studs, passing the tests prescribed in 502-6.
Use the same arc-shield in production as used in the qualification tests.
502-2.6 Data to be Submitted: Before placing orders for studs, submit to the Engineer,
for his approval, the following information on the studs to be purchased:
(1) The name of the manufacturer.
(2) A detailed description of the stud and arc-shield to be furnished.
(3) A certification from the manufacturer that the stud is qualified as specified in
502-2.5.
(4) A copy of the qualification test report as certified by the testing laboratory.
502-2.7 Freedom from Defects: After welding, ensure that the studs are free from any
defect or substance that would interfere with their function as shear connectors.
502-3 Materials.
502-3.1 Metal: For shear connector studs, meet the requirements of ASTM A108, colddrawn bar, Grades 1015, 1017, or 1020, either semi-killed or fully-killed. If using flux-retaining
caps, use caps of a low-carbon grade steel suitable for welding and meeting the requirements of
ASTM A109.
502-3.2 Mechanical Properties: For tensile properties as determined by tests of bar
stock after drawing, or of finished studs, meet the following requirements:
Tensile strength .................................. 60,000 psi (minimum)
Yield strength* ................................... 50,000 psi (minimum)
656
Elongation ................................. 20% in 2 inches (minimum)
Reduction of area ........................................ 50% (minimum)
*As determined by 0.2% offset method.
Determine tensile properties in accordance with ASTM A370. Perform tensile
tests of finished studs on studs welded to test plates. If fracture occurs outside of the middle half
of the gage length, repeat the test.
502-3.3 Quality and Finish: Provide finished studs of uniform quality and condition,
free from injurious laps, fins, seams, cracks, twists, bends, and other injurious defects. Produce a
finish by cold drawing, cold rolling, or machining.
502-3.4 Certification: Ensure that the manufacturer certifies that the studs, as delivered,
are in accordance with the materials requirements of this Subarticle. Furnish certified copies of
in-plant quality control test reports to the Engineer upon request.
502-4 Construction Requirements.
502-4.1 Equipment: End weld stud shear connectors to steel beams or girders with
automatically timed stud welding equipment connected to a suitable power source.
502-4.2 Interlocking: If two or more stud welding guns are to be operated from the same
power source, interlock them so that only one gun at a time can operate and the operating gun
finishes each weld before starting another weld.
502-4.3 Condition of Studs: At the time of welding, ensure that the studs are free from
rust, rust pits, scale, oil, and other deleterious matter which would adversely affect the welding
operation.
502-4.4 Weather Limitations: Do not weld when the base metal temperature is below
0F, or when the surface is wet or exposed to rain or snow.
502-4.5 Position of Welding Gun: While operating, hold the welding gun in position
without movement until the weld metal has solidified.
502-4.6 Preparation of Areas: Prepare the surface where studs are to be welded by
wire-brushing, peening, prick-punching, grinding, or other approved methods to remove paint,
scale, rust, oils, or other deleterious matter which would adversely affect the welding operation.
502-4.7 Spacing: Ensure that longitudinal and lateral spacing of studs with respect to
each other and to edges of beam or girder flanges does not vary more than 1/2 inch from the
dimensions shown in the Plans. However, the Engineer will allow a variation of 1 inch where
required to avoid interference with other attachments on the beam or where welding a new stud
to replace a defective stud. Provide a minimum distance of 1 inch from the edge of a stud to the
edge of a beam, but where possible provide at least 1-1/2 inches.
502-4.8 Testing: After allowing them to cool, bend the first two studs welded on each
beam or girder, 45 degrees by striking the stud with a hammer. If failure occurs in the weld of
either stud, correct the procedure, and weld and test two successive studs successfully before
welding any more studs to the beam or girder. Inform the Engineer of any changes in the
welding procedure at any time during construction. When the temperature of the base metal is
below 32F, bend one stud in each 100 studs welded 45 degrees in addition to the first two bent
as specified above.
502-4.9 Repair of Welds: The Contractor may repair studs, on which a full 360 degrees
weld is not obtained, in accordance with the procedures of ANSI/AASHTO/AWS D1.5, Bridge
Welding Code.
657
502-4.10 Reduction in Height: If the reduction in the height of studs as they are welded
becomes less than 1/16 inch, immediately stop welding and correct the cause. Do not resume
welding until the cause has been corrected.
502-4.11 Replacing Studs: Before welding the replacement stud, remove the defective
stud, grind the area smooth and flush or, in the case of a pullout of metal, fill the pocket with
weld metal, using the shielded metal-arc process with low-hydrogen welding electrodes, and
then grind flush. In compression areas of flanges, the Contractor may weld a new stud adjacent
to the defective area in lieu of repair and replacement of the existing weld.
502-5 Inspection Requirements.
502-5.1 Bend Test: If visual inspection reveals any stud which does not show a full
360 degrees weld, any stud which has been repaired by welding, or any stud in which the
reduction in height due to welding is less than normal, strike such stud with a hammer and bend
15 degrees off the vertical. For studs showing less than a 360 degrees weld, bend the stud in the
direction opposite to the lack of weld. Replace studs that crack in either the weld or the shank.
The Engineer may select additional studs to be subjected to the bend test specified above. The
Contractor may leave the tested studs that show no sign of failure in the bent position.
502-5.2 Unsatisfactory Work: If, during the progress of the shear connectors work,
inspection and testing indicate that the shear connectors being obtained are not satisfactory,
make such changes in welding procedure, welding equipment, and type of shear connector as
necessary to secure satisfactory results, at no expense to the Department.
502-5.3 Requalification: If the Engineer requests, require the manufacturer of the studs
to submit sample studs for requalification in accordance with the procedures of 502-6, at no
expense to the Department.
502-6 Qualification Procedure.
502-6.1 Purpose: The purpose of this procedure is to prescribe weldability tests which
will qualify a shear connector stud for welding under shop or field conditions. The Contractor
may have a university, independent laboratory, other testing authority, or agency perform the
tests. Ensure that the agency performing the tests submits to the manufacturer of the stud a
certified report giving procedures and results for all tests, including the information listed under
502-6.9.
502-6.2 Duration of Qualification: Once a type and size of stud with arc-shield has
been qualified, the Engineer will consider the stud qualified until the manufacturer makes any
change in the base of the stud, the flux, or the arc-shield, which affects the welding
characteristics.
502-6.3 Preparation of Specimens: Prepare test specimens by welding representative
studs to the center of square specimen plates, 1/2 to 3/4 inch thick, of structural steel,
ASTM A36. The manufacturer may weld studs to a large plate and cut the specimen plates to a
size suitable for test equipment used.
502-6.4 Welding Procedure: Weld studs with manufacturer recommended power
source, welding gun, and control equipment. Measure welding voltage, current, and time by
suitable instrumentation, and record these measurements for each specimen. Ensure that lift and
plunge are at the manufacturer-recommended optimum setting.
502-6.5 Number of Test Specimens:
658
(1) Weld 30 test specimens consecutively, with optimum current and time. Make
the optimum current and time the midpoint of the range normally recommended by the
manufacturer for production welding.
(2) Weld 30 test specimens consecutively, with time held constant at optimum but
with current 10% below optimum.
(3) Weld 30 test specimens consecutively, with time held constant at optimum but
with current 10% above optimum.
502-6.6 Qualification Tests:
502-6.6.1 Tensile Tests: Subject 10 of the specimens welded in accordance with
502-6.5 (1), 10 in accordance with 502-6.5 (2), and 10 in accordance with 502-6.5 (3) to a tensile
test. The Engineer will consider a stud qualified if all test specimens have a tensile strength
above the minimum specified in 502-3.2.
502-6.6.2 Bend Tests: Place 20 of the specimens welded in accordance with 5026.5 (1), 20 in accordance with 502-6.5 (2), and 20 in accordance with 502-6.5 (3) in a bend
testing device, and bend alternately 30 degrees in opposite directions until failure occurs. The
Engineer will consider a stud qualified if, on all test specimens, fracture occurs in the shank of
the stud and not in the weld.
502-6.7 Retest: If weld failure occurs in any of the tensile or bend test groups, the
Contractor may retest that group. If weld failure repeats, consider the stud as having failed to
qualify.
502-6.8 Qualification: For a manufacturers studs and arc-shields to be qualified, ensure
that each group of 30 studs, by test or retest, meets the requirements prescribed in 502-6.6.
502-6.9 Report of Tests: Include the following in the laboratory report:
(a) Drawings which show shapes and dimensions with tolerances of studs, arcshields, and flux.
(b) A complete description of materials used in the studs and arc-shields,
including the quantity and analysis of the flux.
(c) A certification that the studs and arc-shields described in the report are
qualified in accordance with 502-6.8.
502-7 Dimensions and Tolerances.
Meet the following dimensions and tolerances:
C
3/4 - 1/64 inch
7/8 - 1/64 inch
L*
4 +0.062 inches
4 -0.125 inches
4 +0.062 inches
4 -0.125 inches
1 1/4 1/64 inch
3/8 inch minimum
1 3/8 1/64 inch
3/8 inch minimum
*4 inches length is standard.
The Contractor may obtain other lengths by special order.
Where:
C = Shaft diameter
L = Total stud length measured from top of head to base of shaft
H = Diameter of head
T = Thickness of head
659
502-8 Method of Measurement.
For the purpose of payment, shear connectors will be classified as Structural Steel. The
quantity to be paid for will be determined in accordance with Section 460.
502-9 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including furnishing and installing shear connectors.
Payment will be made in accordance with Section 460.
660
SECTION 504
STEEL GRID FLOORS
504-1 Description.
Furnish and erect open-type steel grid roadway and sidewalk floors, on the movable
spans of bridges and at other locations shown in the Plans. Where specified in the Plans,
completely fill the floor with concrete.
504-2 Materials and Construction Methods.
504-2.1 General: Meet the following requirements:
Portland Cement Concrete ................................. Section 346
Structural Steel and Miscellaneous Metals ........ Section 460
Shop, Field, and Maintenance Painting of
Structural Steel ................................................... Section 560
504-2.2 Roadway Floor: Construct the roadway floor as an open steel grid with
rectangular openings. Place and weld the grid to the floor stringers as shown in the Plans. If the
flooring requires secondary or supplemental stringers, the Department will consider these
stringers and their fastenings a part of, and included in, the materials to be furnished and erected
under this Section.
504-2.3 Sidewalk Floor: Erect sidewalk flooring consisting of a system of main bars and
secondary bars, arranged in a system of rectangular, reticulum or U-shaped openings. Do not
allow the clear distance in any opening to exceed 5/8 inch in one direction. Do not allow the
longest dimension of any opening to exceed 3 inches. Place and weld the floor to the supporting
members in accordance with the details shown in the Plans, or in accordance with the
manufacturers directions as approved by the Engineer.
504-2.4 Conformance with Manufacturers Specifications: Meet the manufacturers
specifications for the material and construction methods, as approved by the Engineer, for any
type of steel floor used.
504-2.5 Use of Trade Names: Where the Plans refer to the type of floor by
manufacturers designation or trade name, the Contractor may use a similar floor providing
equivalent section modulus per unit width, and equivalent surface qualities, if approved by the
Engineer.
504-3 Painting.
Apply to all exposed areas of steel grid floors the same number, type, and thicknesses of
paint coatings as are specified for painting structural steel. Prepare the surface the same as
required for painting structural steel. Although not required, the Contractor may apply paint on
areas to be covered by concrete.
504-4 Method of Measurement.
The quantities to be paid for will be the plan quantity, in square feet, installed, complete
and accepted. Proper deductions for open joints in the floor will be made in calculating plan
quantity.
661
504-5 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including furnishing and installing the complete floor above the tops of the main floor members
shown in the Plans, furnishing and installing any secondary joists which are required in addition
to the main floor members, filling any specified portion with concrete, furnishing paint materials,
painting, and welding.
Payment will be made under:
Item No. 504- 1Steel Roadway Floor - per square foot.
Item No. 504- 2Steel Roadway Floor - per square foot.
662
SECTION 506
BRIDGE DRAINAGE SYSTEM
506-1 Description.
Construct drainage facilities and accessories to collect and dispose of water from drains
on the bridge structures, in accordance with the details shown in the Plans.
506-2 Materials.
Use materials as specified or required in the Plans. For aluminum materials, submit six
certified copies of the mill analysis, along with a certificate from the producer stating that the
materials used meet all requirements of these Specifications. Forward such reports to the
Engineer.
506-3 Method of Measurement.
The quantity for bridge drainage system to be paid for will be at the Contract lump sum
price.
If bridge drainage piping is included in the Contract, the quantity to be paid for will be at
the length, in feet.
If bridge drains are included in the Contract, the quantity to be paid for will be at the
Contract unit price for each.
506-4 Basis of Payment.
Prices and payments will be full compensation for all work, equipment, and materials
specified in this Section or shown in the Plans, including the complete installation of the
drainage system for the bridge structure.
Payment will be made under:
Item No. 506- 1Bridge Drainage System - lump sum.
Item No. 506- 2Bridge Drainage Piping - per foot.
Item No. 506- 3Bridge Drains - each.
663
SECTION 510
NAVIGATION LIGHTS FOR FIXED BRIDGES
510-1 Description.
Furnish and install navigation lighting systems, including all wiring, conduit, wiring
devices, transformers, enclosures, grounding system, controls, protective devices, lights, etc., as
shown in the Plans and in compliance with Code of Federal Regulations (CFR), Title 33,
Part 118, which is further clarified in U.S. Coast Guard (USCG) Publication A Guide to Bridge
Lighting. Navigation lights must operate from sunset to sunrise and during periods of low
visibility.
510-2 Coordination of Electrical Work.
Use experienced personnel in the type of work required by the Contract Documents to
provide a complete and satisfactory fitting and fully operational installation. Perform all
electrical work either by, or under the immediate supervision of an electrical journeyman.
Schedule and arrange electrical work in a neat, well-organized manner without
interference with the work scheduling of other trades.
510-3 Materials and Equipment.
Meet the equipment and material requirements as shown in the Contract Documents.
Furnish and install only materials and equipment of new stock meeting ANSI, NEC,
NEMA, and UL requirements, and approved by the Engineer, except where the Contract
Documents allow or specify the use of other than new equipment.
Furnish and install marine type products manufactured of corrosion resistant materials.
Furnish and install only fasteners manufactured from ASTM 316 stainless steel with
yield strength 35,000 psi or higher.
Furnish and install ASTM 300 series stainless steel conduit straps or hangers held at not
less than two points.
Furnish and install framework for supporting boxes, switches, and other externally
mounted electrical devices fabricated from ASTM A709 Grade 36 hot-dip galvanized structural
steel.
510-4 Navigation Lights and Aids.
510-4.1 Navigation Lights: Equip all navigation lights with a LED array with a
minimum of 50,000 hour life and bright enough to meet the visibility requirements of CFR
Title 33, Part 118. Mount LED arrays on an internal shock and vibration isolator. Provide, in the
circuit, a lightning surge suppressor capable of absorbing multiple strikes without replacement.
Provide special power supply to provide current limited DC voltage to the LED array.
Furnish and install fixtures with unpainted housings of heavy duty cast aluminum
or bronze construction with a 1-1/2 to 2 inch threaded conduit opening on the bottom. Use only
marine type mounting boxes with minimum 3/4 inch conduit opening. Furnish and install
fixtures with lenses that are standard marine molded, single-piece fresnel type, rigid, heat
resistant glass or U.V. resistant polycarbonate and inside diameter of 7 to 8 inch. Furnish all
stainless steel closure bolts, lens tie rods, and attachment hardware for a complete and accepted
installation.
664
Furnish and install Pier/Fender Lights, Center Channel Lights and Channel
Margin Lights with cast aluminum or bronze swivel assembly and mounting bracket, complete
with stainless steel pivot, watertight O ring seal, bronze bearings, cable entrance fitting, and
stainless steel service chain rated for a minimum 225 pounds load. Use a 1-1/2 or 2 inch
galvanized pipe or stainless steel pipe as a hanger stem with automatic lock at service and
operating positions. Furnish and install a 60% counterweight if stem exceeds 5 feet in length.
Ensure the Pier/Fender Light is equipped with a red 180 degree lens, the Center
Channel Light is equipped with a green 360 degree lens and the Channel Margin Light is
equipped with a red 180 degree lens.
510-4.2 Clearance Gauge Lights: Furnish and install one-piece die-cast aluminum
fixture housing fitted with watertight gasket, stainless steel hinges and fasteners, and adjustable
aiming capability, equipped with a 120 V ac , 50 watt, high-pressure sodium lamp. Use a heavy
cast aluminum connection box body and cover with stainless steel swing bolts, watertight gasket
and provisions for mounting to a platform with four stainless steel lag bolts or screws.
510-5 Disconnect Switches.
Furnish and install switches that are HP rated and meet Federal and NEMA
Specifications with NEMA Type 4X (stainless steel) enclosures, and with metal factory
nameplates that are front cover mounted and contain a permanent record of switch type, catalog
number, and HP rating. Provide switch with visible blades, reinforced fuse clips, and nonteasible, positive, quick make-quick break mechanisms. Provide switch assembly plus operating
handle as an integral part of the enclosure base.
Use switches with defeat able door interlocks that prevent the door from opening when
the operating handle is in the ON position, and whose handle position is easily recognizable and
is padlockable in the OFF position. Use heavy-duty switches with line terminal shields.
510-5.1 Fusible Switch Assemblies: Furnish and install NEMA KS 1 type; load
interrupter enclosed knife switch. Provide fuse Clips that are designed to accommodate Class R
fuses.
510-5.2 Non-fusible Switch Assemblies: Furnish and install NEMA KS 1; HD type,
load interrupter enclosed knife switch.
510-5.3 Enclosures: Furnish and install NEMA KS 1 type enclosure as shown in the
Contract Documents.
510-5.4 Installation: Install disconnect switches where indicated in the Contract
Document or where required by the Engineer. Use separate conduits for line and load
conductors. Install fuses in fusible disconnect switches.
510-6 Supporting and Mounting Devices.
Ensure the sizes, and types of anchors, fasteners and supports used are adequate to carry
the load of the equipment and conduit, including the wire in the conduit.
Space conduit supports to avoid conflicts with reinforcing steel at 5 feet maximum. For
concrete mounting, use anchor bolts and all matching parts and tools recommended by and
provided by the same manufacturer, as well as suitable for dynamic loading caused by vibration
due to traffic. To mount conduit supports and pull boxes, use 1/4 inch diameter anchor system.
To mount channel lights use minimum 1/2 inch diameter anchor system with 3-1/2 inch
embedment and 8 inch edge distance.
665
points.
Use ASTM 300 series stainless steel conduit straps or hangers held at not less than two
Do not use powder-actuated anchors. Do not drill or weld structural steel members. Do
not use bolts smaller than 1/4 inch in diameter except as may be necessary to fit the mounting
holes in small and light devices. Install surface-mounted boxes with minimum of three anchors.
510-7 Conduit.
510-7.1 General: Furnish and install conduit in the quantities and sizes required to
complete the work as shown in the Plans and as required by NEC. Use products listed and
classified by UL as suitable for purpose specified and shown. Do not use non-metallic flexible
conduit, aluminum, or electrical metallic tubing (EMT).
510-7.2 Liquid-Tight Flexible Metal Conduit: Furnish and install, liquid-tight flexible
metal conduit of interlocked steel construction with PVC jacket, and fittings meeting the
requirements of ANSI/NEMA FB 1.
510-7.3 PVC Conduit: Furnish and install, schedule 80 PVC 3/4 inch minimum diameter
conduit meeting the requirements of ASTM D1785 and NEMA TC 2 and fittings and conduit
bodies meeting the requirements of ASTM D2467 and NEMA TC 3.
510-7.4 Fiberglass Reinforced Epoxy Conduit: Furnish and install rigid non-metallic
fiberglass reinforced epoxy conduit and fittings manufactured in accordance with the applicable
standards of ANSI and NEMA TC-14B.
Ensure the conduit has a bell and spigot type coupling and the coupling seal is
made rigid by using an adhesive that will provide a water and vapor tight joint with a tensile
strength equal to that listed for the conduit. An alternative type assembly may be used by
applying a triple seal ribbed gasket of water resistant rubber material. Ensure the gasket is held
firmly in place with a compatible adhesive.
Ensure that all fittings, adapters, and bends are manufactured from the same
materials as the conduit and conform to the dimensional requirements of NEMA TC-14.
Use only fiberglass reinforced epoxy conduit and fittings made by the same
manufacturer to insure proper fit and assembly, listed on the UL approved list and labeled for
Type I service sizes 2 to 6 inches.
Ensure that each piece of conduit and fitting is clearly marked with durable
contrasting ink, stenciled with the following:
1. Nominal size,
2. Bends to show the degree and radius of curvature,
3. Type: SW or HW,
4. Manufacturers name or trademark.
510-7.5 Installation: Install conduit in accordance with National Electrical Contractors
Association (NECA) Standard of Installation and manufacturers instructions.
Arrange supports to prevent misalignment during wiring installation. Support
conduit using straps, lay-in adjustable hangers, clevis hangers, and split hangers. Do not support
conduit with wire or perforated pipe straps, plastic straps, or plastic hangers. Ensure that all wire
used for temporary supports is removed upon completion of installation.
Install an expansion fitting for specified PVC conduit at all structure expansion
joints or where movement between adjacent sections of conduit is expected. Provide certification
to the Engineer from the manufacture that the expansion fitting meets the following minimum
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requirements: compatibility with the connected conduits, water proof, UV protected, and allows
longitudinal movement equal to that of the expansion joint or movement expected.
Route exposed conduit parallel and perpendicular to walls or route conduit in the
railings. Install conduits to be continuous and watertight between boxes or equipment. Protect
conduits at all times from the entrance of water and other foreign matter by being capped or well
plugged overnight and when the work is temporarily suspended.
Cut conduit square using saw or pipe cutter; de-burr cut ends. Bring conduit to
shoulder of fittings; fasten securely. Use conduit hubs to fasten conduit to metal boxes. Do not
install more than the equivalent of three 90 degree bends (total 270 degrees) between boxes. Use
conduit bodies to make sharp changes in direction such as around diaphragms.
Join PVC conduit using cement recommended by manufacturer. Wipe PVC
conduit dry and clean before joining. Apply full even coat of cement to entire area inserted in
fitting. Allow joint to cure for a minimum of 20 minutes before pulling conductors.
Do not use flexible conduit extensions greater than 24 inches in length. Ensure
that all flexible conduit extensions are equipped with bonding jumpers.
Do not allow moisture traps; provide pull box with drain fitting at low points in
exposed conduit system.
510-8 Wiring.
510-8.1 General: Do not use aluminum conductors. Use only SE or RHW on incoming
service and use single conductor with XHHW insulation, unless otherwise noted in the Plans.
Do not use wire smaller than No. 12 AWG.
Furnish insulated conductors of seven or nineteen strand copper with a minimum
98% conductivity and connector accessories for copper in sufficient quantities for a complete
installation.
510-8.2 Installation: Use pull boxes wherever necessary to facilitate the installation of
the conductors. Do not use condulets for pulling more than ten conductors or for branching
conductors.
Splice only in accessible boxes. Make lug connections with high pressure indent
connector tools as recommended by the lug manufacturer. Make splices and taps to carry full
ampacity of conductors without perceptible temperature rise. Tighten all connections to
manufacturer's recommendations. Tape uninsulated conductors and connectors with electrical
tape to 150% of the insulation value of conductor. Ensure all splices are waterproof.
Use solderless pressure connectors with insulating covers for No. 8 AWG and
smaller wire splices and taps. Use split bolt connectors for No. 6 AWG and larger wire splices
and taps.
Pull all conductors into a raceway at the same time. Use soap base wire pulling
lubricant for pulling No. 4 AWG and larger wire.
510-8.3 Testing: Test each circuit for continuity and short-circuits for its complete length
before being connected to its load.
Inspect wire and cable for physical damage and proper connection.
510-8 Method of Measurement.
The quantity to be paid for will be at the Contract lump sum price, completed and
accepted.
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510-9 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 510- 1Navigation Lights - lump sum.
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SECTION 514
PLASTIC FILTER FABRIC (GEOTEXTILE)
514-1 Description.
Install a plastic filter fabric.
514-2 Material.
Meet the plastic filter fabric requirements as specified in Section 985.
514-3 Construction Methods.
514-3.1 General: Place the fabric in the manner and locations as shown on the
construction drawings, in accordance with the manufacturers directions, and as specified in
these Specifications. Place the fabric on areas with a uniform slope that are reasonably smooth,
free from mounds and windrows, and free of any debris or projections which might damage the
fabric.
Loosely lay the material. Do not stretch the material. Replace or repair any fabric
damaged or displaced before or during placement of overlying layers to the satisfaction of the
Engineer and at no expense to the Department.
When overlapping is necessary, the Contractor may sew the seams to reduce
overlaps as specified in 985-3.
Schedule work so that covering the fabric with the specified material does not
exceed the manufacturers recommendations for exposure to ultraviolet light or five days,
whichever is less. If the Engineer determines the exposure time was exceeded, the Contractor
shall replace the fabric at no expense to the Department.
514-3.2 Subsurface Drainage: When indicated in the Plans, place the fabric with the
long dimension parallel to the trench. Place the fabric to provide a minimum 12 inch overlap for
each joint. Do not drop the filter material from heights greater than 3 feet.
514-3.3 Stabilization and Reinforcement: Overlap adjacent strips of fabric a minimum
of 24 inches.
514-3.4 Riprap Filter: Overlap adjacent strips of fabric a minimum of 24 inches, and
anchor them with securing pins (as recommended by the manufacturer) inserted through both
strips of fabric along a line through the midpoint of the overlap and to the extent necessary to
prevent displacement of the fabric.
Place the fabric so that the upstream (upper) strip of fabric overlaps the
downstream (lower) strip.
Stagger vertical laps a minimum of 5 feet. Use full rolls of fabric whenever
possible in order to reduce the number of vertical laps.
Do not drop bedding stone or riprap from heights greater than 3 feet onto the
fabric.
514-4 Method of Measurement.
When separate payment is indicated in the Plans, the quantity to be paid for will be the
area, in square yards, of plastic filter fabric placed excluding all laps, completed and accepted.
When no separate payment for furnishing and placing the plastic filter fabric is contained
in the proposal, the Contractor shall include the cost of all work in the Contract price for the item
or items to which it is incidental.
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514-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including furnishing, placing, and sewing or overlapping the fabric.
Payment will be made under:
Item No. 514- 71Plastic Filter Fabric - per square yard.
670
SECTION 520
CONCRETE GUTTER, CURB ELEMENTS,
AND TRAFFIC SEPARATOR
520-1 Description.
Construct portland cement concrete curb and gutter, concrete traffic separator, valley
gutter, special concrete gutter, and any other types of concrete curb not specified in other
Sections.
520-2 Materials.
520-2.1 Concrete: Use concrete meeting the requirements of Section 347.
520-2.2 Reinforcement: For all steel reinforcement required by the Plans, meet the
requirements of Section 415.
520-2.3 Joint Materials: Meet the requirements of Section 932.
520-3 Forms.
520-3.1 Form Materials: Construct forms for this work of either wood or metal. Provide
forms that are straight, free from warp or bends, and of sufficient strength, when staked, to resist
the pressure of the concrete without deviation from line and grade. For all items constructed on a
radius, use flexible forms.
520-3.2 Depth of Forms: Ensure that forms have a depth equal to the plan dimensions
for the depth of concrete being deposited against them.
520-3.3 Machine Placement: The Contractor may place these items by machine
methods with the approval of the Engineer provided that the Contractor consistently produces an
acceptable finished product, true to line, grade, and cross section.
520-4 Excavation.
Excavate to the required depth, and compact the foundation material upon which these
items are to be placed as specified in 120-9.
520-5 Placing Concrete.
Place the concrete in the forms, and tamp and spade it to prevent honeycombing, and
until the top of the structure can be floated smooth and the edges rounded to the radius shown in
the Plans.
520-6 Joints.
520-6.1 Contraction Joints: Except for machine placed items, the Contractor may form
joints by using dummy joints (either formed or sawed) or by using sheet metal templates. If
using sheet metal templates, ensure that they are of the dimensions, and are set to the lines,
shown in the Plans. Hold templates firmly while placing the concrete. Leave templates in place
until the concrete has set sufficiently to hold its shape, but remove them while the forms are still
in place.
Saw contraction joints, for machine placed items, unless the Engineer approves an
alternate method. Saw the joints as soon as the concrete has hardened to the degree that
excessive raveling will not occur and before uncontrolled shrinkage cracking begins.
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Space contraction joints at intervals of 10 feet except where closure requires a
lesser interval, but do not allow any section to be less than 4 feet in length.
520-6.2 Expansion Joints: Construct expansion joints at all inlets, at all radius points,
and at other locations indicated in the Plans. Locate them at intervals of 500 feet between other
expansion joints or ends of a run. Ensure that the joint is 1/2 inch in width.
520-7 Finishing.
520-7.1 Repair of Minor Defects: Remove the forms within 24 hours after placing the
concrete, and then fill minor defects with mortar composed of one part portland cement and two
parts fine aggregate. The Engineer will not allow plastering on the face of the curb. Remove and
replace any rejected curb, curb and gutter, or valley gutter without additional compensation.
520-7.2 Final Finish: Finish all exposed surfaces while the concrete is still green. In
general, the Engineer will only require a brush finish. For any surface areas, however, which are
too rough or where other surface defects make additional finishing necessary, the Engineer may
require the Contractor to rub the curb to a smooth surface with a soft brick or wood block, using
water liberally. Also, if necessary to provide a suitable surface, the Engineer may require the
Contractor to rub further, using thin grout or mortar.
520-8 Curing.
520-8.1 General: Continuously cure the concrete for a period of at least 72 hours.
Commence curing after completely finishing and as soon as the concrete has hardened
sufficiently to permit application of the curing material without marring the surface. Immediately
replace any curing material removed or damaged during the 72 hour period.
After removing the forms, cure the surfaces exposed by placing a berm of moist
earth against them or by any of the methods described below, for the remainder of the 72 hour
curing period.
520-8.2 Wet Burlap Method: Place burlap, as specified in 925-1, over the entire
exposed surface of the concrete, with sufficient extension beyond each side to ensure complete
coverage. Overlap adjacent strips a minimum of 6 inches. Hold the burlap securely in place such
that it will be in continuous contact with the concrete at all times, and do not allow any earth
between the burlap surfaces at laps or between the burlap and the concrete. Saturate the burlap
with water before placing it, and keep it thoroughly wet throughout the curing period.
520-8.3 Membrane Curing Compound Method: Apply clear membrane curing
compound or white pigmented curing compound, as specified in 925-2, by a hand sprayer
meeting the requirements of 350-3.10, in a single coat continuous film at a uniform coverage of
at least one gallon per 200 square feet. Immediately recoat any cracks, checks, or other defects
appearing in the coating. Thoroughly agitate the curing compound in the drum prior to
application, and during application as necessary to prevent settlement of the pigment.
520-8.4 Polyethylene Sheeting Method: Place polyethylene sheeting, as specified in
925-3, over the entire exposed surface of the concrete, with sufficient extension beyond each
side to ensure complete coverage. Overlap adjacent strips a minimum of 6 inches. Hold the
sheeting securely in place and in continuous contact with the concrete at all times.
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520-9 Backfilling and Compaction.
After the concrete has set sufficiently, but not later than three days after pouring, refill
the spaces in front and back of the curb to the required elevation with suitable material. Place
and thoroughly compact the material in layers not thicker than 6 inches.
520-10 Surface Requirements.
Test the gutter section of curb and gutter with a 10 foot straightedge laid parallel to the
centerline of the roadway and while the concrete is still plastic. Perform straightedging along the
edge of the gutter adjacent to the pavement or along other lines on the gutter cross-section, as
directed by the Engineer. Immediately correct irregularities in excess of 1/4 inch.
520-11 Method of Measurement.
For curb or curb and gutter, the quantity to be paid will be plan quantity, in feet,
measured along the face of the completed and accepted curb or curb and gutter.
For valley gutter or shoulder gutter, the quantity to be paid will be plan quantity, in feet,
measured along the gutter line of the completed and accepted valley gutter or shoulder gutter.
For concrete traffic separator of constant width, the quantity to be paid will be plan
quantity, in feet, measured along the center of its width, completed and accepted, including the
length of the nose.
For concrete traffic separator of varying width, the quantity to be paid will be plan
quantity, in square yards, completed and accepted.
520-12 Basis of Payment.
520-12.1 General: Price and payment will be full compensation for all work specified in
this Section.
520-12.2 Excavation: Excavation will be paid for as roadway excavation in accordance
with 120-12.2.
520-12.3 Reinforcement: Reinforcing steel will not be paid for separately. The
Contractor shall include the cost of the steel in the Contract unit price for the item in which the
steel is placed.
520-12.4 Joint Materials: The Contractor shall include the cost of all joint materials in
the Contract unit price for the item in which they are used.
520-12.5 Asphalt Curb Pad: When detailed in the Plans this material shall be included
in the Contractors unit price for the item in which it is used.
520-12.6 Payment Items: Payment will be made under:
Item No. 520- 1Concrete Curb and Gutter - per foot.
Item No. 520- 2Concrete Curb - per foot.
Item No. 520- 3Concrete Valley Gutter - per foot.
Item No. 520- 4Special Concrete Gutter - per foot.
Item No. 520- 5Concrete Traffic Separator - per foot.
Item No. 520- 6Concrete Shoulder Gutter - per foot.
Item No. 520- 70Concrete Traffic Separator - per square yard.
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SECTION 521
CONCRETE BARRIERS, TRAFFIC RAILING BARRIERS
AND PARAPETS
521-1 Description.
Construct precast or cast in place concrete barriers, traffic railing barriers and parapets,
herein referred to as barrier wall, in accordance with the Design Standards and details shown in
the Plans. Use stationary removable forms or sliding forms to construct the barrier wall. Do not
use permanent precast concrete barrier wall on bridge or box culvert structures.
Provide written certification from the manufacturer of the precast barrier wall that the
barrier wall meets the requirements of this Section. Barrier wall is produced using certification
acceptance; therefore, assume responsibility for performance of all quality control testing and
inspections required by Sections 346 and 400 for barrier wall construction. Perform all Quality
Control Testing and inspections using CTQP qualified testing personnel. Perform compressive
strength testing in a laboratory inspected by CCRL or CMEC.
Ensure that each shipment of products to the job site includes a list of products shipped
and the required written certification statement for each product. Provide this list and
certifications to the Engineer.
521-2 Materials.
Meet the following requirements:
Portland Cement Concrete ................................. Section 346
Reinforcing Steel ............................................... Section 415
Joint Materials........................................................... 932-1.1
Joint Materials*..................................... 932-1.2 and 932-1.3
Reflector Elements* ........................................... Section 993
*Qualified Products List (QPL) items
521-3 Use of Precast Temporary Barrier Wall.
521-3.1 General: Meet the requirements of 102-9.5.2.
521-3.2 Precast Temporary Barrier Wall Meeting the Requirements of the Design
Standards, Index No. 415: Use precast temporary barrier wall when certification is provided to
the Engineer that the precast temporary barrier wall was constructed in accordance with and
meets the requirements of the Design Standards, Index No. 415, and meets the approval of the
Engineer.
521-3.3 Procurement of Proprietary Precast Temporary Barrier Wall: Obtain and
use precast temporary barrier wall listed on the QPL from a manufacturing plant that is currently
on the list of the Producers of Incidental Precast/Prestressed Concrete Products. Producers
seeking inclusion on the list shall meet the requirements of 105-3.
Ensure each precast temporary barrier wall section has permanent clear marking,
showing the manufacture date, serial number, and manufacturers name or symbol and the
Department approved drawing number that it meets. The markings may be located on a plate,
plaque, or cast in the panel.
521-3.4 Procurement of Precast Temporary Barrier Wall Meeting the Requirements
of Design Standards, Index No. 414: Obtain and use precast temporary barrier wall from a
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manufacturing plant that is currently on the list of the Producers of Incidental Precast/Prestressed
Concrete Products. Producers seeking inclusion on the list shall meet the requirements of 105-3.
521-3.5 Reflector Elements: Mount reflectors onto the barriers in accordance with the
details shown in the Plans and the Design Standards.
521-4 Construction.
521-4.1 General: The Contractor may use stationary removable forms or slip form
construction methods provided a completed barrier wall with acceptable alignment and finish is
obtained. Construct forms of metal or timber with a form liner. Do not use forms which are
damaged or are not in alignment. At no expense to the Department, remove and replace sections
of barrier wall having unconsolidated concrete, surface blemishes, deviations in alignment or
profile which exceed tolerances, or other defects which cannot be repaired to the satisfaction of
the Engineer.
521-4.2 Stationary Form Construction: Provide precast or cast in place concrete barrier
wall constructed using stationary forms in accordance with Section 400 and providing a Class 3
finish. Align and erect the stationary form so that all plane surfaces of the finished wall will have
no deviation greater than 3/8 inch measured as an ordinate between the concrete and a 10 foot
straightedge. Correct all alignment deviations greater than 3/8 inch. Straightedge by half lapping
the straightedge for the full length of all plane surfaces.
521-4.3 Slip Form Construction: When electing to use the slip form method in lieu of
the stationary forming method, place the concrete with a slip form machine approved by the
Engineer.
Provide a finished texture to the slip formed barrier wall by hand troweling,
brushing, or both to eliminate pockmarks, blemishes and any other discontinuities in surface
texture. Ensure that the final finish has a fine texture and is free of pinholes, pockmarks, and
blemishes.
Remove and recast or repair sections of slip formed barrier wall having areas of
unconsolidated concrete, having surface blemishes, and/or having pockmarks greater than
1/2 inch in diameter after hand troweling and brushing. Repair areas of unsatisfactory surface
finish by hand methods using mortar screened from the concrete used to construct the barrier
wall. Use the mortar screened from the barrier wall concrete only to fill holes and surface
blemishes below the slip formed surface of the concrete. Do not use mortar as a surface overlay
coating on the barrier wall concrete.
During the finishing operation, while the concrete remains plastic, straightedge all
plane surfaces of the slip formed barrier wall with a 10 foot straightedge. Straightedge by half
lapping the straightedge for the full length of the plane surfaces. Correct any deviation found
during straightedging, greater than 3/8 inch, measured as an ordinate between the concrete
surface and the straightedge, in an approved manner at no expense to the Department. Do not use
surface overlay coatings of mortar screened from the concrete, or surface overlay coatings of
concrete to correct alignment deviations.
521-5 Curing.
Meet the requirements of Section 400.
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521-6 Joints.
521-6.1 General: Place expansion and contraction joints in concrete barrier wall either
mounted on or adjoining rigid structures in a manner similar to the type and method of jointing
used in the supporting or adjoining structure or as shown in the Contract Documents. Place
expansion and contraction joints in concrete barrier wall supported by soil or flexible foundation
materials in the manner detailed in the Plans.
521-6.2 Contraction Joints in Barrier Wall Supported by or Adjoining Rigid
Structures: The Contractor may form or saw contraction joints. When sawing contraction joints,
saw them as soon as the concrete has hardened sufficiently to permit sawing without raveling
and before uncontrolled cracking occurs, but in no case later than 12 hours after casting. Match
contraction joints to adjacent contraction joints in the structure. Space contraction joints at 15 to
30 foot intervals. For barrier wall on bridge structures or approach slabs, space contraction joints
as shown in the Contract Documents.
521-6.3 Expansion Joints in Barrier Wall Supported by or Adjoining Rigid
Structures: Construct expansion joints at right angles to the face, and extend them through the
entire cross-section of the barrier wall. Construct barrier wall expansion joints at the same
location and width as the expansion joints in the structure on which the wall rests and at other
locations shown in the Contract Documents. When constructing reinforced barrier wall, form
expansion joints with an expansion filler material or removable forming materials and secure to
the forms as required to provide proper position. When using slip forming to construct nonreinforced barrier wall, construct expansion joints as in reinforced barrier wall or saw the joint
through the plastic concrete the full depth and width of the barrier section. Where using the
plastic sawing method, place close fitting shields over the concrete on each side of the joint for
protection during sawing and hand finishing of the concrete at the joint.
521-7 Repairs and Rejection.
For permanent precast concrete barrier wall that has not been installed, evaluate cracks,
spalls and other deficiencies in accordance with 450-12. Repair deficiencies in accordance with
450-13 or the plants approved repair methods that are included as part of the Quality Control
Plan (QCP). Ensure that the original performance and durability of the repaired barrier wall is
maintained. Use materials for concrete repair that will meet or exceed the strength requirement
for the class of concrete used. Materials meeting the requirements of Section 930 may be
substituted for non-shrink grout when required by 450-13. Concrete barrier wall is subject to
rejection if it fails to conform to any of the Specification requirements after repair. The
disposition of concrete cracks in barrier wall after installation shall be in accordance with 40021. Cracks in unreinforced, plain concrete barrier walls as detailed in Design Standards, Index
No. 410 do not require repair unless directed by the Engineer.
521-8Method of Measurement.
The quantity to be paid for under this Section will be the plan quantity, in feet, completed
and accepted. The quantity will be measured along the top of the barrier wall from the begin to
end station, including transitional and end sections, with no deduction for expansion joints or
open joints. Barrier wall on bridge structures and approach slabs to be removed shall be included
in the cost of removal of existing structures. Barrier wall to be removed along roadways are
included in the cost of clearing and grubbing, or if a pay item is included, in the cost of removal
of concrete barrier wall.
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521-9 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including all reinforcing steel, conduits, materials and incidentals necessary to complete the
work.
Payment will be made under:
Item No. 521- 1Concrete Barrier Wall - per foot.
Item No. 521- 5Concrete Traffic Railing Barrier (Bridge) - per foot.
Item No. 521- 6Concrete Parapet (Bridge) - per foot.
Item No. 521- 7Retaining Wall System - per foot.
Item No. 521- 8Retaining Wall System, Mounted with Sleeper Slab - per
foot.
Item No. 521- 72Concrete Barrier Wall - per foot.
Item No. 521- 73Removal - per foot.
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SECTION 522
CONCRETE SIDEWALK
522-1 Description.
Construct concrete sidewalks.
522-2 Materials.
Meet the requirements specified in 520-2.
522-3 Forms.
Provide forms as specified in 520-3.
522-4 Foundation.
Compact fill areas, including cut areas under the sidewalk that have been excavated more
than 6 inches below the bottom of sidewalk, to a minimum of 95% of AASHTO T99 density.
The area to be compacted is defined as that area directly under the sidewalk and 1 foot beyond
each side of the sidewalk when right-of-way allows.
522-5 Joints.
522-5.1 Expansion Joints: Form 1/2 inch expansion joints between the sidewalk and the
curb or driveway or at fixed objects and sidewalk intersections with a preformed joint filler
meeting the requirements specified in 932-1.1.
522-5.2 Contraction Joints:
522-5.2.1 Types: The Contractor may use open type or sawed contraction joints.
522-5.2.2 Open-Type Joints: Form open type contraction joints by staking a
metal bulkhead in place and depositing the concrete on both sides. After the concrete has set
sufficiently to preserve the width and shape of the joint, remove the bulkhead. After finishing the
sidewalk over the joint, edge the slot with a tool having a 1/2 inch radius.
522-5.2.3 Sawed Joints: If electing to saw the contraction joints, cut a slot
approximately 3/16 inch wide and not less than 1-1/2 inches deep with a concrete saw after the
concrete has set, and within the following periods of time:
Joints at not more than 30 feet intervals
............................... ...within 12 hours after finishing.
Remaining joints ...... within 96 hours after finishing.
522-6 Placing Concrete.
Place the concrete as specified in 520-5.
522-7 Finishing.
522-7.1 Screeding: Strike-off the concrete by means of a wood or metal screed, used
perpendicular to the forms, to obtain the required grade and remove surplus water and laitance.
522-7.2 Surface Requirements: Provide the concrete with a broom finish. Ensure that
the surface variations are not more than 1/4 inch under a 10 foot straightedge, or more than
1/8 inch on a 5 foot transverse section. Finish the edge of the sidewalk with an edging tool
having a radius of 1/2 inch.
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522-8 Curing.
Cure the concrete as specified in 520-8.
522-9 Method of Measurement.
The quantity to be paid for will be plan quantity, in square yards, completed and
accepted.
522-10 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Excavation will be paid for under the items for the grading work on the project.
Payment will be made under:
Item No. 522- Concrete Sidewalk - per square yard.
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SECTION 523
PATTERNED PAVEMENT
523-1 Description.
Construct patterned pavement on asphalt or concrete pavement areas at locations and
with the color and pattern as specified in the Plans. Use products listed on the Qualified Products
List (QPL), as approved for use in areas subject to vehicular traffic or non-vehicular traffic,
respectively, as specified herein. Install products in accordance with manufacturers
recommendations.
For the purpose of this Specification, patterned pavements are defined as surface
markings applied either as an overlay to the pavement surface or imprinted in the pavement
surface. Vehicular traffic areas are defined as those subject to vehicles within the traveled way,
shoulders and auxiliary lanes. Non-vehicular travel areas include medians, islands, curb
extensions, sidewalks, borders, plazas and other areas typically subject to foot traffic only.
For installation of overlay products in areas subject to vehicular traffic, the finished
thickness shall not exceed 180 mils. Products requiring removal of pavement or requiring
blockouts or trenches below the top of pavement, shall not be used.
Provide the pattern type and color as specified in the Plans. Variations within a pattern
shall comply with ADA requirements.
523-2 Materials.
523-2.1 General: Use only patterned pavement products approved for use in vehicular
and non-vehicular areas, as appropriate, and listed on the QPL. Meet manufacturers
specifications for all patterns, textures, templates, sealers, coatings and coloring materials.
Material coatings used to achieve the pattern and color shall produce an adherent,
weather resistant, skid resistant, wear resistant surface under service conditions. Color shall be
integral and consistent throughout the installation. The composition of materials is intended to be
left to the discretion of the manufacturer.
Materials shall be characterized as non-hazardous as defined by Resource
Conservation and Recovery Act (RCRA), Subpart C, Table 1 of 40 CFR 261.24 Toxicity
Characteristic. Materials shall not exude fumes which are hazardous, toxic or detrimental to
persons or property.
523-2.2 Qualified Products List (QPL): Manufacturers seeking evaluation of their
product shall submit an application in accordance with Section 6 along with the following
documentation:
1. Manufacturers recommendations for applicability of use on concrete or
asphalt surfaces.
2. Manufacturers recommendation for applicability of use in vehicular or
non-vehicular travel areas.
3. Manufacturers specifications and procedures for materials and
installation for each use above.
4. For products proposed for use in vehicular traffic areas, test data
verifying the material meets the requirements of this Section including verification that the
product, installed in accordance with the manufacturers specifications and procedures, has been
tested in accordance with either:
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a. ASTM E-274, Skid Resistance of Paved Surfaces using a
standard ribbed full scale tire at a speed of 40 mph (FN40R), and has a minimum FN40R value
of 35, or
b. ASTM E-1911, Measuring Paved Surface Frictional Properties
Using the Dynamic Friction Tester (DFT), at a speed of 40 mph (DFT40), and has a minimum
DFT40 value of 40.
5. For products proposed for use in non-vehicular traffic areas, test data
verifying the material meets the requirements of this Section including verification that the
product, installed in accordance with the manufacturers specifications and procedures, has been
tested in accordance with ASTM E-303 using the British Pendulum Tester and has a British
Pendulum Number (BPN) of at least 40.
523-2.3 Performance Requirements for Products in Vehicular Travel Areas: In
addition to the submittal requirements of 523-2.2, QPL approval will be contingent on a field
service test demonstrating that the patterned pavement product meets the following performance
measures at the end of three years from opening to traffic:
1. The average thickness shall be a minimum of 50% of the original thickness.
2. Wearing of the material coating shall not expose more than 15% of the
underlying surface area as measured within the traveled way.
3. Friction performance of patterned/textured pavement materials shall meet or
exceed one of the following test method values:
(a) FN40R value of 35 in accordance with ASTM E-274; or,
(b) DFT40 value of 40 in accordance with ASTM E-1911
Manufacturers shall provide a field service test installation of each product within
a marked crosswalk on a roadway with an ADT of 6,000 to 12,000 vehicles per day per lane, on
a site approved by the Department. The test installation shall be a minimum six feet wide and
extend from pavement edge to pavement edge across all traffic lanes and shoulder pavement at
the crosswalk location. The test installation shall be tested by the manufacturer in accordance
with FM 5-592.
523-3 Construction.
523-3.1 Product Submittals: Prior to installation, submit pattern and color samples to
the Engineer for confirmation that the product meets the pattern and color specified in the Plans.
Do not begin installation until acceptance by the Engineer.
523-3.2 Pavement Cuts: Complete all utility, traffic loop detector, and other items
requiring a cut and installation under the finished surface, prior to product installation.
523-3.2 Surface Protection: Protect treated surfaces from traffic and environmental
effects until the product is completely installed, including drying and curing according to the
manufacturers instructions.
523-3.3 Installation Acceptance: For installation on new asphalt roadways, apply
patterned pavement a minimum of 14 days after placement of the adjacent pavement.
Upon completion of the installation, the Engineer will check the area at random
locations for geometric accuracy. If any of the chosen areas are found to be deficient, correct the
entire patterned area at no additional cost to the Department.
Provide certification that the patterned pavement was installed in accordance with
the manufacturers requirements.
681
523-4 Method of Measurement.
The quantity to be paid will be the plan quantity in square yards of patterned pavement,
completed and accepted. No deduction will be made for areas occupied by landscaping,
manholes, inlets, drainage structures, or by any public utility appurtenances within the area.
523-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 523- 1Patterned Pavement (Vehicular Areas) - per square yard.
Item No. 523- 2Patterned Pavement (Non-Vehicular Areas) - per square
yard.
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SECTION 524
CONCRETE DITCH AND SLOPE PAVEMENT
524-1 Description.
Construct concrete pavement in the flow channel of drainage ditches and on slopes in
accordance with the notes and details shown in the Plans.
524-2 Materials.
Concrete........................................................................ Section 347
Preformed Expansion Joint Material and Hot Poured Sealer
...................................................................................... Section 932
Filter Fabric .................................................................. Section 985
Reinforcing Steel .......................................................... Section 415
524-3 Forms.
Provide forms as specified in 520-3.
524-4 Foundation.
Shape and compact the foundation materials, upon which the pavement is to be
constructed, to a firm, even surface, true to grade and cross-section.
Dispose of surplus material.
524-5 Joints and Weep Holes.
524-5.1 Joints: Form open or tooled (dummy) type joints as shown in the Plans. Form
open joints by staking a metal bulkhead in place and placing the concrete on both sides of it.
When the concrete has set sufficiently to preserve the width and shape of the joints, remove the
bulkhead. Upon finishing the pavement over the joint, open and edge the slot with a tool having
a 1/4 inch radius.
524-5.2 Method of Placing Slope Pavement: Place slope pavement in vertical strips,
4 feet, plus or minus 1 inch, wide, except taper radii strips from the 4 foot width at the bottom to
a minimum width of 1 foot at the top. Score the strips horizontally at intervals of 2 feet, plus or
minus 1 inch, with a tool having a double 1/4 inch radius. Edge construction joints between
strips with a tool having a 1/4 inch radius. The Engineer will allow construction joints at
horizontal scorings.
524-5.3 Weep Holes: Locate and construct weep holes as shown in the Plans. Construct
weep holes at the toe of slope for all slope pavements.
524-5.4 Filter Fabric: Locate and construct filter fabric as shown in the Plans and
Design Standards.
524-6 Placing Concrete.
Place the concrete in the forms, tamp and spade it to prevent honeycombing, and until the
top of the structure can be floated smooth and the edges rounded.
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524-7 Finishing.
Roughen the surface of ditch pavement after screeding concrete, unless otherwise
specified, to the approximate shape and grade by a rake or other suitable tool drawn
perpendicular to the direction of flow. Ensure that the furrows are at least 1/4 inch deep.
Strike off slope pavement or smooth surfaced ditch pavement, when specified, true to line
and cross-section, and remove all surplus water and laitance from the surface. Lightly broom the
finish.
524-8 Curing.
Cure the concrete as specified in 520-8.
524-9 Method of Measurement.
524-9.1 Concrete Ditch and Slope Pavement: The quantities to be paid for Concrete
Ditch Pavement and Concrete Slope Pavement will be the plan quantity, in square yards,
completed and accepted. Where the Plans show headers or cut-off walls at the end or edge of the
pavement, the volume of the additional thickness of pavement that constitutes the headers,
calculated in accordance with plan dimensions, will be converted into equivalent square yards of
standard thickness pavement and included in the quantity to be paid for.
No deduction will be made for any areas occupied by manholes, inlets, or other drainage
structures or by public utility appurtenances within the pavement area. The square yard quantity
includes any ditch blocks with ditch or slope pavement on top. When steel reinforcement is
called for in the Plans, payment will be included in the square yard item.
524-9.2 Concrete Core Ditch Blocks: The quantity to be paid for Concrete Core Ditch
Blocks will be the plan quantity of concrete, in cubic yards, completed and accepted. When steel
reinforcement is called for in the Plans, payment will be included in the cubic yard pay item. The
cubic yard pay item includes any ditch block within a grass or earth ditch, without other
pavement on top.
524-10 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including all earthwork, skimmers, and incidental materials necessary to complete the work.
Payment will be made under:
Item No. 524- 1Concrete Ditch Pavement - per square yard.
Item No. 524- 2Concrete Slope Pavement - per square yard.
Item No. 524- 3Concrete Core Ditch Block- per cubic yard.
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SECTION 525
ASPHALT CONCRETE CURB
525-1 Description.
Construct an asphalt concrete curb on a previously laid pavement at the locations shown
in the Plans.
525-2 Materials.
Use a Type SP-12.5 (Traffic Level A, B, or C) asphalt concrete mixture.
525-3 Construction Methods.
Sufficiently roughen the surface of the roadway pavement at the locations where the curb
will be constructed to provide suitable bonding of the pavement and the curb.
Lay the curb by a machine or by other methods to provide the required cross-section. The
Engineer may allow variation in the Plan cross-section for using the particular machine, provided
the Contractor obtains the equivalent cross-sectional area and the specified height of curb.
Provide appropriate compaction as directed by the Engineer.
525-4 Method of Measurement.
The quantity to be paid for will be the length plan quantity, in feet, completed and
accepted. Any additions or deletions thereto as authorized by the Engineer will be determined by
plan dimensions, station-to-station dimensions, final measurement, or any combination thereof,
as measured along the face of the completed and accepted curb.
525-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including all materials and incidentals necessary to complete the work.
Payment will be made under:
Item No. 525- 1Asphaltic Concrete Curb - per foot.
685
SECTION 526
ARCHITECTURAL PAVERS
526-1 Description.
Furnish and install architectural pavers and bedding material manufactured to ASTM
standards. Other necessary elements and pay items of this type of paving, such as edge restraints,
base and subbase materials are not covered in this Section.
526-2 Materials.
526-2.1 General: Architectural pavers shall meet the following requirements:
Proposed Use
Roadways
Commercial Driveways
Sidewalks and Medians
Residential Driveways
ASTM C902
(Brick Paver)
Do Not Use
Do Not Use
X
X
ASTM C1272
(Brick Paver)
X
X
Do Not Use
Do Not Use
ASTM C936
(Concrete Paver)
Do Not Use
X
X
X
Ensure that the pavers are consistent in color, size and appearance. Architectural
paver manufacturer, type, pattern, shape and/or color will be in accordance with Plan details,
when specified.
526-2.2 Architectural Pavers - Roadway: For installations on roadways and
commercial driveways, provide architectural pavers having a minimum thickness of 3-1/8 inch.
526-2.3 Architectural Pavers - Sidewalk: For installations on sidewalks, medians and
residential driveways, provide architectural pavers having a minimum thickness of 2-3/8 inch.
526-2.4 Bedding and Joint Sands: Provide clean, non-plastic bedding and joint sand,
free from deleterious or foreign matter, natural or manufactured from crushed rock.
Ensure the bedding sand meets the grading requirements of ASTM C33 Standard
Specification for Concrete Aggregate.
Ensure the joint sand meets the grading requirements of ASTM C144 Standard
Specification for Aggregate for Masonry Mortar.
Bedding sand may be used for joint sand. Do not use joint sand for bedding sand.
526-2.5 Bedding and Joint Grouts: A suitable grout, in thickness specified by the
manufacturer and approved for use by the Architectural Paver manufacturer, may be substituted
for either bedding sand, joint sand or both when specified in the Plans and approved by the
Engineer.
526-3 Construction Methods.
526-3.1 General:
526-3.1.1 Submittals: For Architectural Pavers Roadway, furnish full size
samples to the Engineer for approval prior to beginning placement. For Architectural Pavers Sidewalk, provide the Engineer a certification that the architectural pavers meet the requirements
of this Section. In addition, for all architectural pavers, submit a certified sieve analysis for
gradation comparing results of the bedding sand and joint sand with the requirements of
ASTM C33 or ASTM C144 as applicable.
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526-3.1.2 Mock-ups: Prior to beginning placement, install a 6 foot by 6 foot
paver area following these specifications. This area will be used to determine surcharge of the
bedding material layer, joint sizes, lines, laying patterns and colors of the job. This area will be
adjacent to an edge treatment, incorporated into the work, and will be the standard from which
the work will be judged.
526-3.1.3 Environmental Conditions: Cover stockpiled materials with
waterproof covering to prevent exposure to rainfall. Do not install bedding materials or
architectural pavers during heavy rains or over wet substrata.
526-3.2 Installation: Install the architectural pavers in the following manner:
A. Spread the bedding material evenly over the base course and screed to plan
thickness, not to exceed a thickness of 1-1/2 inch. Do not disturb the screeded bedding material.
Ensure placement of sufficient bedding material to stay ahead of the laid architectural pavers. Do
not use the bedding material to fill depressions in the base course.
B. Lay architectural pavers in the pattern(s) shown in the Plans and maintain
straight pattern lines.
C. Joints between the architectural pavers, on average, will be between 1/16 to
3/16 inch wide.
D. Fill gaps at the edges of the paved area with cut or edge architectural pavers.
E. When utilizing bedding and joint sand:
1. Use a low amplitude vibrator capable of 5,000 foot-pounds with 7100 Hz frequencies to vibrate and compact architectural pavers into bedding sand.
2. Vibrate the architectural pavers, sweeping dry joint sand into the joints
and vibrating, until the joints are full. Do not vibrate within 3 feet of the unrestrained edges of
the architectural pavers.
3. At the end of each day, all work within 3 feet of laying face must be left
fully compacted, with sand-filled joints.
4. Sweep off the excess sand.
F. Leave a final surface elevation of architectural pavers of 1/8 to 1/4 inch above
adjacent drainage inlets, concrete collars or channels.
G. Do not permit the final surface elevations of the pavers to deviate more than
3/8 inch under a 10 foot long straightedge, or more than 1/8 inch between adjacent pavers.
526-4 Method of Measurement.
The quantity to be paid for will be the area in square yards for Architectural Pavers,
measured in place, completed and accepted. Measurement will be as specified in 9-1.3.1. No
deduction will be made for the areas occupied by ornamental trees left within and any other areas
occupied by manholes, inlets, drainage structures or by public utility appurtenances within the
normal areas of the architectural pavers.
526-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section and the
quantity, determined as provided above, will be paid for at the contract unit price per square yard
for architectural pavers.
Payment shall be made under:
Item No. 526- 1-1- Pavers, Architectural (Roadway) - per square yard.
Item No. 526- 1-2- Pavers, Architectural (Sidewalk) - per square yard.
687
SECTION 527
DETECTABLE WARNINGS ON WALKING SURFACES
527-1 Description.
Furnish and install Detectable Warning devices on newly constructed and/or existing concrete
or asphalt walking surfaces (curb ramps, sidewalks, shared-use paths, etc.) constructed in accordance
with the Design Standards, Index No. 304.
527-2 Materials.
527-2.1 Detectable Warning: Provide Detectable Warnings in accordance with the
Americans with Disabilities Act Standards for Transportation Facilities, Section 705. Use Detectable
Warnings consisting of materials intended for exterior use subject to routine pedestrian traffic and
occasional vehicular traffic. Use Detectable Warnings with size and pattern shown in the Plans
comprised of truncated domes aligned in parallel rows in accordance with the Design Standards,
Index No. 304. Do not use detectable warnings with a diagonal pattern.
527-2.1.1 Preformed Materials: Use Detectable Warnings consisting of weatherresistant tiles or pavers that are cast into concrete, or tiles or mats that are surface-applied to concrete
or asphalt surfaces with adhesives and mechanical fasteners or torch-applied preformed
thermoplastic.
527-2.1.2 Field-Formed Materials: Use Detectable Warnings applied as a secondary
application to the substrate.
527-2.2 Material Properties: Provide Detectable Warnings that meet the following minimum
material property requirements when tested in accordance with the indicated Standard appropriate to
the material.
PROPERTY
Slip Resistance
STANDARD
FM 3-C1028
Wear Resistance
FM 5-594
Water Absorption*
ASTM D570
Adhesion/Bond Strength**
FM 5-589
Non-Hazardous
Submit Material Safety
Classification
Data Sheet (MSDS)
TEST VALUE
Dry Coefficient of Friction 0.8 min.
Wet Coefficient of Friction 0.65 min.
(include recessed areas between truncated
domes)
Average Volume Loss: no more than 0.06 cm3
Not to exceed 5%.
150 psi min. tensile adhesion strength
Non-Hazardous, per RCRA Subtitle C
* Applies only to plastic materials.
** Applies only to surface-applied materials.
527-2.3 Color/Contrast: Use safety yellow, brick red or black colored Detectable Warnings
on concrete walking surfaces. Use safety yellow colored Detectable Warnings on asphalt walking
surfaces. Acceptable Detectable Warnings shall meet the following criteria for a duration of three
years.
COLOR
Safety Yellow
LIGHT REFLECTANCE VALUES (LRV) CAP Y*
25 45
688
Brick Red
Black
5 15
05
*When measured with a spectrophotometer
527-2.4 Qualified Products List: Methods or products used to form Detectable Warnings in
wet concrete will not be permitted. Use Detectable Warnings listed on the Departments Qualified
Products List (QPL). Manufacturers seeking evaluation of products for inclusion on the QPL shall
submit an application in accordance with Section 6 and include certified test reports from an
independent lab showing the product meets the requirements of this Section and the Design
Standards, Index No. 304 Acceptance Criteria and manufacturers drawings, specifications and
procedures for materials and installation, including touch-up and repair.
527-3 Installation Procedures.
527-3.1 Surface Preparation and Installation: Prepare the surface in accordance with the
manufacturers recommendations. Use only products and materials appropriate for the surface on
which they will be applied. Install in accordance with the manufacturers instructions, using materials
and equipment recommended and approved by the manufacturer. For surface-applied tiles or mats,
use adhesives applied over the entire surface and mechanical fasteners.
527-4 Method of Measurement.
Detectable Warnings applied to newly constructed walking surfaces will be included in the
cost of the walking surface. Detectable Warnings applied to existing walking surfaces will be paid
per each location where Detectable Warnings are furnished, installed and accepted.
527-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section, including
all labor, surface preparation, materials and incidentals necessary to complete the work for Detectable
Warnings installed on existing walking surfaces.
Payment will be made under:
Item No. 527- 1Detectable Warnings on Existing Walking Surfaces - each.
689
SECTION 530
RIPRAP
530-1 Description.
Construct riprap composed of sand-cement or rubble (consisting of broken stone or
broken concrete) as shown in the Design Standards and in the Plans. When specified in the
Plans, place bedding stone under the rubble riprap. When specified in the Plans or Design
Standards, place geotextile fabric under the riprap.
530-2 Materials.
530-2.1 Sand-Cement:
(1) Portland Cement: Provide cement from an approved source meeting the
requirements of Section 921. Certify that cement meets the requirements of the Contract
Documents.
(2) Fine Aggregate: Meet the requirements of 902-3.3.
(3) Sacks: Provide sacks made of jute, cotton, or scrim reinforced paper capable
of holding the sand-cement mixture without leakage. Ensure that sack material is permeable and
absorptive enough to permit passage of water to provide for hydration of the cement. Ensure that
paper used in sacks is non-asphalt laminated with a polyester fiber scrim reinforcement in a
three-way directional pattern, has an embossed finish, and is perforated approximately 3/32 inch
in approximate 1 inch centers. Extend perforations continuously through the entire wall.
Provide sacks of uniform size and dimensions, in order to provide
uniformity of lines in the completed work. Use sacks that are free from holes and strong enough
to withstand handling without ripping or splitting. Use only one type and size of sack at any one
structure.
(4) Grout: Provide sand from an approved source meeting the requirements of
902-3.3. Provide cement from an approved source meeting the requirements of Section 921.
(5) Geotextile Fabric: Meet the requirements of Section 514 and Design
Standards, Index 199.
530-2.2 Rubble:
530-2.2.1 Rubble (Bank and Shore Protection): Provide sound, hard, durable
rubble, free of open or incipient cracks, soft seams, or other structural defects, consisting of
broken stone with a bulk specific gravity of at least 2.30. Ensure that stones are rough and
angular.
For this application, use broken stone meeting the following gradation and
thickness requirements:
Weight Maximum
Pounds
700
Weight 50%
Pounds
300
Weight Minimum
Pounds
60
Ensure that at least 97% of the material by weight is smaller than Weight Maximum pounds].
Ensure that at least 50% of the material by weight is greater than Weight 50% pounds].
Ensure that at least 85% of the material by weight is greater than Weight Minimum pounds.
Minimum Blanket
Thickness in Feet
2.5
530-2.2.2 Rubble (Ditch Lining): Use sound, hard, durable rubble, free of open
or incipient cracks, soft seams, or other structural defects, consisting of broken stone or broken
690
concrete with a bulk specific gravity of at least 1.90. Ensure that stones or broken concrete are
rough and angular.
Use broken stone or broken concrete meeting the following gradation and
thickness requirements:
Weight Maximum
Pounds
75
Weight 50%
Pounds
30
Weight Minimum
Pounds
4
Ensure that at least 97% of the material by weight is smaller than Weight Maximum pounds.
Ensure that at least 50% of the material by weight is greater than Weight 50% pounds].
Ensure that at least 90% of the material by weight is greater than Weight Minimum pounds].
Minimum Blanket
Thickness in Feet
1.5
530-2.2.3 Physical Requirements of Broken Stone and Broken Concrete: Use
broken stone and broken concrete meeting the following physical requirements:
Absorption
(FM 1-T85)
Los Angeles Abrasion
(FM 1-T096)
Soundness (Sodium Sulphate)
(AASHTO T104)
Flat and elongated pieces
Dirt and Fines
Drop Test***(EM 1110-2-2302)
Maximum 5%
Maximum loss 45%*
Maximum loss 12%** (after five cycles)
Materials with least dimension less than one third
of greatest dimension not exceeding 10% by
weight.
Materials less than 1/2 inch in maximum dimension
accumulated from interledge layers, blasting or
handling operations not exceeding 5% by weight.
No new cracks developed, or no existing crack
widened additional 0.1 inch, or final largest
dimension greater than or equal to 90% original
largest dimension of dropped piece.
* Ensure that granite does not have a loss greater than 55% and that broken concrete does not have a loss greater than 45%.
** The Engineer may accept rubble exceeding the soundness loss limitation if performance history shows that the material will
be acceptable for the intended use. The Engineer will waive the soundness specification for rubble riprap (broken stone and
broken concrete) when project documents indicate it will be placed in or adjacent to water or soil with a sulfate content less than
150 parts per million and a pH greater than 5.0.
*** The Engineer will waive the Drop Test unless required to ensure structural integrity. Provide all equipment, labor and
testing at no expense to the Department. EM refers to the US Army Corps of Engineers Specification Engineering Method.
530-2.2.4 Source Approval and Project Control: The Engineer will approve
mineral aggregate sources in accordance with 6-2.3 as amended by the following:
(1) The Engineer may perform Independent Verification tests on all
materials placed on the project.
(2) The Engineer will check the gradation of the riprap by visual
inspection at the project site. Resolve any difference of opinion with the Engineer in accordance
with the method provided in FM 5-538. Provide all equipment, labor, and the sorting site at no
expense to the Department.
691
(3) The Engineer may test components in a blend of rubble processed
from different geologic formations, members, groups, units, layers or seams. The Engineer may
select components based on like color, surface texture, porosity, or hardness. The Engineer will
reject any blend if a component that makes up at least five percent by volume of the blend does
not meet these specifications.
530-2.3 Bedding Stone: Use Bedding Stone of either a durable quality limestone or other
quarry run stone, with a bulk specific gravity of not less than 1.90 and that is reasonably free
from thin, flat and elongated pieces. Ensure that the bedding stone is also reasonably free from
organic matter and soft, friable particles. Meet the following gradation limits:
Standard Sieve Sizes
Inches
12 inches
10 inches
6 inches
3 inches
1 inch
Individual Percentage by Weight Passing
100
70 to 100
60 to 80
30 to 50
0 to 15
The Engineer will conduct source approval and project control of bedding stone
as specified in 530-2.2.4. In lieu of limestone or other quarry run stone, the Contractor may
substitute non-reinforced concrete from existing pavement that is to be removed and which
meets the above requirements for commercial bedding stone.
530-2.4 Geotextile Fabric: Meet the requirements of Section 514 and Design Standards,
Index 199.
530-3 Construction Methods.
530-3.1 Sand-Cement:
530-3.1.1 Mixing Materials: Proportion sand and cement in the ratio of 5 cubic
feet of sand to 94 lbs. (1 bag) of cement. If proportioning the materials by mass, use a density of
85 lbs\ft3 (loose volume) for sand. The Contractor may batch sand at the moisture content
occurring in the stockpile.
Mix the sand and cement until the mixture is of uniform color.
530-3.1.2 Filling Sacks: Accurately measure the mixed material into each sack,
taking care to place the same amount of material in each sack; keep at least the top 6 inches of
the sacks unfilled to allow for proper tying or folding and to ensure against breaking of the sack
during placing.
530-3.1.3 Placing: Place the filled sacks with their tied or folded ends all in the
same direction. Lay the sacks with broken joints, in a regular pattern. Ram or pack the sacks
against each other so as to form a close and molded contact after the sand and cement mixture
has set up. Remove and replace sacks ripped or torn in placing with sound, unbroken sacks.
Then, thoroughly saturate all sacks with water.
530-3.1.4 Grouting: Immediately after watering, fill all openings between sacks
with dry grout composed of one part Portland cement and five parts sand.
530-3.1.5 Toe Walls: The Contractor may construct toe walls of riprap for fill
slopes of poured in place concrete in lieu of sand cement in sacks. Meet the concrete
692
requirements as specified in Section 347. If using sand cement in sacks for the toe walls, fill the
entire trench excavated for the toe walls with sand cement in sacks.
530-3.2 Rubble: Dump rubble in place forming a compact layer conforming to the neat
lines and thickness specified in the Plans. Ensure that rubble does not segregate so that smaller
pieces evenly fill the voids between the larger pieces.
530-3.3 Bedding Stone: Place bedding stone without puncturing or tearing the geotextile
fabric. Remove and replace geotextile fabric damaged as a result of operations at no expense to
the Department.
The Engineer will allow an in place thickness tolerance of plus or minus 1 inch.
530-4 Method of Measurement.
530-4.1 Sand-Cement: The quantity to be paid for will be the volume, in cubic yards, of
sand actually used in the sand cement mixture and grout, satisfactorily placed and accepted.
If sand cement is proportioned by volume, the sand will be measured loose in an
approved measure prior to mixing with cement. If sand cement is proportioned by weight,
approved scales will be used for this purpose and the volume will be calculated using a standard
conversion factor for sand of 85 lbs/ft3. No adjustment of batch weights to allow for varying
moisture content of the sand will be made.
For toe walls, the quantity to be paid for will include only the volume of sand
cement in sacks or concrete placed within the neat lines shown in the Plans for the toe walls.
530-4.2 Rubble and Bedding Stone: The quantities to be paid for will be the weight, in
tons, in surface dry natural state, by railroad scales, truck scales, or barge displacement. The
Contractor shall determine the weights as follows:
(1) Railroad Weights: The Contractor shall weigh railroad cars on railroad scales,
before and after loading or before and after unloading. If weighed by other than the Engineer, a
certified statement of weights will be required. Certificates of weight, furnished by the railroad
company, will be acceptable without further certification.
(2) Truck Weights: The Contractor shall weigh trucks on certified scales, loaded
and empty, as prescribed above for railroad weights. The Contractor shall weigh trucks in the
presence of the Engineer, or furnish certificates of weights.
(3) Barge Displacement: The Engineer will measure each barge. The Contractor
shall fit each barge with gauges graduated in tenths of a foot increments. The Contractor shall
locate a gauge at each corner of the barge near the lower end of the rake. The Contractor shall
furnish additional gauges amidships if the Engineer deems necessary. The Engineer will compute
all weights.
530-5 Basis of Payment.
530-5.1 Sand-Cement: Price and payment will be full compensation for all work
specified in this Section, including all materials, labor, hauling, excavation, and backfill.
Include the cost of dressing and shaping the existing fills (or subgrade) for
placing riprap in the Contract unit price for riprap (sand-cement).
530-5.2 Rubble: Price and payment will be full compensation for all work specified in
this Section, including all materials, hauling, excavation, and backfill.
Include the cost of dressing and shaping the existing fills (or subgrade) for
placing riprap in the Contract unit price for riprap (rubble).
693
As an exception to the above, concrete that is shown to be removed from an
existing structure and subsequently disposed of by being used in the embankment as riprap will
not be paid for under this Section. Include the cost of such work under removal of existing
structures.
530-5.3 Bedding Stone: Price and payment will be full compensation for all work
specified in this Section, including all materials and hauling.
Include the cost of dressing and shaping the existing fills (or subgrade) for
placing bedding stone in the Contract unit price for riprap (rubble).
530-5.4 Geotextile Fabric: Include the cost of materials and installation of the geotextile
fabric in the contract unit price for riprap.
530-5.5 Payment Items. Payment will be made under:
Item No. 530- 1Riprap (Sand-Cement) - per cubic yard.
Item No. 530- 3Riprap (Rubble) - per ton.
Item No. 530- 74- Bedding Stone - per ton.
694
SECTION 534
CONCRETE SOUND BARRIERS
534-1 Description.
Furnish and install concrete sound barriers with pile, posts and panels constructed in
accordance with Design Standards, Index No. 5200; unless the Plans indicate otherwise, based
on specific design or aesthetic criteria unique to the project.
Obtain Precast Concrete Sound Barrier components from a manufacturing plant that is
currently on the list of Producers with Accepted Quality Control Programs. Producers seeking
inclusion on the list shall meet the requirements of 105-3.
534-2 Materials.
Meet the following requirements:
Portland Cement Concrete ..................................Section 346
Reinforcing Steel ................................................Section 415
534-3 Component Construction.
Construct concrete components in accordance with Section 400. Precast wall components
are produced using certification acceptance; therefore, assume responsibility for performance of
all quality control testing and inspections required by Sections 346 and 400 for the precast
component construction. Perform all Quality Control Testing using Construction Training and
Qualification Program (CTQP) qualified testing personnel. Perform compressive strength testing
in a laboratory inspected by the Cement and Concrete Reference Laboratory (CCRL) or
Construction Materials Engineering Council (CMEC), with all deficiencies corrected.
Ensure that each panel and post is permanently and clearly marked by ink, stamping the
tongue and groove portion of the panel and post. Mark the panel with the panel type, date cast,
project number, manufacturers name or symbol and the post with the date cast, project number
and manufacturers name or symbol.
534-4 Shop Drawing Submittal.
Do not include shop drawings of the basic concrete panel details, submit only the
information requested below. Submit shop drawings in accordance with Section 5, showing a
plan and elevation of the sound walls with the following project specific information provided:
1. Begin and end wall stations with offsets
2. Horizontal and vertical alignments of the wall
3. Panel locations
a. Graphic details and graphic panel locations
b. Fire hose access hole locations
c. Drainage panel locations and type
4. Post locations
5. Elevations of top of panel, bottom of panel, and panel joints
6. Existing and proposed ground elevations
7. Utility locations
8. Non-standard post and panel details
9. Non-standard post and pile connection details
10. Non-standard Post Cap Details
11. Lifting devices
695
534-5 Construction Methods.
A. Prior to beginning earthwork on the project, stake the wall location in the field and
establish the final ground line elevations at the base of the walls. Use these elevations to develop
the shop drawings, including a complete elevation view of each wall indicating top and bottom
elevations as well as the roadway grade. Protect the final ground elevations established in the
field for the duration of the project, and do not adjust without prior approval of the Engineer.
Keep to a minimum the clearing and grubbing, and trimming of trees as necessary to construct
the walls.
B. All posts shall be held plumb in auger cast piles with an installation template. The
template shall be such that the installation tolerances can be maintained. The template shall
remain in place for a minimum of 12 hours after post installation.
C. Shimming of wall panels above the pile collar and beneath the bearing pads is
permitted, up to a maximum of 1-1/2 inches. Shims must be either stainless steel (Type 304 or
316) or engineered copolymer plastic. Plastic shims must have a minimum compressive strength
of 8,000 psi, without any fractures. Stacked shim plates must be bonded together with a
compatible epoxy adhesive. Stacking of shims is permitted as follows:
1. for shimming heights of one inch or less, provide up to four 1/4 inch shims
2. for shimming heights greater than one inch, use a minimum of one 3/4 inch
shim.
D. Install the walls in accordance with the Plans, and with the shop drawings submitted to
and approved by the Engineer. Secure joints and connections in such a manner as to be
structurally sound and without visible openings in the system allowing sound transmission.
E. Repair marred, chipped, scratched, or spalled areas of walls at no expense to the
Department in accordance with the manufacturers recommendations or at the Engineers
direction.
F. Place trench backfill for wall construction in accordance with 125-8. Use select
materials for the trench backfill.
If, in the opinion of the Engineer, the trench is too narrow to compact, backfill the
trench excavation with flowable fill meeting the requirements of Section 121 or concrete meeting
the requirements of Section 346 or 347 to the satisfaction of the Engineer and at no expense to
the Department.
G. Dispose of all excess excavation in a manner satisfactory to the Engineer.
H. Keep right of way fence that is scheduled to be salvaged in place until completing the
wall or, in the opinion of the Engineer, as long as possible.
I. After erecting the wall, leave the disturbed area in a finished condition at the direction
of the Engineer, and grass or sod the area as indicated in the Plans.
J. Erection Tolerances:
1. Variation from plumb: plus or minus 1/4 inch/post height
2. Panel alignment: plus or minus 1/4 inch
3. Top of panel elevation: plus or minus 3/4 inch
4. Elevation difference of adjacent panels: plus or minus 1/2 inch
5. Joint taper over panel length: plus or minus 1/2 inch
6. Top of collar elevation: plus or minus 3/4 inch
7. Post placement:
a. variation from specified location plus or minus 1/2 inch
b. variation from specified elevation plus or minus 1/4 inch
696
8. Continuity of graphics, fracture fins, etc across joints: 1/4 inch
K. When building sound barriers on top of earth berms, construct the berms of fill
material compacted to 95% of the maximum density as determined by AASHTO T99.
L. Provide the concrete wall with a uniform color, pattern, and texture as shown in the
Plans.
534-6 Test Wall.
Erect a test wall section not less than 50 feet in length before starting general wall
construction at the project site. The Engineer will use the erection of the test wall to determine if
the Contractors methods and equipment are sufficient to produce a sound barrier that meets the
requirements of the Contract Documents. The Contractor may revise his methods and equipment
as necessary, at any time during the positioning of the test wall, in order to satisfactorily meet all
Contract requirements. Build the test wall at a permanent wall location, as directed by the
Engineer. If the test wall does not meet the construction tolerances, remove and dispose of it at
no expense to the Department. Include the cost of the test wall in the cost of the sound barrier.
534-7 Repairs or Rejection.
For precast concrete sound barrier components that have not been installed, evaluate
cracks, spalls and other deficiencies in accordance with 450-12. Repair deficiencies in
accordance with 450-13 or with the plants approved repair methods that are included as part of
the Quality Control Plan (QCP). Ensure that the original performance and durability of repaired
sound barrier components are maintained. Use materials for concrete repair that will meet or
exceed the strength requirement for the class of concrete used. Materials meeting the
requirements of Section 930 may be substituted for non-shrink grout when required by 450-13.
Precast concrete sound barrier components are subject to rejection if they fail to conform to any
of the requirements after repair. For precast concrete sound barrier components that have been
installed, the disposition of concrete cracks shall be in accordance with 400-21.
534-8 Method of Measurement.
The quantity to be paid for will be the plan quantity, in square feet, measured in place,
completed and accepted, of the area bounded by the top of the top panel and the bottom of the
bottom panel without deductions for openings in the panels, and the beginning to end limits
shown in the control drawings.
534-9 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including but not limited to: furnishing all materials, labor, panels, special panels, posts, post
caps, collars, reinforcing steel, foundations, drain holes, fire hose access holes, grating, neoprene
pads, equipment, alignment pins, etc. necessary to construct the sound barriers. Include in this
price, the cost of sound barrier wall realignments, special erection methods, etc. required to
construct the wall.
Payment will be made under:
Item No. 534- 72Concrete Sound Barrier - per square foot.
697
SECTION 536
GUARDRAIL
536-1 Description.
Construct metal guardrail on posts of timber, steel, or as specified in accordance with the
Contract Documents and the Design Standards.
Also, remove existing guardrail, construct guardrail anchorages, and replace guardrail
posts, as specified in the Plans.
536-2 Materials.
536-2.1 Guardrail: Construct guardrail of the standard W-beam or thrie beam type. Use
steel materials for the rail and rail elements meeting the steel requirements of 967-1.
536-2.2 Posts:
536-2.2.1 General: Unless the Contract Documents designate a particular type of
post, the Contractor may choose the type of post to use. Use posts of either timber, or steel, and
of the sizes and dimensions shown in the Plans. Use the particular type selected throughout a run
of rail, except where special steel posts are required.
536-2.2.2 Timber Posts: Meet the requirements of the latest edition of the
Southern Pine Inspection Bureaus Standard Grading Rules for Southern Pine Lumber, for No. 1
grade timber, and treat the posts in accordance with the requirements for posts in 955-5.3. Ensure
that penetration of preservative is in accordance with requirements for round piles and fence
posts in 955-6.2. Shape and drill the posts prior to treatment, and ensure that they do not vary
more than 1 inch from the specified length. Dress all timber posts on all four sides (S4S).
536-2.2.3 Steel Posts: Use steel posts meeting the requirements of ASTM A36
steel. Galvanize the steel posts in accordance with the requirements of ASTM A123, with
2 oz/ft2 of zinc coating. Drill the steel posts prior to galvanizing.
The Contractor may use steel guardrail posts of either a rolled section or a
welded structural shape with nominal dimensions as shown in the Design Standards.
For welded structural shapes, meet the following requirements:
(1) Ensure that the design properties of the shape meet or exceed
the design properties for a W 6 x 9 shape as contained in the AISC Manual of Steel
Construction.
(2) Weld in accordance with the requirements of ASTM A769.
(3) After cutting steel posts to length, place a weld to seal the
spaces between the web plate and flange plates.
(4) Galvanize as specified above after completing all drilling and
welding.
536-2.3 Anchor Blocks: Use anchor blocks of Class I concrete, and construct and place
them in accordance with the requirements shown in the Plans or as directed by the Engineer.
536-2.4 Offset Blocks: Use guardrail offset blocks of either timber, steel, recycled
plastic, or rubber, and of the sizes specified in the Design Standards.
Treat timber blocks in accordance with the requirements for posts in 955-5.3.
Ensure that penetration of preservative is in accordance with requirements for round piles and
fence posts in 955-6.2. For timber offset blocks, meet the requirements of the latest edition of the
Southern Pine Inspection Bureaus Standard Grading Rules for Southern Pine Lumber, for No. 1
698
grade timber. Dress all timber offset blocks on all four sides (S4S). Ensure that timber offset
blocks do not vary more than 0.25 inch from the specified length.
Use rubber or recycled plastic blocks that have a minimum Durometer hardness
of 50 (ASTM D2240), show no cracking at the end of an ozone exposure of 100 plus or minus
10 pphm for 15 hours at 100F (ASTM D1149 mounting Type A), do not exceed 15 points
change in Durometer hardness in oven ageing for 70 hours at 158F (ASTM D573), and show no
cutting or tearing under a 6,500 lb load applied through a guardrail section. Ensure that the
blocks present a neat appearance and have plane surfaces. Provide rubber or recycled plastic
blocks that are 6 inches wide, 8 inches deep and 14 inches high. Allow dimensional tolerances of
plus or minus 5/8 inch in height, plus or minus 3/8 inch in width, and plus or minus 3/8 inch in
depth.
Use recycled plastic offset blocks that meet the requirements of Section 972 and
are listed on the Qualified Products List (QPL). Manufacturers seeking evaluation of their
product shall submit an application in accordance with Section 6 and include certified test
reports from an approved independent test laboratory that shows the material meets all the
requirements of this Section and Section 972.
Use steel offset blocks that meet the requirements of 536-2.2.3.
536-2.5 Reflector Elements: Mount reflectors onto the guardrail in accordance with the
details shown in the Plans and the Design Standards. Provide reflectors that meet the
requirements of 993-3.
536-2.6 Certification: Provide the Engineer a certification from the manufacturer
confirming that all materials (timber posts, anchor and offset blocks, reflector elements, and all
other accessories) meet the requirements of this Section, Section 6 and the Design Standards.
Provide the Engineer a copy of the certification at least ten days prior to guardrail construction.
For steel rail and rail elements, provide the Engineer with a certified mill analysis
from the manufacturer meeting the requirements of Section 967.
For steel posts and steel offset blocks furnish the Engineer a certified mill
analysis from the manufacturer showing the physical and chemical properties of each heat
meeting the requirements of ASTM A36, the amount of spelter coating, and galvanization
meeting the requirements of ASTM A123.
Also furnish the Engineer a Certificate of Compliance certifying that the guardrail
system, materials and construction practices comply with applicable Design Standards and
Specifications.
Acceptance of furnished material will be based on the Certificate of Compliance,
material certification and visual inspection by the Engineer.
536-3 Setting Posts.
Set standard length posts vertically to the depth shown in the Design Standards. Set
special length posts vertically to the depth shown in the Plans. Align and realign posts as
necessary, until final acceptance. Where the posts are not set in concrete or mounted on
structures, backfill the post holes with suitable thoroughly tamped material. As an alternate
method, the Contractor may use a post-driving machine, meeting the approval of the Engineer
and capable of driving the posts without damaging them.
For guardrail post replacement, backfill and compact the existing hole prior to setting the
new post.
699
If driving timber posts, the Contractor may either block out holes in the asphalt for the
posts during the asphalt paving operation or cut holes through the asphalt mat prior to the post
installation. Blocked out holes or cut holes in the asphalt pavement shall be at least 50% larger
than the sectional area of the timber post. After completing driving of the posts patch the area of
asphalt around each post with fresh hot bituminous mixture.
If driving steel posts, drive the post directly through the asphalt mat. Fill depressions or
cracks with fresh, hot bituminous mixture in a manner meeting the approval of the Engineer.
For either timber or steel post locations, in which rock, concrete or asphalt thicker than
2 inches exist, remove such material and backfill with suitable material, thoroughly tamped as
detailed in the Design Standards.
536-4 Erection of Rail.
Erect the guardrail panels, supports, anchors, etc., as shown in the Design Standards.
536-5 Existing Guardrail.
Stockpile guardrail, so specified, within the right-of-way at a location approved by the
Engineer. Dispose of all remaining guardrail not specified for stockpiling.
536-6 Method of Measurement.
536-6.1 Guardrail: The quantity to be paid for will be the plan quantity, in feet,
constructed, in place and accepted.
The plan length of a run of guardrail will be the end to end measurement
including panels (thrie-beam, nested, and W-thrie beam transition panels) directly associated
with anchorage assemblies and guardrail transitions.
536-6.2 End Anchorage Assembly: The quantity to be paid for will be the number of
each type as designated, constructed, in place and accepted.
536-6.3 Special Guardrail Post: The quantity to be paid for will be the number of each,
constructed, in place and accepted.
The designation Special Guardrail Post will include only such posts as require
special fabrication, for installation at locations where the normal setting would conflict with
concrete structures, such as approach slabs, culvert slabs, footings, inlets, etc. Special posts,
however, will not include posts for double-face median guardrail, regardless of whether they are
embedded in or attached to concrete.
536-6.4 Bridge Anchorage Assembly: The quantity to be paid for will be the number of
each, constructed, in place and accepted.
536-6.5 Concrete Barrier Wall Anchorage Assembly: The quantity to be paid for will
be the number of each, constructed, in place and accepted.
536-6.6 Guardrail Post Replacement: The quantity to be paid for will be the number of
each, replaced.
536-6.7 Removal of Existing Guardrail: The quantity to be paid for will be the length,
in feet, measured prior to removal.
536-6.8 Other Rail:
536-6.8.1 Rub Rail: The quantity to be paid for will be the plan quantity, in feet,
constructed, in place and accepted.
536-6.8.2 Pipe Rail: The quantity to be paid for will be the plan quantity, in feet,
constructed, in place and accepted.
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536-7 Basis of Payment.
536-7.1 Guardrail: Price and payment will be full compensation for all work specified
under this Section, including furnishing and installing acrylic plastic reflectors, posts, all panels,
and all other materials as specified. Payment will be made under the items as follows:
a. Where the Contractor furnishes all materials for the guardrail, and the Engineer
does not require shop-bent rails, payment will be made under the basic item of guardrail.
b. Where the radius of the guardrail installation is such as to require shop bending
of the guardrail panels, payment will be made under the item of Guardrail (Shop-bent Panels).
536-7.2 End Anchorage Assembly: Price and payment will include furnishing and
installing all components specified in the Plans and Design Standards.
536-7.3 Special Guardrail Post: Price and payment will include all costs for furnishing
and installing the special posts that are over and above the costs for the normal posts, which are
replaced by such special posts.
536-7.4 Bridge Anchorage Assembly: Price and payment will include furnishing and
installing the special end shoes, wood blocks or retrofit wing posts, concrete anchor posts, thriebeam terminal connectors, backup plates, filler plates, and other necessary hardware.
536-7.5 Concrete Barrier Wall Anchorage Assembly: Price and payment will include
furnishing and installing connections to concrete barrier walls, as shown on the Design
Standards, Index Nos. 400 and 410.
536-7.6 Guardrail Post Replacement: Price and payment will include all labor,
materials, and equipment required for removal and disposal of existing posts in areas provided
by the Contractor, backfilling and compacting existing holes, and replacement with new posts.
536-7.7 Removal of Existing Guardrail: Price and payment will include all labor and
equipment required for removal and disposition of the existing guardrail, as specified in the
Plans. No additional payment will be made for the removal of the back rail on double face
guardrail, thrie beam guardrail, nested rail, safety pipe rail, rub rail or end anchorages.
536-7.8 Other Rail:
536-7.8.1 Rub Rail: Price and payment will include all components specified in
the Plans and Design Standards, Index No. 400.
536-7.8.2 Pipe Rail: Price and payment will include all components specified in
the Plans and Design Standards, Index No. 400.
536-7.9 Payment Items: Payment will be made under:
Item No. 536- 1Guardrail - per foot.
Item No. 536- 2Guardrail (Shop-Bent Panels) - per foot.
Item No. 536- 5Rub Rail - per foot.
Item No. 536- 6Pipe Rail - per foot.
Item No. 536- 7Special Guardrail Post - each.
Item No. 536- 8Bridge Anchorage Assembly - each.
Item No. 536- 73Removal of Existing Guardrail - per foot.
Item No. 536- 76Special Length Guardrail Post - each.
Item No. 536- 82Concrete Barrier Wall Anchorage Assembly - each.
Item No. 536- 83Guardrail Post Replacement- each.
Item No. 536- 85End Anchorage Assembly - each.
701
SECTION 538
RESETTING GUARDRAIL
538-1 Description.
Remove and reset the existing guardrail at locations shown in the Plans.
538-2 Materials.
Replace non-reusable hardware and posts as determined by the Engineer with new
materials necessary to complete the reset installation.
Provide new offset blocks for all installations.
Meet the requirements specified in 536-2.
538-3 Construction Methods.
Prevent damage to reusable hardware and posts.
Set posts in accordance with the requirements of 536-3 using a consistent type of post
throughout a run of guardrail.
Install guardrail panels, anchors, hardware, and reflector elements in accordance with the
design standards and plan details.
Reusable materials damaged during resetting operations must be replaced at no cost to
the Department.
Reset posts in a manner that prevents any subsequent settlement after the blocks and
panels are reattached.
538-4 Method of Measurement.
The quantities to be paid for will be the length, in feet, of reset guardrail; the number of
end anchorage assemblies of each type as designated; the number of special posts, and the
number of bridge anchorage assemblies; all as actually constructed and accepted.
The plan length of a run of reset guardrail will be determined as a multiple of the nominal
panel lengths except that any panel which is cut off will be field-measured.
538-5 Basis of Payment.
Prices and payments for resetting guardrail will be full compensation for all work
specified in this Section.
Price and payment for end anchorage assemblies, special guardrail posts, and bridge
anchorage assemblies will be as specified in Section 536.
Payment for new guardrail materials furnished to replace items determined to be nonreusable, excluding any items damaged by the Contractor, will be paid for at the actual invoiced
cost including transportation charges, to which cost will be added an amount equal to 25% of the
total charges.
Payment will be made under:
Item No. 538- 1Resetting Guardrail - per foot.
702
SECTION 544
CRASH CUSHIONS
544-1 Description.
Install redirective and non-redirective crash cushions (of the sizes and types designated in
the Plans. Redirective crash cushions are safety devices with capabilities to redirect the
impacting vehicle over the full length of the device. Non-redirective crash cushions allow
controlled penetration of the impacting vehicle over the full length of the device.
544-2 Qualified Products List (QPL).
Use crash cushions listed on the QPL. Manufacturers seeking evaluation of their crash
cushions shall furnish certified test reports showing that their products meet all test requirements
of NCHRP 350 or the Manual for Assessing Safety Hardware 2009 (MASH).
544-3 Construction.
Handle and install manufactured materials or articles in accordance with the
manufacturers instructions and the Design Standards.
Use crash cushions delineated with a Type I Object Marker specified in Section 705 or
sheeting in accordance with 990-2.
Perform repairs necessary due to defective material, work, or operations without
additional cost to the Department.
Restore crash cushions damaged by the traveling public after the installation is
completed, accepted and serving its intended purpose on an open section of bridge or roadway
within 24 hours.
544-4 Compensation.
Price and payment will be full compensation for the complete system or module in place
and accepted, including object marker or sheeting. Payment for restoring damaged crash
cushions will be the manufacturers/distributors invoice price for the new materials/parts plus
20% markup. The 20% markup is compensation for all necessary work, including but not limited
to labor, equipment, supplies and profit, as authorized by the Engineer.
Relocation of an existing crash cushion to a permanent location called for in the Plans
shall be paid for at the Contract unit price for relocating existing systems. Price and payment will
be full compensation for relocating and reinstalling the system in accordance with the
manufacturers instructions and the Design Standards.
Payment will be made under:
Item No. 544- 74Relocate Crash Cushion - each.
Item No. 544- 75Crash Cushion - each.
703
SECTION 546
RUMBLE STRIPS
546-1 Description.
Construct Rumble Strips in accordance with the details shown in the Plans and Design
Standards.
546-2 Materials for Raised Rumble Strips.
Construct Raised Rumble Strips using one of the following:
(a) Thermoplastic materials listed on the Qualified Products List (QPL), meeting
the requirements of 971-1 and 971-6. Ensure that the material used can be restored to its original
dimensions by using a self bonding overlay meeting these requirements. Submit a certified test
report to the Engineer indicating that the materials meet all requirements specified.
Before applying thermoplastic materials on portland cement concrete
surfaces, apply a primer sealer recommended by the manufacturer.
(b) Any plant-mixed hot bituminous mixture meeting the requirements of a jobmix formula issued by the Department, except open-graded friction course.
Prior to the application of any plant-mixed hot bituminous material, apply
a tack coat meeting the requirements of 300-2.3.
The mixture will be accepted on the basis of visual inspection by the
Engineer with no further testing required.
546-3 Application.
546-3.1 Raised Rumble Strips: Notify the Engineer before the placement of raised
rumble strips. Apply raised rumble strips having well defined edges. Remove and replace any
raised rumble strips not meeting the requirements of the Contract Documents at no additional
cost to the Department.
Before applying raised rumble strips, remove any material that would adversely
affect the bond of the raised rumble strips by a method approved by the Engineer.
Apply raised rumble strips only to dry surfaces, and only when the ambient air
and surface temperature is at least 55F and rising.
546-3.2 Ground-In Rumble Strips: Before the construction of any ground-in rumble
strips, demonstrate to the Engineer that the equipment to be used can achieve a depression
having well defined edges and a smooth interior finish without snagging or tearing the finished
pavement.
Before opening the adjacent lane to traffic, ensure that all debris generated by the
grinding process is removed and disposed of daily by vacuum or a method approved by the
Engineer. Do not dispose of the debris within the right of way. Do not use the debris generated
by the grinding process in recycled asphalt.
Restore any pavement to the satisfaction of the Engineer at no additional cost to
the Department, when ground-in rumble strips do not meet the requirements of the Contract
Documents.
546-4 Method of Measurement.
The quantity of raised rumble strips to be paid for under this Section will be the plan
quantity per set, constructed and accepted.
704
The quantity of ground-in rumble strips to be paid for under this Section will be the plan
quantity in miles, constructed and accepted. The plan quantity will be determined based on the
roadway length minus bridge lengths for each shoulder on which rumble strips are to be
constructed.
546-5 Compensation.
Prices and payments will be full compensation for all work specified in this Section,
including, all cleaning and preparing of surfaces, disposal of all debris, furnishing of all
materials, application, curing and protection of all items, protection of traffic, furnishing of all
tools, machines and equipment, and all incidentals necessary to complete the work. Final
payment will be withheld until all deficiencies are corrected.
Payment will be made under:
Item No. 546- 71Rumble Strip Sets - per set.
Item No. 546- 72Rumble Strips - per mile.
705
SECTION 548
RETAINING WALL SYSTEMS
548-1 Description.
Construct permanent and temporary retaining wall systems in accordance with this
Section and in conformance with the lines, grades, design, and dimensions shown in the Contract
Documents or established by the Engineer. Unless otherwise noted in the Plans, provide a wall
system listed on the Departments Qualified Products List (QPL) based on the FDOT Wall Type
shown in the Plans. Sheet pile walls and cast-in-place walls are not included in this Section. All
other wall systems used to cut back existing slopes are paid for under the same pay item numbers
shown in 548-12. Construct all walls of a specific type (MSE (Mechanically Stabilized Earth),
counterfort, etc.), using the same wall system and supplier. If different types of wall systems
must be used in such a manner that causes one wall to interact with or influence another wall,
coordinate the detailing of these areas of interaction/influence with the assistance of the
Contractors Engineer of Record.
Obtain each Precast Concrete Retaining Wall System from an approved incidental precast
manufacturing plant that is currently on the Departments list of Producers with Accepted
Quality Control Programs. Producers seeking inclusion on the list shall meet the requirements of
105-3.
Ensure that each wall system component is permanently and legibly marked in
accordance with 548-5.
Ensure that each shipment of products to the job site includes a signed or stamped
delivery ticket in accordance with the Materials Manual, Section 8.2 Volume II, and the required
written certification statement for each product shipped. Provide these tickets and certifications
to the Engineer.
548-2 Materials.
Purchase the precast components, soil reinforcement, attachment devices, joint filler,
filter fabric, and all necessary incidentals from the wall supplier chosen.
548-2.1 Concrete: Ensure that concrete utilized for wall components is as specified in
the Contract Documents and is consistent with the concrete class, environmental classification
and admixture requirements for durability as stated in the Contract Documents. Produce and
supply concrete for all wall components meeting the requirements of Section 346.
Produce and supply concrete for the leveling pad meeting the requirements of
Section 347. Assume responsibility for performance of all testing required by Section 346. Use
Department approved mix designs.
548-2.2 Reinforcing Steel: Meet the requirements of Section 931 utilizing Grade 60
(Black) steel.
548-2.3 Backfill Reinforcement: For walls utilizing backfill reinforcement, use
reinforcement consisting of steel wire mesh, metal strips or structural geosynthetics as required
for the wall system chosen. Use backfill reinforcement of the same length from top to bottom of
wall at any section. For tiered walls, use backfill reinforcement of the same length within the
height of each tier at any section.
Use steel wire mesh and embedded loops shop fabricated from cold drawn steel
wire meeting the minimum requirements of ASTM A82, and weld into the finished mesh fabric
in accordance with ASTM A185. Use longitudinal and transverse wires of equal and constant
706
diameter within a given piece of mesh reinforcement. Use steel strips hot rolled from bars to the
required shape and dimensions with physical and mechanical properties meeting ASTM A572
Grade 65 or as shown in the Contract Documents. Use shop-fabricated hot rolled steel tie straps
meeting the minimum requirements of ASTM A1011/A1011 M, Grade 50, or as shown in the
Contract Documents.
Ensure that steel reinforcing strips, tie strips, reinforcing mesh and connectors
used in permanent walls are galvanized in accordance with ASTM A123 or ASTM A153, as
applicable. For typical applications, punch or drill holes in metal items before galvanizing. Field
drilled holes for bin walls are permitted. Repair field drilled holes; field cut ends and other
damage to galvanized surfaces in accordance with Section 562.
Use structural geosynthetics made of polypropylene, select high density
polyethylene or high-tenacity polyester fibers having cross-sections sufficient to permit
significant mechanical interlock with the backfill. Use geosynthetics having a high tensile
modulus in relation to the backfill. Use geosynthetics having high resistance to deformation
under sustained long term design load while in service and resistant to ultraviolet degradation, to
damage under normal construction practices and to all forms of biological or chemical
degradation normally encountered in the material being reinforced. Do not use uncoated
polyester (PET) reinforcements or reinforcements weakened or damaged by high pH
environments within the flowable fill.
Store the geosynthetics in conditions above 20F and not greater than 140F.
Prevent mud, wet cement, epoxy, and like materials from coming into contact with and affixing
to the geosynthetic material. Rolled geosynthetic may be laid flat or stood on end for storage.
Cover the geosynthetic and protect from sunlight prior to placement in the wall system.
Carefully inspect all reinforcement, steel and geosynthetics to ensure they are the
proper size and free from defects that may impair their strength and durability.
548-2.4 Attachment Devices: Use backfill reinforcement attachment devices as required
by the wall system chosen.
548-2.5 Joint Materials and Filter Fabrics:
548-2.5.1 Horizontal Joint Filler: Use elastomeric or polymeric pads/fillers in
all horizontal joints between precast components as recommended by the wall manufacturer.
Ensure that the pads are of sufficient size and hardness to limit vertical stresses on the pad and
concrete surface and to prevent concrete to concrete contact at the joints.
548-2.5.2 Joint Covers: Cover joints and other wall openings with geotextile
fabric meeting the requirements of Section 985 and Type D-5, Design Standards, Index No. 199.
Apply an adhesive approved by the Engineer to the back of the precast component for
attachment of the fabric material.
548-2.5.3 Alignment Pins: Ensure that pins used to align the precast components
during construction are of the size, shape and material required for the wall system chosen.
548-2.6 Backfill Material:
548-2.6.1 General: Provide compacted select backfill or flowable fill within the
retaining wall volume when the option for flowable fill is shown in the Plans. The retaining wall
volume is defined to extend from the top of the leveling pad or footing, or bottom of walls which
do not have footing or leveling pads, to the finish grade line and from the face of the wall to a
vertical plane passing through the end of the extreme wall component (straps, counterforts, etc.)
plus 1 foot.
707
548-2.6.2 Compacted Select Backfill: Meet the requirements of Sections 105
and 120 except as noted within this Section. Have the backfill material tested for every soil type
for pH, resistivity, sulfate and chloride content by a Department approved independent testing
laboratory prior to placement. Provide certification to the Engineer that the results have met the
requirements of this Section and are signed and sealed by a Professional Engineer, registered in
the State of Florida.
For constructing the retaining wall volume, do not use backfill material
containing more than 2.0% by weight of organic material, as determined by FM 1-T 267 and by
averaging the test results for three randomly selected samples from each stratum or stockpile of a
particular material. If an individual test value of the three samples exceeds 3%, the stratum or
stockpile will not be suitable for constructing the retaining wall volume.
Ensure that the material is non-plastic as determined by AASHTO T90
and the liquid limit as determined by AASHTO T89 is less than 15. The pH, as determined by
FM 5-550, shall not be lower than 5.0 and not higher than 9.0.
Use backfill for walls using soil reinforcements that meets the following
gradation limits determined in accordance with AASHTO T27 and FM 1-T 011:
Sieve Size
3-1/2 inches
3/4 inch
No. 4
No. 40
No. 100
No. 200
Percent Passing
100
70-100
30-100
15-100
0-65
0-12
In addition, for permanent walls utilizing metallic soil reinforcement, use
backfill that meets the following electro-chemical test criteria for determining corrosiveness:
Criteria
Resistivity: > 3000 ohm -cm
Soluble sulfate content: < 200 PPM
Soluble chloride content < 100 PPM
Test Method
FM 5-551
FM 5-553
FM 5-552
For walls not using soil reinforcement, use backfill that meets the
following gradation limits determined in accordance with AASHTO T27 and FM 1-T 011:
Sieve Size
3-1/2 inches
No. 200
Percent Passing
100
0-12
548-2.6.3 Flowable Fill: Meet the requirements of Section 121 except as noted
within this Section and the Plans.
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548-3.Qualified Products List (QPL).
All proprietary retaining wall systems shall be listed on the QPL. Manufacturers seeking
evaluation of products for inclusion on the QPL shall submit an application in accordance with
Section 6, independently certified test reports, and calculations and drawings in accordance with
the latest edition of the AASHTO LRFD Bridge Design Specifications and FDOT Structures
Design Guidelines (SDG) signed and sealed by a Professional Engineer registered in the State of
Florida. Provide calculations and drawings showing details, notes, materials, dimensions, sizes,
and other information as described below for a complete description of the retaining wall system.
1. Soil Reinforcement durability and/or corrosion data;
2. Differential settlement the wall system can tolerate without exceeding normal
stress range of the soil reinforcement and wall facing, or the construction tolerances in this
Section;
3. The effects of water flow;
4. Applicable environmental classifications as outlined in the SDG;
5. Provide signed and sealed design calculations. Design calculations may be
either by hand or by a wall company program with hand calculations verifying the program
output. It is only necessary to include sample hand calculations for a 20 foot height for each soil
condition.
6. Corrosion and durability design procedures for soil reinforcement elements;
7. Provide 11 inch x17 inch drawings showing:
a. Notes specific to the wall system;
b. Panel sizes and reinforcing;
c. Soil reinforcement connection to wall facings;
d. Wall panel abutment interfacing;
e. Slip joints;
f. Steps in leveling pad;
g. Soil reinforcing details around all vertical obstructions;
h. Filter fabric placement at panel joints and around all obstructions;
i. Details for skewing soil reinforcement (15 degrees maximum) without
cutting;
j. Corner elements (required at all angle breaks greater than 5 degrees);
k. Bin wall details for acute corners (required at all acute corners where
interior corner angle is less than 70 degrees);
l. Details showing how to accommodate long term (post construction) wall
settlement in excess of 4 inches without attaching soil reinforcement to the abutment; and,
m. Details of how to ground the wall system.
8. Pull-out test data for the proposed wall/reinforcement connection, and size and
type of soil reinforcement for wall system. Testing shall be done by an independent soil testing
laboratory or testing agency certified by the Department. Ensure test data includes all sizes and
types of soil reinforcement to be utilized on Department projects. Default AASHTO values may
be used for conventional soil reinforcement. For soil reinforcement grids, include all various
configurations and combinations of longitudinal and transverse wires.
9. Other information pertinent to the design and performance of the wall system
as necessary.
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10. A field construction manual describing construction requirements and
sequencing for the wall system. Submit manual in 8.5 inch x 11 inch format in either pdf or MS
Word format.
548-4 Shop Drawings.
Provide shop drawings and calculations in accordance with Section 5. Provide
calculations and drawings showing details, notes, materials, dimensions, sizes and other
information necessary for the complete fabrication and erection of the retaining wall system. As
a minimum, provide the following:
1. Elevation view showing the final ground line and elevations of the top
and bottom of wall at the begin and end of wall, all breaks in vertical alignment and all whole
stations and 25 foot station increments.
2. Sections showing the length, size and designation of soil reinforcement.
3. Plan view showing the horizontal alignment and offsets from the
horizontal control line to the exterior face of the wall; the location of utilities, drainage structures
and other items that impact the wall; the limits of the reinforced soil volume; and, the location of
piles within the reinforced earth volume.
4. Details for construction around utilities, drainage structures and other
items that impact the wall; for placement of soil reinforcement at acute corners; for addressing
conflicts between soil reinforcement and obstructions in the reinforced soil volume; for
addressing different wall types intersecting and impacting each other.
5. General notes and design parameters including design soil
characteristics; factored bearing resistance and factored bearing pressure for each wall height
increment and other notes required for construction of the walls.
6. Design calculations for each wall height increment detailed in the shop
drawings.
548-5 Concrete Component Construction.
Construct concrete components in accordance with Section 400. Precast wall components
are produced using certification acceptance; therefore, assume responsibility for performance of
all quality control testing and inspections required by Sections 346 and 400 for the precast
component construction. Perform all Quality Control (QC) inspection and testing using
Construction Training and Qualification Program (CTQP) qualified personnel. Perform
compressive strength testing in a laboratory meeting and maintaining at all times the
qualification requirements listed in Section 105. The minimum time for form removal is
12 hours. Unless otherwise indicated in the Contract Documents, apply a Class 3 finish to the
concrete surface for the front face, and roughly screed the rear face to eliminate open pockets of
aggregate and surface distortions in excess of 1/4 inch.
548-5.1 Curing: Cure concrete components in accordance with Section 400.
548-5.2 Tolerances: Meet the following manufactured tolerances:
1. Precast Component Dimensions: Lateral position of soil reinforcement
attachment devices - within 1 inch. All other dimensions - within 3/16 inch.
2. Precast Component Squareness: Angular distortion of the component shall not
exceed 0.2 inches in 5 feet.
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3. Precast Component Surface Finish: Surface defects on smooth formed surfaces
measured on a length of 5 feet shall not exceed more than 0.1 inches. Surface defects on textured
finished surfaces measured on a length of 5 feet shall not exceed 5/16 inch.
548-5.3 Marking of Precast Components: Permanently and legibly mark the following
information on the back of each precast wall panel by etching: the panel number or type, piece
mark, project number (if applicable), date cast and precast manufacturers name or symbol with
the approved producers QC stamp affixed.
548-6 Repairs or Rejection of Precast Components.
For precast concrete wall components that have not been installed, evaluate cracks, spalls
and other deficiencies in accordance with 450-12. Repair deficiencies in accordance with 450-13
or the plants approved repair methods that are included as part of the QC Plan. Ensure that the
original performance and durability of repaired wall components are maintained. Use materials
for concrete repair that will meet or exceed the strength requirement for the class of concrete
used. Materials meeting the requirements of Section 930 may be substituted for non shrink grout
when required by 450-13.
For precast concrete wall components that have been installed, the disposition of concrete
cracks shall be in accordance with 400-21.
The Department will reject all precast concrete wall components not meeting the quality
standard of this Section and referenced Specifications. In addition, any of the following defects
will be sufficient cause for rejection by the Department:
1. Defects that indicate unsatisfactory molding.
2. Defects indicating honeycombed or open texture concrete.
3. Defects in the physical characteristics such as:
Signs of aggregate segregation;
Broken or cracked corners;
Soil reinforcement attachment devices improperly installed/damaged;
Lifting inserts not useable;
Exposed reinforcing steel;
Insufficient cover over reinforcing steel;
Cracks at the alignment pipe or pin;
Insufficient concrete compressive strength;
Precast component thickness in excess of plus or minus 3/16 inch from
that shown in the Contract Documents; or
Stained front face, due to excess form oil or other reasons.
If the face of the precast component is stained or discolored to the point of rejection, the
stain or discoloration may be removed or a Department approved stain or a Class 5 finish may be
applied to attain a uniform appearance for the entire structure, to the satisfaction of the Engineer.
548-7 Handling Storage and Shipping.
Handle, store and ship all components in a manner that prevents chipping, cracks,
fractures, excessive bending stresses, mud, dirt and debris. Support precast components in
storage on firm blocking located immediately adjacent to the attachment device.
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548-8 Construction Requirements.
548-8.1 General: Due to the unique nature of the structure and concept, procure from the
wall supplier fully detailed shop drawings, technical instructions, guidance in preconstruction
activities and on-site technical assistance during construction. Closely follow any instructions
from the wall supplier, unless otherwise directed by the Engineer. Submit a copy of any
instructions from the wall supplier to the Engineer. Verify all pertinent retaining wall
information (soil parameters, wall alignment, utility locations, conflicting structures) prior to the
wall supplier finalizing shop drawings. Bring any conflicts not shown in the Contract Documents
to the Engineers attention.
548-8.2 Wall Excavation: Excavate to the limits shown in the Contract Documents and
in conformance with Section 125.
548-8.3 Foundation Preparation: Grade the foundation for the structure level for a
width equal to or exceeding the limits of the retaining wall volume or as shown in the Contract
Documents. Prepare the foundation in conformance with Section 125.
In addition to the compaction requirements of Section 125, compact the graded
area with an appropriate vibratory roller weighing a minimum of 8 tons for at least five passes or
as directed by the Departments District Geotechnical Engineer. Remove and replace any soft or
loose foundation subsoils incapable of sustaining the required compaction to the Engineers
satisfaction.
For permanent MSE wall systems, provide an unreinforced concrete leveling pad
as shown in the Contract Documents. Cure the leveling pad a minimum of 12 hours before
placement of precast wall components.
548-8.4 Wall Erection: Assemble, connect and support wall components as
recommended by the wall supplier. As backfill material is placed behind the wall face, maintain
the wall in the vertical position or slightly battered into the backfill to provide a final vertical
alignment (by means of bracing, temporary wooden wedges placed in the joint at the junction of
the two adjacent precast components on the external side of the wall or other alignment aids).
Remove wooden wedges as soon as the precast component above the wedged precast component
is completely erected and backfilled. External bracing is required for the initial lift of MSE
systems.
Place soil reinforcement normal to the face of the wall, unless otherwise shown in
the Contract Documents or as directed by the Engineer. Do not cut or kink soil reinforcement.
Do not connect soil reinforcement to piles or allow soil reinforcement to bear against piles. Field
cut soil reinforcement only at locations as shown in the approved shop drawings. Prior to
placement of the reinforcement, compact the backfill in accordance with 548-8.5.
548-8.4.1 Tolerances for Permanent Walls: Ensure that vertical tolerances
(plumbness) and horizontal alignment tolerances do not exceed 3/4 inch when measured with a
10 foot straightedge. The maximum allowable offset in the joint between precast components is
3/4 inch. The final overall vertical tolerance of the completed wall (plumbness from top to
bottom) shall not exceed 1/2 inch per 10 feet of wall height. Horizontal and vertical joints
between precast components shall not be less than 1/2 inch or more than 1-1/4 inches. Walls
which do not meet these tolerances will not be accepted by the Department and must be removed
and reconstructed at no cost to the Department.
548-8.4.2 Tolerances for Temporary Walls: Ensure that vertical tolerances
(plumbness) and horizontal alignment tolerances do not exceed 3 inches when measured with a
10 foot straightedge. The final overall vertical tolerance of the completed wall (plumbness from
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top to bottom) shall not exceed 1 inch per 3 feet of wall height, not to exceed a total of 6 inches.
Walls which do not meet these tolerances will not be accepted by the Department and must be
removed and reconstructed at no cost to the Department.
548-8.5 Backfill Placement:
548-8.5.1 Compacted Select Backfill: Perform work in accordance with an
approved QC Plan meeting the requirements of 105-3. A LOT is defined as a single lift of
finished embankment not to exceed 500 feet in length or cumulative length of continuous,
interconnected walls. Backfill within 3 feet from the panels and backfill beyond 3 feet from the
panels are separate LOTs. Overlapping retaining wall volumes may be considered one LOT,
excluding the 3 feet width behind the panels. Strips up to 8 feet wide between two retaining wall
volumes constructed with the same material in one operation may be considered as one LOT
with the retaining wall volumes. Isolated compaction operations will be considered as separate
LOTs. For multiple phase construction, a LOT will not extend beyond the limits of the phase.
Place the backfill closely following the erection of each course of precast
components or soil reinforcement layers and spread by moving the machinery parallel to the wall
face. Do not allow equipment heavier than 8 tons closer than 3 feet behind the wall face. Place
backfill in a manner to avoid any damage or disturbance to the wall materials or misalignment of
the facing materials. Remove and replace any wall materials which become damaged or
disturbed during backfill placement at no cost to the Department, or correct as directed by the
Engineer. Remove and reconstruct any misalignment or distortion of the wall facing due to
placement of backfill outside the limits of this specification at no cost to the Department.
Sheepfoot, grid rollers or other types of equipment employing a foot are
not allowed. Achieve compaction within 3 feet of the back of the wall face using a power
operated roller or plate weighing less than 1,000 pounds. At a distance greater than 3 feet from
the back of the wall, a vibratory roller may be used, provided that the frequency and amplitude
combined with bulk weight of the roller has performed satisfactorily at a trial section of the same
type of wall. A smooth wheel or rubber tire roller is considered adequate. Ensure that the
maximum lift thickness after compaction does not exceed 6 inches. Decrease the lift thickness if
necessary, to obtain specified density.
Perform backfill compaction in a way that the compactor moves in a
direction parallel to the wall face and proceeds from a distance not less than 3 feet behind the
wall face toward the end of the soil reinforcement element.
Ensure that the moisture content of the backfill material prior to and
during compaction is uniformly distributed throughout each layer of material. Use backfill
material having a placement moisture content at the dry side of the optimum moisture content.
To achieve the required compaction moisture content, use water that meets the requirements of
Section 923. Do not use saltwater. Do not transport excessively moist backfill materials to the
site for any reason. The Engineer will determine the optimum moisture content in accordance
with FM 5-521.
At the end of each days operation, shape the last level of backfill to
permit runoff of rainwater away from the wall face or provide a positive means of controlling
run off away from the wall such as temporary pipe, etc.
548-8.5.2 Flowable Fill: Perform work in accordance with an approved QC Plan
meeting the requirements of 105-3. Metallic wall components (including metallic soil
reinforcements) must not be in partial contact with the flowable fill. If the metallic components
contact the flowable fill, the metallic components must be completely encapsulated by the
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flowable fill.
548-9 Acceptance Program.
548-9.1 General Requirements: Meet the requirements of 120-10 except delete the
requirement of 120-10.1.4.1, 120-10.1.4.3, 120-10.2 and 120-10.3.
548-9.2 Maximum Density Determination: Determine the maximum QC density in
accordance with FM 1 T-180. Determine the maximum density in accordance with
AASHTO T99, Method C.
Perform gradation tests on the sample collected in accordance with AASHTO T27
and FM 1-T 011. Classify soils in accordance with AASHTO M145 in order to determine
compliance with embankment utilization requirements.
548-9.3 Density Testing Requirements: Ensure compliance with the requirements of
nuclear density testing in accordance with FM 1-T 238. Determine the in-place moisture content
for each density test. Use FM 1-T 238, FM 5-507 (Determination of Moisture Content by Means
of a Calcium Carbide Gas Pressure Moisture Tester), or FM 5-535 (Laboratory Determination of
Moisture Content of Granular Soils by Use of a Microwave Oven) for moisture determination.
Perform these tests at a minimum frequency of one set of tests per LOT.
Determine test locations including stations and offsets, using the random number
generator provided by the Engineer. Do not use note pads or work sheets to record data for later
transfer to the density log book. Notify the Engineer upon successful completion of QC testing
on each LOT.
548-9.4 Acceptance Criteria: Obtain a minimum density of 90% of the maximum dry
density as determined by FM 1 T-180 within 3 feet behind the wall face and obtain a minimum
density of 95% of the maximum dry density as determined by FM 1 T-180 from beyond 3 feet
behind the wall face.
548-9.4.1 Optional Acceptance Criteria for A-3 and A-2-4 Materials: Obtain a
minimum density of 95% of the maximum dry density as determined by AASHTO T99 within
3 feet behind the wall face and obtain a minimum density of 100% of the maximum dry density
as determined by AASHTO T99 beyond 3 feet behind the wall face.
The combined width from both MSE wall backfill (excluding the 3 feet
zone from the panels) and embankment material may be considered the same LOT if the same
material is used; the material in both wall backfill and embankment is compacted with the same
procedure, equipment and compacting effort; and the maximum lift thickness after compaction in
both wall backfill and embankment is 6 inches.
548-9.5 Frequency: Conduct sampling and testing at a minimum frequency listed in the
table below. The Engineer will perform verification sampling and tests at a minimum frequency
listed in the table below.
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Test Name
Maximum Density
Quality Control (QC)
One per soil type
Verification
One per soil type
One set of tests per four LOTs for each
type of QC test.
Density
One set of tests per LOT
Gradation
One per Maximum Density
One per Maximum Density
LL&PI
One per Maximum Density
One per Maximum Density
Soil Classification
One per Maximum Density
One per Maximum Density
Organic Content
One per soil type
One per soil type
In addition, for permanent walls utilizing metallic soil reinforcement, test for
corrosiveness at a minimum frequency of one test per soil type at point of placement according
to the electro-chemical table in 548-2.6. The Engineer will collect enough material to split and
create two separate samples and retain one for resolution at point of placement until LOTs
represented by the samples are accepted. The Engineer will perform verification tests for
corrosiveness at a minimum frequency of one test per soil type.
548-9.6 Verification Comparison Criteria and Resolution Procedures:
548-9.6.1 Maximum Density Determination: The Engineer will collect enough
material to split and create two separate samples and retain one for resolution until LOTs
represented by the samples are accepted.
The Engineer will meet the requirements of 120-10.4.1 except replace
AASHTO T99, Method C with FM 1-T 180, Method D. If the Contractor selects the Optional
Acceptance Criteria, the Engineer will verify the QC results of AASHTO T99, Method C in
accordance with 120-10.4.1.
548-9.6.2 Density Testing: Meet the requirements of 120-10.4.2.
548-9.6.3 Soil Classification: The Engineer will meet the requirements of
120-10.4.3 except test the sample retained in 548-9.6.1 instead of taking the additional one.
548-9.6.4 Gradation: The Engineer will verify the QC results if the verification
result meets the gradation limits set forth in the gradation table of 548-2.6. Otherwise, the
Engineer will test the sample retained in 548-9.6.1. The State Materials Office or an AASHTO
accredited laboratory designated by the State Materials Office will perform resolution testing.
The material will be sampled and tested in accordance with AASHTO T27 and FM 1-T 011.
If the resolution test result satisfies the required gradation limits, the
LOTS will be verified. If the resolution test results do not meet the required gradation limits,
reconstruct the LOTS with acceptable material. The Engineer will perform new verification
testing.
548-9.6.5 Liquid Limit and Plasticity Index (LL&PI): The Engineer will verify
the QC results if the verification result satisfies the plasticity index and liquid limit criteria set
forth in 548-2.6. Otherwise, the Engineer will test the sample retained in 548-9.6.1. The State
Materials Office or an AASHTO accredited laboratory designated by the State Materials Office
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will perform resolution testing. The material will be sampled and tested in accordance with
AASHTO T90 and AASHTO T89, respectively.
If the resolution test result satisfies the required criteria, LOTS of that soil
type will be verified. If the resolution test results do not meet the required criteria, reconstruct
the corresponding LOTS with acceptable material. The Engineer will perform new verification
testing.
548-9.6.6 Corrosiveness: The Engineer will verify the QC results if the
verification result satisfies the electro-chemical test criteria set forth in 548-2.6. Otherwise, the
Engineer will test the sample retained in 548-9.5. The State Materials Office or an AASHTO
accredited laboratory designated by the State Materials Office will perform resolution testing.
The material will be sampled and tested in accordance with FM 5-550, FM 5-551, FM 5-552 and
FM 5-553.
If the resolution test result satisfies the required criteria, material of that
soil type will be verified and accepted. If the resolution test results do not meet the required
criteria, reject the material and reconstruct with acceptable material.
548-9.6.7 Organic Content: The Engineer will verify the QC results if the
verification result satisfies the organic content test criteria set forth in 548-2.6. Otherwise, the
Engineer will collect three additional samples. The material will be sampled and tested in
accordance with FM 1-T 267 and by averaging the test results for three randomly selected
samples from at least one lift per soil type. The State Materials Office or an AASHTO accredited
laboratory designated by the State Materials Office will perform resolution testing.
If the resolution test result satisfies the required criteria, material of that soil type
will be verified and accepted. If the resolution test results do not meet the required criteria, reject
the material and reconstruct with acceptable material.
548-10 Certification.
Furnish a copy of all test reports which are necessary to document compliance with the
Specifications, at least ten days prior to wall construction.
Also furnish the Engineer a certificate of compliance certifying that the retaining wall
materials, backfill and construction practices comply with this Section.
Acceptance of furnished material will be based on the certificate of compliance,
accompanying test reports, and visual inspection by the Engineer.
548-11 Method of Measurement.
The quantity to be paid for will be the plan quantity, in square feet, completed and
accepted, of the area bounded by the following:
For permanent retaining wall systems: the top of the coping, the top of the
leveling pad or top of structural footings and the begin and end wall limits as shown on the wall
control drawings.
For temporary retaining wall systems: the top of wall, the ground line and the
begin and end wall limits as shown on the wall control drawings.
548-12 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including the design of the wall system, excavation required specifically for wall construction
below the normal roadway template, backfill reinforcement, leveling pad, footings, copings, light
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pole pedestals, fabric material, horizontal joint materials, alignment pins, repairs, labor,
equipment, and other materials necessary to complete the wall in an acceptable manner as shown
on the Contract drawings. The cost of backfill for the normal roadway template will be included
in the cost of embankment or borrow excavation, as applicable.
Payment will be made under:
Item No. 548-12Retaining Wall System (Permanent) - per square foot.
Item No. 548-13Retaining Wall System (Temporary) - per square foot.
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SECTION 550
FENCING
550-1 Description.
Furnish, erect and reset metal fence of the type and at the locations shown in the Plans.
550-2 Types of Fence.
The types of fence are designated as follows:
Type A (Farm Fence).
Type B (Chain-Link Fence).
Type R (Chain-Link Fence for Pedestrian Overpass).
550-3 Materials.
550-3.1 Type A Fence (Farm Fence): Meet the requirements of Section 954 for timber
posts and braces. For metal posts and braces, and for recycled plastic fence posts, meet the
requirements of the Design Standards.
For the fabric and all other accessories, meet the requirements of the Design
Standards.
550-3.2 Type B Fence (Chain-Link): For the posts, braces, fabric and all accessories
other than the concrete for bases, meet the requirements of the Design Standards.
Use concrete as specified in Section 347, or a premix approved by the Engineer
for bases. The requirements contained in 347-2.2, and 347-3 will not apply.
550-3.3 Type R Fence (Chain-Link for Pedestrian Overpass): Use the fabric and
accessories specified in the Plans.
550-3.4 Resetting Fence: Use material from the existing fence. For any additional
materials required, provide the same type of material as in the existing fence and as specified
herein, including gates when applicable.
550-3.5 Optional Use of Materials: For Type A Fence, a combination of steel,
aluminum, timber, recycled plastic or concrete posts may be used. Unless otherwise called for in
the Plans, line posts of one material may be used with corner, pull and end post assemblies of a
different material. The Engineer will permit the use of line posts of only one optional material
and pull posts assemblies of only one optional material between corner and end post assemblies.
Within individual corner and end post assemblies, the Engineer will allow the use of only one
optional material.
For Type B Fence, a combination of zinc-coated steel fence members, aluminum
coated fence members and aluminum alloy fence members may be used. Unless otherwise
indicated in the Plans, the Engineer will allow the use of only one type of fabric material, one
type of line post material and one type of pull assembly material between corner and end post
assemblies.
550-3.6 Certification: Provide the Engineer with certified test reports from the
manufacturer confirming that all materials (posts, braces, fabric and all other accessories)
conform to the requirements of this Section, Section 6 and the Design Standards. Provide the
Engineer a copy of the certification at least ten days prior to fence construction.
Also furnish the Engineer a Certificate of Compliance certifying that the fencing
system, materials and construction practices comply with the applicable Design Standards and
Specifications.
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Acceptance of furnished material will be based on the Certificate of Compliance,
accompanying test reports and visual inspection by the Engineer.
550-4 Construction Methods.
550-4.1 General: Install the fence in accordance with the specific requirements of this
Article and with the details shown on the Design Standards for the particular type of fence called
for, except for Type R Fence which shall be detailed in the Plans. Construct the fence in close
proximity to the right of way line except as otherwise detailed in the Plans. Assume
responsibility for obtaining satisfactory permits or permission from property owners for any
encroachments required to perform the work, and for proper scheduling of the fence installation
with the removal of existing fence where it is necessary to provide continuous security to
adjacent areas already fenced. In order to meet this requirement, where necessary for
maintaining security of livestock on adjacent property during construction of the new fence, the
Engineer may require the erection and subsequent removal of temporary fencing.
550-4.2 Spacing of Posts: Space posts as shown in the Design Standards, within a
tolerance of 12 inches, except where definite spotting of corner posts is required. Ensure that in
any line of fence, the over-spacings and the under-spacings shall approximately compensate. Set
additional line posts at abrupt changes in grade.
550-4.3 Clearing: Where the clearing and grubbing for the project includes the area
occupied by the fence, clear the area to the limits shown in the Plans. If the limits are not shown
in the Plans, clear the area at least 2 feet wide on each side of the fence line. The Engineer may
direct that desirable trees be left in place and may restrict clearing where permission from the
property owners cannot be obtained.
550-4.4 Construction Over Irregular Terrain and Other Obstructions:
550-4.4.1 Clearance of Bottom of Fence: Install the fence such that the bottom
of the fence, in general, follows the contour of the ground. The fence is detailed in the Plans at
approximately 3 inches above ground line. Over irregular ground, however, the Engineer will
permit a minimum clearance of 1 inch and a maximum of 6 inches for a length not to exceed
8 feet, and, for Type A fence, with the barbed wire spaced midway between ground and bottom
of fabric.
550-4.4.2 Grading: Where necessary to secure proper vertical alignment and to
meet the clearance requirements, fill depressions (except where filling would obstruct proper
drainage) and cut down knolls and ridges. Provide a substantial and permanent foundation for
the fence.
550-4.4.3 Use of Extra-Length Posts. At locations where it is impracticable to
adjust the ground level, the Engineer may require that posts of additional length be set and that
the opening at the bottom be closed by additional barbed wire, stretched taut between poles, with
no vertical distance between wires greater than 3 inches. For all such posts requiring a concrete
base, extend the concrete downward to the bottom of the extra-length post.
550-4.5 Setting Posts: If rock occurs within the required depth of the post hole, or
pavement which is to remain in place exists at the location of a post, drill a hole of a diameter
slightly larger than the greatest dimension of the post or footing and grout in the post or footing.
Set timber posts either by digging or by driving. Set recycled plastic fence posts in accordance
with the Design Standards.
550-4.6 Placing Fabric: Do not place fabric and barbed wire until the posts have been
permanently positioned and concrete foundations have attained adequate strength. Place the
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fabric by securing one end and applying sufficient tension to remove all slack before making
permanent attachments at intermediate points. Fasten the fabric to all end, corner and pull posts
by approved means. Fasten the fabric using tools designed for the purpose, in accordance with
the manufacturers recommendations. Apply the tension for stretching by mechanical fence
stretchers or with single-wire stretchers designed for the purpose.
550-4.7 Electrical Grounds: Wherever a power line passes over the fence, install a
ground directly below the point of crossing. Install a ground rod consisting of a galvanized rod
with connection of similar metal if required, or of other appropriate material, 8 feet in length and
at least 5/8 inch in diameter. Drive the rod vertically until the top of the rod is approximately
6 inches below the ground surface. Use a No. 6 conductor to connect the rod and all fence
elements. Connect the conductor to each fence element and the ground rod by means of noncorrosive electrical-type clamps.
550-5 Method of Measurement.
550-5.1 General: The quantities to be paid for will be plan quantity for the number of
gates and the length of each type of fence constructed and accepted. In addition, extra payment
will be made, in accordance with 550-6.2, for additional lengths of post approved by the
Engineer for the crossing of depressions in accordance with 550-4.4.3, muck areas, or other areas
of inadequate support for a post of standard length.
550-5.2 Measurement of Fence Length, and Payment: The length of fence to be paid
for will be plan quantity completed and accepted. Measurement for resetting fence will be the
actual length of existing fence reset, including gates when applicable.
550-6 Basis of Payment.
550-6.1 Basic Items of Fencing: The Contract unit price per foot for the item of fencing,
will be full compensation for all work and materials necessary for the complete installation,
including line posts, corner, end, and pull posts. Such price and payment will include, but not be
limited to, the following specific incidental work.
(a) Any work required to level and prepare the terrain along the line of the fence.
(b) Any additional clearing incidental to construction of the fence.
(c) All preparation for post holes, in whatever type of material, as specified
herein.
(d) Any furnishing and installing of electrical grounds.
(e) Any additional work or materials required for special construction over
irregular terrain, or terrain of inadequate support for the posts, including the additional barbed
wire, but not including the extra lengths of posts ordered by the Engineer.
(f) Any cost of erection and removal of any temporary fencing, which may be
necessary for maintaining security of livestock, etc., on adjacent property during construction of
the new fence.
550-6.2 Payment Rates for Extra-Length Posts: Any extra length posts added to
complete installation of the fence will require an invoice. The Contractor will be compensated
for invoice price plus 10% as payment for any extra length posts.
The standard length of steel, recycled plastic and aluminum posts will be the
required length as indicated in the Plans or Design Standards for each type and case.
The payment for additional length of post will include the cost of additional
concrete to extend concrete bases, as applicable.
720
550-6.3 Gate Payment: The quantities to be paid for will be full compensation for all
labor, materials, posts, and associated hardware for the complete installation of the type gate
specified in the Plans, and accepted by the Engineer.
550-6.4 Payment Items: Payment shall be made under:
Item No. 550- 10Fencing - per foot.
Item No. 550- 60Gates - each.
721
SECTION 555
DIRECTIONAL BORE
555-1 Description.
555-1.1 Scope of Work: The work specified in this Section documents the approved
construction methods, procedures and materials for Directional Boring, also commonly called
Horizontal Directional Drilling (HDD).
555-1.2 General: HDD is a trenchless method for installing a product that serves as a
carrier pipe for transporting solids, liquids or gasses (under pressure or gravity flow), or serves as
a conduit, casing, or duct for a carrier pipe, cable, or wire line products. It is a multi-stage
process consisting of site preparation and restoration, equipment setup, and drilling a pilot bore
along a predetermined path and then pulling the product back through the drilled space. When
necessary, enlargement of the pilot bore hole may be necessary to accommodate a product larger
than the pilot bore hole size. This process is referred to as back reaming and is done at the same
time the product is being pulled back through the pilot bore hole.
Accomplish alignment of the bore by proper orientation of the drill bit head as it
is being pushed into the ground by a hydraulic jack and determine orientation and tracking of the
drill bit. In order to minimize friction and prevent collapse of the bore hole, introduce a soil
stabilizing agent (drilling fluid) into the annular bore space from the trailing end of the drill bit.
Select or design drilling fluids for the site specific soil and ground water
conditions. Confine free flowing (escaping) slurry or drilling fluids at the ground surface during
pull back or drilling. Remove all residual slurry from the surface and restore the site to
preconstruction conditions.
555-2 Materials.
555-2.1 General: Materials are defined as carrier pipe or conduit, casing, or duct that
becomes the installed product. Incidental materials that may or may not be used to install the
product depending on field requirements are not paid for separately and will be included in the
cost of the installed product. Plastic pipe sections are to be butt fused. Metal pipe sections are to
be butt welded. Restrained joint connectors (external connectors, bell and spigot and any joint
that overlaps a portion of the product to be installed) are to be installed according to the
manufacturers specifications and instructions.
555-2.2 Material Type: The following material standards are to be interpreted as the
minimum in place standards. Use materials that are appropriate for the stresses generated by the
selected equipment and field conditions. It is not intended to portray that the use of materials
with these minimum material standards will retain their required properties if the stress limits are
exceeded for which they were designed during installation. Ensure that the appropriate material
is used to retain compliance once it is installed.
Material Type
Polyethylene (PE)
Material Standards for HDD Installation
Non-Pressure
ASTM D3350
ASTM F714
722
Pressure
ASTM D 2513
ASTM D3350
ASTM F714
Material Standards for HDD Installation
High Density Polyethylene
(HDPE)
ASTM D3350
ASTM F714
Polyvinyl-Chloride (PVC)
ASTM D4396
ASTM D1784
Steel
ASTM A 139 Grade B (1)
ASTM D3350
ASTM F714
ASTM D2513
ASTM D1784
AWWA C900
AWWA C905
AWWA C605
AWWA C200
API 2B(2)
(1)
No hydrostatic test required
Dimensional tolerances only
(2)
555-3 Construction Site Requirements.
555-3.1 Pedestrian Traffic: When and where installations temporarily disrupt use of a
pedestrian way, provide a safe alternate route in accordance with the Design Standards, Index
Nos. 600 and 660.
555-3.2 Site Conditions:
(a) Carry out excavation for entry, exit, recovery pits, slurry sump pits, or any
other excavation as specified in Section 120. Sump pits are required to contain drilling fluids if
vacuum devices are not operated throughout the drilling operation, unless approved by the
Engineer.
(b) Within 48 hours of completing installation of the product, clean the work site
of all excess slurry or spoils. Take responsibility for the removal and final disposition of excess
slurry or spoils. Ensure that the work site is restored to pre-construction conditions or as
identified in the Plans.
(c) Provide MOT in accordance with the Design Standards and the MUTCD when
and where the former is silent.
(d) Exposure of product shall be limited to 3 feet and 14 consecutive days unless
approved by the Engineer.
555-3.3 Damage Restoration: Take responsibility for restoration for any damage caused
by heaving, settlement, separation of pavement, escaping drilling fluid (frac-out), or the
directional drilling operation, at no cost to the Department.
555-3.3.1 Remediation Plans: When required by the Engineer, provide detailed
plans which show how damage to any roadway facility will be remedied. These details will
become part of the As-Built Plans Package. Remediation plans must follow the same guidelines
for development and presentation of the As-Built Plans. When remediation plans are required,
they must be approved by the Engineer before any work proceeds.
555-4 Quality Control.
555-4.1 General: Take control of the operation at all times. Have a representative who is
thoroughly knowledgeable of the equipment, boring and Department procedures, present at the
job site during the entire installation and available to address immediate concerns and emergency
operations. Notify the Engineer 48 hours in advance of starting work. Do not begin installation
until the Engineer is present at the job site and agrees that proper preparations have been made.
723
555-4.1.1 Product Testing: When there is any indication that the installed
product has sustained damage and may leak, stop all work, notify the Engineer and investigate
the damage. The Engineer may require a pressure test and reserves the right to be present during
the test. Perform pressure test within 24 hours, unless otherwise approved by the Engineer.
Furnish a copy of test results to the Engineer for review and approval. The Engineer is allowed
up to 72 hours to approve or determine if the product installation is not in compliance with the
specifications. The Engineer may require non-compliant installations to be filled with
excavatable flowable fill.
555-4.1.2 Testing Methods: Testing may consist of one of the following methods
and must always meet or exceed the Departments testing requirements:
(a) Follow the product manufacturers pressure testing recommendations.
(b) Ensure carrier pipes installed without a casing meet the pressure
requirements set by the owner. If the owner does not require pressure testing, the Engineer may
require at least one test.
(c) A water tight pipe and joint configuration where the product is
installed beneath any pavement (including sidewalk) and front shoulders is required. The
Engineer will determine when and where water tight joint requirements will be applied to the
ultimate roadway section for future widening. When a product is located elsewhere, the pipe and
joint configuration must meet or exceed soil tight joint requirements. Conduct tests for joint
integrity for one hour. The test for a soil tight joint allows up to 0.1 gallon of water leakage at a
sustained pressure of 2 PSI. The water tight joint criteria allows no leakage at all for a sustained
pressure of 5 PSI.
555-4.1.3 Failed Bore Path: If conditions warrant removal of any materials
installed in a failed bore path, as determined by the Engineer, it will be at no cost to the
Department. Promptly fill all voids with excavatable flowable fill.
555-4.2 Product Locating and Tracking: The method of locating and tracking the drill
head during the pilot bore will be shown in the Plans. The Department recognizes walkover, wire
line, and wire line with surface grid verification, or any other system as approved by the
Engineer, as the accepted methods of tracking directional bores. Use a locating and tracking
system capable of ensuring the proposed installation is installed as intended. If an area of radio
signal interference is expected to exceed 5 feet, the Engineer may specify the use of a suitable
tracking system. The locating and tracking system must provide information on:
(a) Clock and pitch information
(b) Depth
(c) Transmitter temperature
(d) Battery status
(e) Position (x, y)
(f) Azimuth, where direct overhead readings (walkover) are not possible (i.e.
subaqueous or limited access transportation facility)
(g) Ensure proper calibration of all equipment before commencing directional
drilling operation.
(h) Take and record alignment readings or plot points such that elevations on top
of and offset dimensions from the center of the product to a permanent fixed feature are
provided. Such permanent fixed feature must have prior approval of the Engineer. Provide
elevations and dimensions at all bore alignment corrections (vertical and horizontal) with a
minimum distance between points of 100 feet. Provide a sufficient number of elevations and
724
offset distances to accurately plot the vertical and horizontal alignment of the installed product.
A minimum of three elevation and plot points are required.
Install all facilities such that their location can be readily determined by electronic
designation after installation. For non-conductive installations, attach a minimum of two separate
and continuous conductive tracking (tone wire) materials, either externally, internally or integral
with the product. Use either a continuous green sheathed solid conductor copper wire line
(minimum #12 AWG for external placement with the carrier pipes or minimum #14 AWG for
internal placement in the conduit, casing or duct) or a coated conductive tape. Conductors must
be located on opposite sides when installed externally. Connect any break in the conductor line
before construction with an electrical clamp, or solder, and coat the connection with a rubber or
plastic insulator to maintain the integrity of the connection from corrosion. Clamp connections
must be made of brass or copper and of the butt end type with wires secured by compression.
Soldered connections must be made by tight spiral winding of each wire around the other with a
finished length minimum of 3 inches overlap. Tracking conductors must extend 2 feet beyond
bore termini. Test conductors for continuity. Each conductor that passes must be identified as
such by removing the last 6 inches of the sheath. No deductions are allowed for failed tracking
conductors. Failed conductor ends must be wound into a small coil and left attached for future
use.
555-4.3 Product Bore Hole Diameter: Minimize potential damage from soil
displacement/settlement by limiting the ratio of the bore hole to the product size. The size of the
back reamer bit or pilot bit, if no back reaming is required, will be limited relative to the product
diameter to be installed as follows:
Maximum Pilot or Back-Reamer Bit Diameter When Rotated 360 Degrees
Outside Pipe Diameter Inches*
Maximum Bit Diameter Inches
<8
Diameter + 4
8 to 24
1.5 x Diameter
>24
Diameter + 12
*Use manufacturers recommendation for pipe with restrained joints.
555-4.4 Drilling Fluids: Use a mixture of bentonite clay or other approved stabilizing
agent mixed with potable water with a minimum pH of 6.0 to create the drilling fluid for
lubrication and soil stabilization. Do not use any other chemicals or polymer surfactants in the
drilling fluid without written consent from the Engineer. Certify to the Engineer in writing that
any chemicals to be added are environmentally safe and not harmful or corrosive to the facility.
Identify the source of water for mixing the drilling fluid. Any water source used other than a
potable water source may require a pH test.
555-4.5 Equipment Requirements: Ensure that appropriate equipment is provided to
facilitate the installation as follows:
System
Description
Maxi-HDD
Midi-HDD
Pipe
(1)
Diameter
Inches
18
and greater
Up to 16
HDD Equipment
Bore Length
Feet
Torque
Ft-Lbs
Trust/Pullback
Lbs
>1,000
>10,000
>70,000
Up to 1,000
1,900 to 9,999
20,001 to 69,999
725
System
Description
Mini-HDD
Pipe
(1)
Diameter
Inches
Up to 6
HDD Equipment
Bore Length
Feet
Up to 600
Torque
Ft-Lbs
Up to 1,899
Trust/Pullback
Lbs
Up to 20,000
(1)
For the above, multiple pipe or conduit installations must not exceed the total outside pipe diameters stated above (not coupler
diameter if using pipe with restrained joints).
Match equipment to the size of pipe being installed. Obtain the Engineers
approval for installations differing from the above chart. Ensure that the drill rod can meet the
bend radius required for the proposed installation.
555-4.6 Thrust/Pullback Requirements: Unless approved by the Engineer, limit use of
HDD equipment to installing the following product sizes and lengths based on the following
product size, force and length relationships.
Lbs
Product
Size (1)
Inches
4
or <
6
or <
8
or <
10
or <
12 [300]
or <
HDD Bore Equipment Thrust/Pullback Capacity
5,000 to
7,001 to
12,001 to
16,001 to
25,001 to
7,000
12,000
16,000
25,000
40,000
>40,000
Maximum Pullback Distance In Feet
400
or <
600
or <
800
or <
1,000
or <
2,000
or <
Engineers
Discretion
> 12 [300]
(1)
for the above, where a single pull of multiple conduits is to be attempted, the applicable product size must be determined by
the diameter of a circle that will circumscribe the individual conduits as a group.
555-5 Drilling Operations:
555-5.1 Installation Process: Ensure adequate removal of soil cuttings and stability of
the bore hole by monitoring the drilling fluids such as the pumping rate, pressures, viscosity and
density during the pilot bore, back reaming and pipe installation. Relief holes can be used as
necessary to relieve excess pressure down hole. Obtain the Engineers approval of the location
and all conditions necessary to construct relief holes to ensure the proper disposition of drilling
fluids is maintained and unnecessary inconvenience is minimized to other facility users.
To minimize heaving during pull back, the pull back rate is determined in order to
maximize the removal of soil cuttings without building excess down hole pressure. Contain
excess drilling fluids at entry and exit points until they are recycled or removed from the site or
vacuumed during drilling operations. Ensure that entry and exit pits are of sufficient size to
contain the expected return of drilling fluids and soil cuttings.
726
Ensure that all drilling fluids are disposed of or recycled in a manner acceptable to
the appropriate local, state, or federal regulatory agencies. When drilling in suspected
contaminated ground, test the drilling fluid for contamination and appropriately dispose of it.
Remove any excess material upon completion of the bore. If in the drilling process it becomes
evident that the soil is contaminated, contact the Engineer immediately. Do not continue drilling
without the Engineers approval.
When conditions warrant, as determined by the Engineer, back reaming for
enlarging the bore diameter shall be accomplished by connecting the reamer to trailing drill
stems at the exit pit of the pilot bore. The drill pipe shall remain in the bore hole until the final
product is pulled into place. After the pilot bore is established, do not push anything from the
entry pit to the exit pit.
The timing of all boring processes is critical. Install a product into a bore hole
within the same day that the pre-bore is completed to ensure necessary support exists.
555-5.2 Boring Failure: If an obstruction is encountered during boring which prevents
completion of the installation in accordance with the design location and specification, the pipe
may be taken out of service and left in place at the discretion of the Engineer. Immediately fill
the product left in place with excavatable flowable fill. Submit a new installation procedure and
revised plans to the Engineer for approval before resuming work at another location. If, during
construction, damage is observed to the FDOT facility, cease all work until resolution to
minimize further damage and a plan of action for restoration is obtained and approved by the
Engineer.
555-6 Documentation Requirements.
555-6.1 Boring Path Report: Furnish a Bore Path Report to the Engineer within seven
days of the completion of each bore path. Include the following in the report:
(a) Location of project and financial project number including the Permit Number
when assigned
(b) Name of person collecting data, including title, position and company name
(c) Investigation site location (Contract Plans station number or reference to a
permanent structure within the project right of way)
(d) Identification of the detection method used
(e) Elevations and offset dimensions as required in 555-4.2
555-6.2 As-Built Plans: Provide the Engineer a complete set of As-Built Plans showing
all bores (successful and failed) within 30 calendar days of completing the work. Ensure that the
plans are dimensionally correct copies of the Contract Plans and include roadway plan and
profile, cross-section, boring location and subsurface conditions as directed by the Engineer. The
plans must show appropriate elevations and be referenced to a Department Bench Mark when
associated with a Department project, otherwise to a U.S. Geological Survey (USGS) grid
system and datum, or a specific location on top of an existing Department head wall. Plans must
be same scale in black ink on white paper, of the same size and weight as the Contract Plans.
Submittal of electronic plans data in lieu of hard copy plans is preferred and may be approved by
the Engineer if compatible with the Department software. Specific plans content requirements
include but may not be limited to the following:
(a) The Contract plan view shows the center line location of each facility
installed, or installed and placed out of service, to an accuracy of 1 inch at the ends and other
points physically observed in accordance with the bore path report.
727
(b) As directed by the Engineer, provide either a profile plan for each bore path,
or a cross-section of the roadway at a station specified by the Engineer, or a roadway centerline
profile. Show the ground or pavement surface and crown elevation of each facility installed, or
installed and placed out of service, to an accuracy within 1 inch at the ends and other exposed
locations. On profile plans for bore paths crossing the roadway show stationing of the crossing
on the Contract Plans. On the profile plans for the bore paths paralleling the roadway, show the
Contract Plans stationing. If the profile plan for the bore path is not made on a copy of one of the
Contract profile or cross-section sheets, use a 10 to 1 vertical exaggeration.
(c) If, during boring, an obstruction is encountered which prevents completion of
the installation in accordance with the design location and specification, and the product is left in
place and taken out of service, show the failed bore path along with the final bore path in the
Plans. Note the failed bore path as Failed Bore Path - Taken Out of Service. Also show the
name of the Utility owner, location and length of the drill head and any drill stems not removed
from the bore path.
(d) Show the top elevation, diameter and material type of all utilities encountered
and physically observed during the subsoil investigation. For all other obstructions encountered
during a subsoil investigation or the installation, show the type of material, horizontal and
vertical location, top and lowest elevation observed, and note if the obstruction continues below
the lowest point observed.
(e) Include bore notes on each plan stating the final bore path diameter, product
diameter, drilling fluid composition, composition of any other materials used to fill the annular
void between the bore path and the product, or facility placed out of service. Note if the product
is a casing as well as the size and type of carrier pipes placed within the casing as part of the
Contract work.
555-7 Method of Measurement.
The method of measurement will be based on the length of product measured in place
along the surface of the ground, complete and accepted. No additions or deductions will be made
for sweeps in either the vertical or horizontal direction to complete the installation.
555-8 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including furnishing and installing product, from plan point of beginning to plan point of ending
at plan depth, removal of excavated materials and spoils, removal and disposal of drilling fluids,
backfilling, and complete restoration of the site. Bundled product in a single bore will be paid for
as a single bore based on the equivalent outside pipe diameter (not restrained joint diameter).
Separate payment shall not be made for individual products in a bundle.
The cost to populate the installed product (such as wires, pipes or carriers in
conduit/casing/ducts) will be made under a separate pay item.
The installation and attachment of tracking conductors (wire or tape) will be included in
the cost of the bore and will not be paid for separately.
No payment will be made for failed bore paths, injection of excavatable flowable fill,
products taken out of service or incomplete installations.
No payment will be made for directional boring until a Bore Path Report has been
delivered to the Engineer.
Payment will be made under:
Item No. 555- 1Directional Bore - per foot.
728
SECTION 556
JACK AND BORE
556-1 Description.
556-1.1 Scope of Work: The work specified in this Section documents the
approved construction methods, procedures and materials for Jack and Bore (J&B), also
known as auger boring. Micro tunneling (MT) is also included in the category of J&B for
purposes of specifications.
556-1.2 General: J&B is a method for installing a product (often called a casing)
that may serve as a direct conduit for liquids or gases, or as a duct for carrier (Pipe, cable,
or wire line products). It is a multi-stage process consisting of constructing a temporary
horizontal jacking platform and a starting alignment track in an entrance pit at a desired
elevation. The product is then jacked by manual control along the starting alignment track
with simultaneous excavation of the soil being accomplished by a rotating cutting head in
the leading edge of the products annular space. The ground up soil (spoil) is transported
back to the entrance pit by helical wound auger flights rotating inside the product. J&B
typically provides limited tracking and steering as well as limited support to the
excavation face.
Micro tunneling is conducted similar to J&B with the exception that it is
remotely controlled, guided pipe jacking process that provides continuous support to the
excavation face. The guidance system usually consists of a laser mounted in the tunneling
drive shaft which communicates a reference line to a target mounted inside the MT
machines articulated steering head. The MT process provides the ability to control the
excavation face stability by applying mechanical or fluid pressure to counterbalance the
earth and hydrostatic pressures.
Removal and disposition of excess material varies, is the responsibility of
the boring contractor and is not covered under this Specification. However, the cost of
removal or final disposition is included in the cost of the J&B operation.
No J&B conduit may be left open ended without approval of the Engineer
to prevent the conduit from acting as a drainage structure.
556-2 Materials.
Select materials approved for installation within the right-of-way based on their
suitability for the construction method as defined in Table 556-2.1. After determining
product suitability, individual material standards as contained in Table 556-2.2 apply.
Table 556-2.1
Product Suitability by Construction Method
Type
Pipe/Casing Installation
Suitable Pipe/Casing
Mode
Jack and Bore
Jacking
Steel, Plastic
DI, FRPM, PC, PCCP,
Micro tunneling
Jacking
RCCP, RCP, Steel
Table 556-2.2
Material Standards Acceptable for J&B and MT Installations
729
Material Type
Ductile Iron (DI)
Fiberglass Reinforced
Polymer Mortar (FRPM)
Polymer Concrete (PC)
Prestressed Concrete
Cylinder Pipe (PCCP)
Reinforced Concrete
Cylinder Pipe (RCCP)
Reinforced Concrete
Pipe (RCP)
Steel
(1)
(2)
Polyvinyl Chloride (PVC)
Acrylonitrile Butadiene
Styrene (ABS)
Reinforced Thermosetting
Resin Pipe (RTRP)
No hydrostatic test required
Dimensional tolerances only
Non-Pressure
AWWA C150/C151
ASTM A716
Pressure
AWWA C150/C151
DIN 54815-1 & 2
ASTM D3517
AWWA C950
N/A
N/A
AWWA C301
N/A
ASTM C361
ASTM D3262
ASTM A139 Grade B(1)
API 2B(2)
ASTM D1785
ASTM C361
AWWA C300/C302
AWWA C200
API 2B(2)
ASTM D1785
ASTM D1527
ASTM D1527
ASTM D2296 or
ASTM D2997
ASTM D2996 or
ASTM D2997
ASTM C 76
Unless otherwise tested and approved by the Department, only use encasement
pipe or uncased carrier pipe material that is new and has smooth interior and exterior
walls.
556-2.1 Steel Pipe Casing and Welds: In addition to meeting or exceeding the
conditions contained in Table 556-2.1 and Table 556-2.2, meet the following
requirements:
(a) The size of the steel casing must be at least 6 inches larger than the
largest outside diameter of the carrier. Casing size must accommodate pressure pipe or
carrier pipe joint restraints.
(b) The casing pipe must be straight seam pipe, spiral seam pipe, or
seamless pipe.
(c) All steel pipe may be bare inside and out, with the manufacturers
recommended minimum nominal wall thicknesses to meet the greater of either
installation, loading or carrier requirements.
(d) All steel casing pipe must be square cut and have dead-even lengths
which are compatible with the J&B equipment.
Use steel pipe casings and welds meeting or exceeding the thickness
requirements to achieve the service life requirements noted in the Department Drainage
Manual Chapter 6. For purposes of determining service life, ensure that casings installed
under roadways meet or exceed cross drain requirements and casings under driveways
meet or exceed side drain pipe requirements. For purposes of material classification,
consider steel pipe casing structural plate steel pipe. Ensure that steel pipe casing of
insufficient length achieves the required length through fully welded joints. Ensure that
joints are air-tight and continuous over the entire circumference of the pipe with a bead
730
equal to or exceeding the minimum of either that required to meet the thickness criteria of
the pipe wall for jacking and loading or service life. A qualified welder must perform all
welding.
556-2.2 Reinforced Concrete Pipe Casing: In addition to meeting or exceeding
the conditions contained in Tables 556-2.1 and Table 556-2.2, meet the following
requirements:
Ensure that concrete pipe complies with the following minimum
requirements:
(a) 5,000 psi concrete compressive strength
(b) Class III, IV, or V as required by load calculations, with a
C-wall
(c) Full circular inner and/or outer reinforcing cage
(d) Multiple layers of steel reinforcing cages, wire splices, laps and
spacers are permanently secured together by welding in place
(e) Straight outside pipe wall with no bell modification
(f) No elliptical reinforcing steel is allowed
(g) Single cage reinforcement with a 1 inch minimum cover from
the inside wall
(h) Double cage reinforcement with a 1 inch minimum cover from
each wall
(i) Joints are gasket type
(j) Additional joint reinforcement
Upon installation, the Engineer may, at his discretion, require the
Contractor to perform concrete wiping or injection of the joints if it is believed the joints
have not maintained their water tightness during the jacking operation. No additional
payment will be made for this operation.
556-2.3 Plastic Pipe Casing: Plastic pipe may be jacked and bored if its physical
properties are sufficient, and it is rigid such that when supported or suspended at mid
point it maintains a straight alignment. If plastic pipe is Jacked and Bored it may not be
used as a pressurized carrier. Plastic pipe casing installed by the jack and bore method
requires the use of an auger. Open end jacking without the use of an auger for continuous
cleanout of the bore as the pipe is advanced is not permitted. Closed end jacking is not
permitted.
556-2.4 Pipe Couplings and Joints: In addition to meeting or exceeding the
conditions contained in Tables 556-2.1 and 556-2.2, to minimize potential for bore
failure, couplings must not project at right angles from the casing diameter by more than
3/4 inch.
(a) Steel Pipe Coupling and Joints:
1. Welds must comply with 556-2.1(d) when couplings are not
used or when the coupling thickness is less than the casing thickness.
2. When couplings are used the casing joint needs only to be tack
welded. Couplings must have a full bead weld such that the thickness, when measured at
an angle of 45 degrees to the casing and coupling interface, must be no less than the
casing thickness.
(b) Plastic Pipe Couplings and Joints:
731
1. Must meet or exceed all ASTM strength and composition
standards established for the casing material to which they are being attached.
2. Joints must be made sufficiently strong to withstand the
pressures of jacking. All chemical welds must be completely set and cured before any
jacking is attempted.
556-3 Construction Site Requirements.
556-3.1 The Americans with Disabilities Act: When and where installations
temporarily disrupt pedestrian use of sidewalk areas for periods exceeding two
consecutive work days, provide an alternate route that meets ADA requirements.
556-3.2 Site Conditions:
(a) Carry out excavation for entry, exit, recovery pits, auger slurry sump
pits, or any other excavation as specified in Section 120. Unless approved by the
Engineer, sump pits are required to contain auger fluids if vacuum devices are not
operated throughout the boring operation.
(b) Within 48 hours of completing installation of the boring product,
ensure that the work site is cleaned of all excess auger fluids or spoils. Removal and final
disposition of excess fluids or spoils is the responsibility of the boring Contractor and
ensure that the work site is restored to pre-construction conditions or as identified in the
Plans.
(c) Restore excavated areas in accordance with the specifications and
Design Standards.
(d) Provide MOT in accordance with the Department Design Standards
and the MUTCD when and where the former is silent.
(e) Ensure that equipment does not impede visibility of the roadway user
without taking the necessary precautions of proper signing and Maintenance of Traffic
Operations.
556-3.3 Ground Water Control: Investigate all sites for possibility of having to
manage groundwater problems that may occur due to seasonal changes or natural
conditions.
(a) When ground water level must be controlled, use a system and
equipment that is compatible with the properties, characteristics, and behavior of the soils
as indicated by the soil investigation report.
556-3.4 Damage Restoration: Take responsibility for restoring any damage
caused by heaving, settlement, separation of pavement, escaping boring fluid (frac-out) of
the J&B operation at no cost to the Department.
556-3.4.1 Remediation Plans: When required by the Engineer, provide
detailed plans which show how damage to any roadway facility will be remedied. These
details will become part of the As-Built Plans Package. Remediation Plans must follow
the same guidelines for development and presentation of the As-Built Plans. When
remediation plans are required, they must be approved by the Engineer before any work
proceeds.
556-4 Quality Control.
556-4.1 General: Take control of the operation at all times. Have a representative
who is thoroughly knowledgeable of the equipment, boring, and Department procedures
present at the job site during the entire installation and available to address immediate
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concerns and emergency operations. Notify the Engineer 48 hours in advance of starting
work. Do not begin the installation until the Engineer is present at the job site and agrees
that proper preparations have been made.
556-4.2 Construction Process and Approval: For all installations, submit
sufficient information to establish the proposed strategy for providing the following:
(a) An indication of where the leading edge of the casing is located with
respect to line and grade and the intervals for checking line and grade. Indication may be
provided by using a water gauge (Dutch level) or electronic transmitting and receiving
devices. Other methods must have prior approval. Maintain a record of the progress at the
job site.
(b) Equipment of adequate size and capability to install the product and
including the equipment manufacturers information for all power equipment used in the
installation.
(c) A means for controlling line and grade.
(d) A means for centering the cutting head inside the borehole.
(e) Provide a means for preventing voids by assuring:
1. The rear of the cutting head from advancing in front of the
leading edge of the casing by more than 1/3 times the casing diameter and in stable
cohesive conditions not to exceed 8 inches.
2. In unstable conditions, such as granular soil, loose or flowable
materials, the cutting head is retracted into the casing a distance that permits a balance
between pushing pressure, pipe advancement and soil conditions.
3. Development of and maintaining a log of the volume of spoil
material removal relative to the advancement of the casing.
(f) Adequate casing lubrication with a bentonite slurry or other approved
technique.
(g) An adequate band around the leading edge of the casing to provide
extra strength in loose unstable materials when the cutting head has been retracted into
the casing to reduce skin friction as well as provides a method for the slurry lubricant to
coat the outside of the casing.
(h) At least 20 feet of full diameter auger at the leading end of the casing.
Subsequent auger size may be reduced, but the reduced auger diameter must be at least
75% of the full auger diameter.
(i) Water to be injected inside the casing to facilitate spoil removal. The
point of injection shall be no closer than 2 feet from the leading edge of the casing.
556-4.3 Testing:
556-4.3.1 Product Testing: When there is any indication that the installed
product has sustained damage and may leak, stop the work, notify the Engineer and
investigate damage. The Engineer may require a pressure test and reserves the right to be
present during the test. Perform pressure test within 24 hours unless otherwise approved
by the Engineer. Furnish a copy of the test results to the Engineer for review and
approval. The Engineer shall be allowed up to 72 hours to approve or determine if the
product installation is not in compliance with specifications. The Engineer may require
non-compliant installations to be filled with excavatable flowable fill.
556-4.3.2 Testing Methods: Testing may consist of one of the following
methods but must always meet or exceed Department testing requirements.
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recommendations.
(a) Follow the Product Manufacturers pressure testing
(b) Ensure that the product carrier pipes installed without a casing
meet the pressure requirements set by the owner. If the owner does not require pressure
testing, the Engineer may require at least one test.
1. The Department requires a water tight pipe and joint
configuration where the product is installed beneath any pavement (including sidewalk)
and front shoulders. The Engineer will determine when and where water tight joint
requirements shall be applied to the ultimate roadway section for future widening. When
under the pavement conduct an air pressure test for leaks in the presence of the Engineer
at a minimum test pressure of 20 PSI by either of the following methods.
i. Standard 24 hour pressure test with a recording
chart or,
ii. A dragnet type leak detector or equivalent device
capable of detecting pressure drops of 1/2 PSI for a time period recommended by the
manufacturer.
2. When a product is not located under the pavement, the
pipe and joint configuration must meet or exceed soil tight joint requirements. The test
for a soil tight joint allows up to 0.1 gallon of water leakage at a sustained pressure of
2 PSI. The water tight joint criteria allows no leakage at all for a sustained pressures of
5 PSI. Conduct test for joint integrity for one hour.
556-4.4 Product Locating and Tracking: Install all facilities such that their
location can be readily determined by electronic designation after installation. For nonconductive installations, attach a minimum of two separate and continuous conductive
tracking (tone wire) materials, either externally, internally, or integral with the product.
Use either a continuous green sheathed solid conductor copper wire line (minimum
#12 AWG for external placement or minimum #14 AWG for internal placement in the
conduit/casing) or a coated conductive tape. Ensure that conductors are located on
opposite sides when installed externally. Connect any break in the conductor line before
construction with an electrical clamp or solder, and coat the connection with a rubber or
plastic insulator to maintain the integrity of the connection from corrosion. Clamp
connections must be made of brass or copper and of the butt end type with wires secured
by compression. Soldered connections must be made by tight spiral winding of each wire
around the other with a finished length minimum of 3 inches overlap. Tracking
conductors must extend 2 feet beyond bore termini. Conductors must be tested for
continuity. Identify each conductor that passes by removing the last 6 inches of the
sheath. No deductions are allowed for failed tracking conductors. Failed conductor ends
must be wound into a small coil and left attached for future use.
556-4.5 Augering Fluids: Use a mixture of bentonite clay or other approved
stabilizing agent mixed with potable water with a minimum pH of 6.0 to create the
drilling fluid for lubrication and soil stabilization. Vary the fluid viscosity to best fit the
soil conditions encountered. Do not use other chemicals or polymer surfactant in the
drilling fluid without written consent of the Engineer. Certify in writing to the Engineer
that any chemicals to be added are environmentally safe and not harmful or corrosive to
the facility. Identify the source of water for mixing the drilling fluid. Approvals and
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permits are required for obtaining water from such sources as streams, rivers, ponds or
fire hydrants. Any water source used other than potable water may require a pH Test.
556-4.6 Micro-Tunneling (MT) and Micro Tunnel Boring Machine (MTBM)
Requirements:
556-4.6.1 Performance Requirements: The MTBM must meet the
following minimum performance requirements:
(a) Capable of providing positive face support regardless of the
MTBM type.
(b) Articulated to enable controlled steering in both the vertical and
horizontal direction to a tolerance of plus or minus 1 inch from design alignment.
(c) All functions are controlled remotely from a surface control
unit.
(d) Capable of controlling rotation, using a bi-directional drive on
the cutter head or by using anti-roll fins or grippers. The Engineer must approve other
methods.
(e) Capable of injecting lubricant around the exterior of the pipe
being jacked.
(f) Indication of steering direction.
For slurry systems, the following is also required:
(g) The volume of slurry flow in both the supply and return side of
the slurry loop.
(h) Indication of slurry bypass valve position.
(i) Indication of pressure of the slurry in the slurry chamber.
556-4.7 Failed Bore Path: If conditions warrant removal of any materials
installed in a failed bore path, as determined by the Engineer, it will be at no cost to the
Department. Promptly fill all voids by injecting all taken out of service products that have
any annular space with excavatable flowable fill.
556-5 Jack and Bore and Micro-Tunneling Operations:
556-5.1 Installation Process: Provide continuous pressure to the face of the
excavation to balance groundwater and earth pressures. Ensure that shafts are of
sufficient size to accommodate equipment, the pipe selected and to allow for safe
working practices. Provide entry and exit seals at shaft walls to prevent inflows of
groundwater, soil, slurry and lubricants. Use thrust blocks designed to distribute loads in
a uniform manner so that any deflection of the thrust block is uniform and does not
impart excessive loads on the shaft itself or cause the jacking frame to become
misaligned.
The jacking system must have the capability of pushing the pipe in J&B
operations or MTBM and pipe for MT operations through the ground in a controlled
manner and be compatible with the anticipated jacking loads and pipe capacity. Monitor
the jacking force applied to the pipe and do not exceed the pipe manufacturers
recommendations.
Ensure that the pipe lubrication system is functional at all times and
sufficient to reduce jacking loads. Use pipe lubrication systems that include a mixing
tank, holding tank and pumps to convey lubricant from the holding tank to application
points at the rear of the MTBM. Maintain sufficient fluids on site to avoid loss of
lubrication.
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Power Distribution System must be identified in the Plans package or
permit provisions as well as any noise constraints. Identity spoil removal capability and
method to avoid creating hindrance to other activities which may be necessary in the
area.
556-5.2 Excess Material and Fluids: Monitor the pumping rate, pressures,
viscosity and density of the boring fluids to ensure adequate removal of soil cuttings and
the stability of the borehole. Contain excess drilling fluids, slurry and soil cuttings at
entry and exit points in pits until they are recycled or removed from the site.
Ensure that all boring fluids are disposed of or recycled in a manner
acceptable to the appropriate local, state or federal regulatory agencies. When jacking and
boring in suspected contaminated ground, test the boring fluid for contamination and
dispose of appropriately. Remove any excess material upon completion of the bore. If it
becomes evident that the soil is contaminated, contact the Engineer immediately. Do not
continue boring without the Engineers approval.
556-5.3 Boring Failure: If an obstruction is encountered which prevents
completion of the installation in accordance with the design location and specifications;
the pipe may be taken out of service and left in place at the discretion of the Engineer.
Immediately fill the product left in place with excavatable flowable fill. Submit a new
installation procedure and revised plans to the Engineer for approval before resuming
work at another location. If damage is observed to any property, cease all work until a
plan of action to minimize further damage and restore damaged property is submitted and
approved by the Engineer.
556-6 Documentation Requirements.
556-6.1 Boring Path Report: Furnish a Bore Path Report to the Engineer within
14 days of the completion of each bore path. Submit the As-Built-Plans to the Engineer
within 30 calendar days. No payment will be made for directional boring work until the
Bore Path Report has been delivered to the Department. Include the following
information in the report:
(a) Location of project and financial project number including the Permit
Number when assigned.
(b) Name of person collecting data, including title, position and company
name.
(c) Investigation site location (Contract Plans station number or reference
to a permanent structure within the project right-of-way).
(d) Identification of the detection method used.
(e) Spoils removal log.
(f) As-built placement plans showing roadway plan and profile, crosssection, boring location and subsurface conditions as defined in Bore Path Plans below.
Reference the shown plan elevations to a Department Bench Mark when associated with
a Department project, otherwise to a USGS grid system and datum or to the top of an
existing Department head wall. These plans must be the same scale in black ink on white
paper, of the same size and weight and as the Contract Plans. Submittal of electronic
plans data in lieu of hard copy plans may be approved by the Engineer if compatible with
the Department software.
556-6.2 As-Built Plans: Provide the Engineer with a complete set of
As-Built-Plans showing all bores (successful and failed) within 30 calendar days of
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completion of the work. Plans must be dimensionally correct copies of the Contract
Plans. Include notes on the plans stating the final bore path diameter, facility diameter,
drilling fluid composition, composition of any other materials used to fill the annular void
between the bore path and the facility or facility placed out of service. If the facility is a
casing, note this, as well as the size and type of carrier pipes to be placed within the
casing as part of the Contract work. Produce the plans as follows:
(a) On the Contract plan view, show the centerline location of each
facility, installed or installed and placed out of service to an accuracy within 1 inch at the
ends and other points physically observed. They show the remainder of the horizontal
alignment of the centerline of each facility installed or installed and placed out of service
and note the accuracy with which the installation was monitored.
(b) As directed by the Engineer, provide either a profile plan for each bore
path, or a cross-section of the roadway at a station specified by the Engineer, or a
roadway centerline profile. Also show the ground or pavement surface and the crown
elevation of each facility installed, or installed and placed out of service, accurately to
within 1 inch at the ends and other points physically observed. Show the remainder of the
vertical alignment of the crown of each facility installed, or installed and placed out of
service and note the accuracy with which the installation was monitored. On profile plans
for bore paths crossing the roadway, show the Contract Plans stationing. On the profile
plans for bore paths paralleling the roadway show the Contract Plans stationing. If the
profile plan for the bore path is not made on a copy of one of the contract profile or crosssection sheets, use a 10 to 1 vertical exaggeration.
(c) If a bore path is not completed, show on the plans the failed bore path
along with the name of the utility owner and the final bore path. Note the failed bore path
as Failed Bore Path. Also show the location and length of the cutting head and any
product not removed from the bore path.
(d) Show the crown elevation, diameter and material type of all utilities
encountered and physically observed during the subsoil investigation. For all other
obstructions encountered during subsoil investigation or the installation, show the type of
material, horizontal and vertical location, top elevation and lowest elevation observed,
and note if the obstruction continues below the lowest point observed.
556-7 Method of Measurement.
The method of measurement will be the actual length of the installation, measured
in place along the surface of the ground, complete and accepted. No additions or
deductions will be made for sweeps in either the vertical or horizontal direction to
complete the installation.
556-8 Basis of Payment.
Price and payment will be full compensation for all work and materials required
to complete the work specified in this Section, including furnishing and installing
casings, from plan point of beginning to plan point of ending at plan depth, removal of
excavated materials and spoils, removal and disposal of drilling fluids, backfilling, and
complete restoration of the site.
The installation of tracking conductors (wire or tape) will be included in the cost
of the bore and will not be paid for separately.
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No payment will be made for failed bore paths, injection of excavatable flowable
fill, products taken out of service or incomplete installations.
No payment will be made for jack and bore until a Bore Path Report has been
delivered to the Engineer.
Payment will be made under:
Item No. 556- 1Jack and Bore - per foot of bore diameter.
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SECTION 557
VIBRATORY PLOWING
557-1 Description.
557-1.1 Scope of Work: The work specified in this Section documents the
approved construction methods, procedures and materials for vibratory plowing, also
known as cable plowing.
557-1.2 General: Vibratory plowing is a trenchless method for installing a
product which typically consists of a cable or small conduit for later insertion of wire line
products. It is a multi-stage process consisting of positioning a vibrating plow equipped
with a trailing product guide which feeds the cable or conduit to the depth setting of the
plow as it moves forward. The product is inserted into the ground continuously along a
predetermined path and depth. Reshape any disturbance of the ground surface such as
localized residual mounding or grooves, by grading and compaction. If a conduit is
installed, subsequent operations may involve pulling a desired product back through the
conduit. The vertical depth of installation is controlled by two factors, hydraulic
adjustment of the plow shear head and the surface contours. The depth of insertion must
be continually adjusted to compensate for changes in terrain to ensure compliance with
depth criteria. Horizontal profiles or steering the bore is accomplished by proper
orientation of a tractor which pulls the vibratory plow. Alignments are generally limited
to straight sections with minor deviation unless approved by the Engineer.
557-2 Construction Site Requirements.
557-2.1 Site Conditions: Consider vibratory plowing an excavation method and
comply with all applicable provisions required of excavation methods.
(a) Ensure that subsequent excavation for manholes, hand pulls, or other
service vaults, recovery pits or any other excavation is carried out as specified in
Section 120.
(b) After completing installation of the product, restore the work site.
Restore excavated or plowed areas in accordance with the Specifications and Design
Standards.
(c) It is the plowing Contractors responsibility for removal of excess
material or debris created during the construction process as well as restoring the site to
the condition which existed before construction.
(d) Exposure may be allowed for periods exceeding 14 consecutive days if
the exposure is limited to 3 feet or less. Periods longer than described above may be
approved by the Engineer if it will not affect maintenance or construction activities.
(e) Ensure that equipment does not impede visibility of the roadway user
without taking the necessary precautions of proper signing and maintenance of traffic
operations.
557-2.2 Damage Restoration: Take responsibility for restoring any damage
caused by cutting, heaving, settlement or separation of pavement at no cost to the
Department.
557-2.2.1 Remediation Plans: When required by the Engineer, provide
detailed plans which show how damage to any roadway facility will be remedied and
739
include this as part of the As-Built Plans Package. Remediation Plans must follow the
same guidelines for development and presentation of the As-Built Plans.
557-3 Quality Control.
557-3.1 General: Take control of the operation at all times, have a representative
who is thoroughly knowledgeable of the equipment and procedures, present at the job site
during the entire installation and available to address immediate concerns and emergency
operations. Notify the Engineer 48 hours in advance of starting work. Do not begin
installation until the Engineer is present at the job site and agrees that proper preparations
have been made.
557-3.2 Alignment: Ensure that the plow operator maintains a true and consistent
alignment. Deviation from the approved alignment more than 1 foot in either direction to
avoid obstructions such as boulders, stumps or general vegetation will not be allowed
unless approved by the Engineer. Document all approved deviations from the original
permitted alignment.
557-3.3 Product Locating and Tracking: For all installations, submit sufficient
information to establish the proposed strategy for compliance with the permit.
(a) Define what reference will be used to control and ensure alignment as
permitted will be maintained with respect to line and grade. Also indicate the intervals for
checking line and grade and maintain a record at the job site.
(b) Ensure the equipment is of adequate size and capability to install the
project. This includes the equipment manufacturers information for all power equipment
used in the installation.
(c) Define the means for controlling line and grade.
Install all facilities in such a way that their location can be readily
determined by electronic designation after installation. For non-conductive installations,
accomplish this by attaching a minimum of two separate and continuous conductive wires
(minimum 12 gauge) either externally, internally, or integrally with the product. Any
break in the conductor must be connected by electrical clamp of brass or solder and
coated with a rubber or plastic insulator to maintain the integrity of the connection from
corrosion.
557-4 Documentation.
557-4.1 Plowing Path Report: Furnish a Plowing Path Report to the Engineer
within 14 days of the completion of each installation. Include the following information
on the report:
(a) Location of project and financial project number including the permit
number when assigned.
(b) Name of person collecting data, including title, position and company
name.
(c) Contract Plans station number or reference to a permanent structure
within the project right-of-way.
(d) As-built placement plans showing roadway plan and profile, crosssection and plowing location and elevations every 100 feet along the alignment.
Reference shown plan elevations to a Department bench mark when associated with a
Department project, otherwise to a USGS grid system and datum, or to the top of an
existing Department head wall. These plans must be the same scale in black ink on white
740
paper, of the same size and weight and as the Contract Plans. Submittal of electronic
plans data in lieu of hard copy plans may be approved by the Engineer if compatible with
the Department software.
557-4.2 As-Built Plans: Submit the completed As-Built Plans to the Engineer
within 30 calendar days. Ensure that the plans are dimensionally correct copies of the
Contract Plans. Include notes on each plan stating the final plow path, facility diameter
and any facility placed out of service. If the facility is a duct, note this, as well as the size
and type of product to be placed within the duct as part of the permitted work. Produce
the plans as follows:
(a) On the Contract plan view, show the centerline location of each facility
installed to an accuracy within 1 inch at the ends and other points physically observed.
Show the remainder of the horizontal alignment of the centerline of each facility installed
and note the accuracy with which the installation was monitored.
(b) As directed by the Engineer, provide either a profile plan for each path,
or a cross-section of the roadway at a station specified by the Engineer, or a roadway
centerline profile. Show the ground or pavement surface and the crown elevation of each
facility installed to an accuracy within 1 inch at the ends and other points physically
observed. Show the remainder of the vertical alignment of the crown of each facility
installed and note the accuracy with which the installation was monitored. On profile
plans for paths crossing the roadway show the Contract Plans stationing of the crossing.
On the profile plans for paths paralleling the roadway also show the Contract Plans
stationing. If the profile plan for the path is not made on a copy of one of the Contract
profile or cross-section sheets, use a 10 to 1 vertical exaggeration.
(c) If, during installation, an obstruction is encountered which prevents
installation of the product in accordance with this Specification, submit a new installation
procedure and revised plans to the Engineer for approval before resuming work along a
new alignment. If a section of a plowing path fails without installing a product or it has
been removed, show the failed section of the plow path along with the final plow path on
the plans. Note the failed path as Failed Plow Path. Do not leave any products in a
failed plow path. If breakage occurs or the plow path fails, remove all products from the
broken or failed section of the plow path.
(d) On all of the plans, show the crown elevation, diameter and material
type of all utilities encountered and physically observed during installation. For all other
obstructions encountered during a subsoil investigation or the installation, show the type
of material, horizontal and vertical location, top elevation and lowest elevation observed,
and note if the obstruction continues below the lowest point observed.
557-5 Method of Measurement.
Payment will be based on the length of the installation, measured in place along
with the surface of the ground, completed and accepted.
557-6 Basis of Payment.
Payment will be full compensation for all work specified in this Section,
including all installations, from plan point of beginning to plan point of ending (i.e. pull
box) at plan depth, removal and disposal of excavated materials such as boulders, stumps,
and debris, or grading and backfilling to complete restoration of the site. Bundled product
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in a single plow will be paid for as a single plow based on the required vibrating plow
head size. Separate payment will not be made for individual products in a bundle.
The installation of tracking conductors will be included in the cost of the plow
and will not be paid for separately.
No payment will be made for a failed plow path or incomplete installations. The
removal of all materials installed in a failed plow path will be at no cost to the
Department.
No payment will be made for installations until the Plowing Path Report has been
delivered to the Engineer.
Payment will be made under:
Pay Item No. 557- 1- Vibratory Plowing - per foot of aggregate product
pull diameter.
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SECTION 560
COATING NEW STRUCTURAL STEEL
560-1 Description
Coat new structural steel in accordance with the requirements of this Section. Apply the
coating system designated in the Contract Documents.
560-2 Materials.
560-2.1 Coating System: Use only coating products and systems meeting the
requirements of Section 975 and listed on the Departments Qualified Products List (QPL).
Use Type M coal tar epoxy coatings meeting the requirements of Section 926 and
listed on the Departments QPL for coating of permanent bulkhead sheet piles and H piles.
560-2.2 Thinners, Solvents and Cleaners: Use thinners, solvents and cleaners listed on
the coating manufacturers product data sheet.
560-2.3 Caulking: Use caulks that are paintable, compatible with the coating system and
recommended by the coating manufacturer as part of the coating system.
560-2.4 Soluble Salts Test Kit: Use a soluble salts test kit in accordance with SSPCGuide 15 utilizing a Class A retrieval method. Ensure the test sleeve or cell creates a sealed,
encapsulated environment during ion extraction and is suitable for testing all structural steel
surfaces.
560-2.5 Abrasives: Use properly sized abrasives to achieve the required cleanliness and
anchor profile. Use abrasives meeting the requirements of SSPC-AB 1, Mineral and Slag
Abrasives, SSPC-AB 2, Cleanliness of Recycled Ferrous Metallic Abrasives, or SSPC-AB 3,
Newly Manufactured or Re-Manufactured Steel Abrasive and do not introduce any
contamination that interferes with the coating application and performance.
Provide certification to the Engineer that the abrasives used meet the requirements
of this Section and do not contain any chlorides and other salts.
For recycled abrasives, verify compliance with the conductivity and cleanliness
requirements of SSPC-AB 2 after each recycling or more frequently if required by the Engineer.
Select a sample from each recycling machine in use and conduct the water-soluble contaminant
and oil content tests outlined in SSPC-AB 2 at least one time each week or more frequently if
directed by the Engineer. Conduct the non-abrasive residue and lead content tests as directed by
the Engineer. If test results do not meet requirements, notify the Engineer immediately, remove
and replace the abrasive, clean the recycling equipment, and conduct tests each day to confirm
the equipment is functioning properly. Return to the weekly testing interval as directed by the
Engineer.
560-2.6 Rust Preventative Compound: Use a Class 3 rust preventative compound
meeting the requirements of Military Specification MIL-C-11796C, Corrosion Preventative
Compound, Petrolatum, Hot Applied.
560-2.7 Storage: Store materials in conformance with the manufacturers
recommendations.
560-3 Equipment.
560-3.1 Compressed Air: Use a compressed air system capable of delivering clean, dry,
continuous nozzle pressure to achieve the required surface cleanliness and profile or spray
pattern. The system must comply with the instructions and recommendations of the manufacturer
of the abrasive blasting system or coating application system.
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560-3.2 Abrasive Blasting System: Design the blasting system to produce the specified
cleanliness and profile.
560-3.3 Coating Application System: Use the coating application equipment approved
by and in accordance with the coating manufacturers technical data requirements.
560-4 Environmental, Health and Safety Requirements.
Isolate the work areas with containment devices, canvasses, tarpaulins or screens during
all surface preparation and coating application operations. Dispose of all debris and waste
products generated in accordance with all Federal, State and Local regulations.
560-5 Quality Control.
560-5.1 Shop Preparation and Application: Prior to applying coatings, provide a
current Corporate Quality Control Plan approved by the American Institute of Steel Construction
(AISC) under the Sophisticated Paint Endorsement Program or SSPC under the SSPC-QP3
certification to the State Materials Office for approval.
560-5.2 Field Preparation and Application: Provide a current Corporate Quality
Control Plan approved by SSPC under the SSPC-QP1 and/or SSPC-QP2 certifications as
appropriate and a site specific Coating Quality Control Plan to the Engineer at least 14 calendar
days prior to beginning coatings work. Do not begin coatings work until the site specific Coating
Quality Control Plan has been approved by the Engineer.
560-5.3 Inspection: Ensure that all inspection equipment is maintained in accordance
with the manufacturers instructions, calibrated, and in good working condition. Ensure that all
activities are observed and approved by a quality control coatings inspector meeting the
requirements of this Section. Maintain daily inspection reports at the job site for review by the
Engineer. Provide all daily inspection reports upon completion of the project to the Engineer or
more frequently as requested by the Engineer.
560-6 Qualifications.
560-6.1 Shop: Provide documentation to the Engineer at least 14 days prior to beginning
work that the shop performing any work in accordance with this Section is certified by AISC
Sophisticated Paint Endorsement or by SSPC to the requirements of SSPC-QP3.
560-6.2 Field Contractor: Provide documentation to the Engineer at least 14 days prior
to beginning work that the field contractor performing any work in accordance with this Section
is certified by SSPC to the requirements of SSPC-QP1 and/or SSPC-QP2 as appropriate.
560-6.3 Quality Control Inspectors in the Shop and Field: Provide documentation to
the Engineer that all personnel performing quality control inspections are certified at a minimum
as a National Association of Corrosion Engineers (NACE) Coating Inspector Level I or a SSPC
Level 1 Bridge Coating Inspector and that they report directly to a Quality Control Supervisor
who is certified either as a NACE Coating Inspector Level 3 or a SSPC Level 2 Bridge Coating
Inspector.
560-6.4 Certifications: Maintain certifications for the duration of the Contract. If the
certifications expire, do not perform any work until certifications are reissued.
Notify the Engineer of any change in certification status.
560-7 Surface Preparation.
560-7.1 General: Ensure all surfaces to be coated are clean, dry, and free from oil,
grease, dirt, dust, soluble salts, corrosion, peeling coating, caulking, weld spatter, mill scale and
any other surface contaminants. Prepare all surfaces that will become inaccessible after
744
fabrication, erection, or installation while accessible. Sequence the surface preparations and
coating operations so that freshly applied coatings will not be contaminated by dust or foreign
matter. Protect all equipment and adjacent surfaces not to be coated from surface preparation
operations. Protect working mechanisms against intrusion of abrasive. In the event that any
rusting or contamination occurs after the completion of the surface preparation, prepare the
surfaces again to the initial requirements. Perform surface preparation work only when the
temperature of the steel surface is at least 5F above the dew point temperature.
560-7.2 Mechanical Removal of Surface Defects: Break all corners resulting from
sawing, burning, or shearing. In areas where burning has been used, remove the flame hardened
surface of the steel to the extent necessary to achieve the required surface profile after abrasive
blast cleaning. Remove all weld slag and weld spatter. Conduct all of this work in accordance
with AASHTO/NSBA Steel Bridge Collaboration S 8.1.
560-7.3 Cleaning: Clean all steel surfaces in accordance with the requirements of SSPCSP 1.
560-7.4 Washing: Wash all steel surfaces in accordance with the requirements of SSPCSP 12.
560-7.5 Soluble Salts Detection and Removal: Determine the chloride, sulfate and
nitrate concentrations on all steel surfaces using soluble salts test kits meeting the requirements
of 560-2.4. Measure the concentration levels using the method described in SSPC-TU 4. Perform
the tests after washing and after each applied coat of the coating system. Test three random
locations in the first 1000 square feet and one random location for each subsequent 1000 square
feet. Ensure the non-visible surface contaminant concentrations on blast-cleaned surfaces do not
exceed the levels in SSPC-SP 12 Table A1 NV2 for chloride, soluble ferrous iron and sulfate and
10 g/cm2 for nitrate. When any concentration exceeds these levels rewash the entire surface
area and retest. If additional washing does not reduce the concentration to the acceptable level, a
surface treatment or water additive may be used. Use a surface treatment or water additive that is
approved by the coating system supplier and the Engineer.
560-7.6 Abrasive Blast Cleaning: Prepare steel by abrasive blast cleaning to nearwhite metal condition as defined in SSPC-SP 10. Use SSPC VIS 1 as an aid in establishing
cleanliness. After abrasive blast cleaning, ensure the surface profile meets the requirements of
the coating manufacturers product data sheet. Determine the surface profile using replica tape in
accordance with ASTM D4417, Method C.
Perform all abrasive blast cleaning within a containment system to ensure
confinement of all particulates. Design the containment system to comply with all applicable
Federal, State, and Local regulations. Ensure the abrasive blast cleaning does not produce holes,
cause distortion, remove metal, or cause thinning of the substrate.
560-7.7 Hand and Power Tool Cleaning: Prepare steel by power and hand tool cleaning
as defined in SSPC-SP 11, SSPC-SP 3, and SSPC-SP 2 for touch up and repair when approved
by the Engineer. Use SSPC-VIS 3 as an aid in establishing cleanliness.
560-8 Surfaces Not to be Coated.
560-8.1 Galvanized Surfaces: Do not coat galvanized surfaces unless specified in the
Contract Documents.
560-8.2 Surfaces to be in contact with Concrete: Do not coat the areas of contact
surfaces of steel to be encased or embedded in concrete, or coated with concrete unless specified
in the Contract Documents. When specified, prepare the contact surfaces and apply primer.
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560-8.3 Faying Surfaces: After application of the primer, protect the contact surfaces of
members to be joined by high-strength bolts in friction type joints from all other coatings and
foreign material.
560-8.4 Machine Finished Surfaces: Apply a coating of rust preventative compound to
all machine finished or similar surfaces that are not to be coated, or will not be coated
immediately.
560-8.5 Surfaces to be Welded: Mask off surfaces within 1 inch of field welded
connections before the application of any shop coating. Apply a mist coat of primer that is less
than 1 mil dry film thickness to surfaces where shear studs will be welded.
560-9 Application.
560-9.1 General: Apply a complete coating system to all structural steel surfaces except
surfaces indicated in 560-8. Apply a complete coating system to all surfaces that will become
inaccessible after fabrication, erection, or installation.
Apply the prime coat in the shop. Apply the intermediate coat in the shop or field.
Only apply the finish coat after erection and after concrete work is complete.
Prior to the application of any coating, inspect the substrate for contamination and
defects, and prepare the surface in accordance with 560-7 before application of the next coat.
Apply each coat including a stripe coat in a color that contrasts with the substrate
or preceding coat. For exterior surfaces, apply a finish coat color meeting Federal Standard,
595B, Shade 36622, unless otherwise specified in the Contract Documents.
560-9.2 Weather and Temperature Limitations: Do not spray coating when the
measured wind speed in the immediate coating area is above 15 miles per hour. Do not apply
coatings when contamination from rainfall is imminent or when the ambient air temperature,
relative humidity, dew point temperature, or temperature of the steel is outside limits of the
coating manufacturers product data sheet.
560-9.3 Sealing Using Caulk: Completely seal the perimeter of all faying surfaces,
cracks and crevices, joints open less than 1/2 inch, and skip-welded joints using caulk. Apply the
caulk to the joint following the caulk manufacturers recommendations. Ensure the caulk bead
has a smooth and uniform finish and is cured according to the caulk manufacturers
recommendation prior to the application of the coating system.
560-9.4 Protection of Adjacent Surfaces: Protect all surfaces and working mechanisms
not intended to be coated during the application of coatings. Clean surfaces that have been
contaminated with coatings until all traces of the coating have been removed. Do not allow
material from cleaning and coating operations to be dispersed outside the work site.
560-9.5 Mixing and Thinning: Mix all coatings in accordance with the manufacturers
product data sheet. Only mix complete kits. Use thinners and solvents in accordance with the
requirements of the coating manufacturers product data sheet and confirm that the amount of
thinner added does not result in the coating exceeding VOC regulations stated in Section 975.
Perform all mixing operations over an impervious surface with provisions to
prevent runoff to grade of any spilled material.
560-9.6 Application Methods: Use coating application equipment and apply coatings
per the coating manufacturers product data sheet. Application with brushes may be permitted for
minor touchup of spray applications, stripe coats, or when otherwise approved by the Engineer.
Adjust spray equipment to produce an even, wet coat with minimum overspray. Apply coatings
in even, parallel passes, overlapping 50 percent. Agitate coatings during application as required
by the coating manufacturers product data sheet.
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560-9.7 Stripe Coating: Apply stripe coats to achieve complete coverage and proper
thickness on welds, corners, crevices, sharp edges, bolts, nuts, rivets, and rough or pitted
surfaces. Stripe coating is not required for the inside surface area of all steel box girders.
560-9.8 Thickness of Coats: Apply coatings to the thickness as identified in the
manufacturers product data sheet. After application of each coat, thoroughly inspect the surfaces
and measure the dry film thickness (DFT) in accordance with SSPC-PA 2. When the DFT is
deficient or excessive, correct in accordance with the coating manufacturers recommendations
and retest the area.
560-9.9 Coating Drying, and Curing: Apply coatings within the time specified by the
coating manufacturers product data sheet for drying and recoating. Test the coating for proper
cure before handling and shipping. Test for cure in accordance with the manufacturers
recommended method. Meet the requirements of ASTM D4752 for inorganic zinc primers or
ASTM D5402 for organic zinc primers when the manufacturers technical data sheet does not
state a specified cure test. Obtain the acceptance criteria from the coating manufacturer and
report the results to the Engineer.
Prior to assembling bolted connections, test and verify that the primer coating on
the faying surfaces has cured to a resistance rating of 5 in accordance with ASTM D4752,
ASTM D5402, or the coating manufacturers requirements. If cure testing is performed per the
coating manufacturers requirements, submit the test results to the Engineer for approval prior to
assembling the bolted connection.
560-9.10 Coating Finish: Apply each coat free of runs, sags, blisters, bubbles, and mud
cracking; variations in color, gloss, or texture; holidays; excessive film buildup; foreign
contaminants; orange peeling; and overspray.
560-10 Touchup and Repair.
Clean and coat all welds, rivets, bolts, and all damaged or defective coating and rusted
areas in accordance with 560-7 and 560-9. Upon approval by the Engineer, aluminum mastic
may be used in accordance with the manufacturers recommendations. Aluminum mastic must
contain aluminum pigment and minimum 80% volume solids.
560-11 Coating of Permanent Sheet, Pipe and H Piles.
560-11.1 Surface Preparation: Prepare the substrate in accordance with 560-7. Provide
a depth of anchor profile in accordance with the manufacturers product data sheet, but in no
case less than 2.5 mils. Re-blast piles not coated during the same shift or if the surface to be
coated no longer meets the requirements SSPC-SP 10.
560-11.2 Application of Coating: Unless otherwise shown in the Contract Documents,
apply the inorganic zinc primer to all surfaces of H and sheet piles and the exterior surface of
pipe piles. Unless otherwise shown in the Contract Documents, apply coal tar-epoxy coatings to
the exposed side of sheet piles from the top of the piles to a depth of five feet below the lower of
the design ground surface or the design scour depth. Apply the inorganic zinc primer in
accordance with this Section. Apply the coal tar-epoxy in accordance with the following specific
requirements:
(1) Apply the coal tar-epoxy system in two coats. The time interval between the
first coat and the second coat will be in strict accordance with the coating manufacturers
published specifications. Apply the first coat to yield a dry film thickness of 8 to 10 mils. Apply
the second coat to attain a total dry film thickness of the two coats between 16 and 20 mils.
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(2) Ensure that no portion of the coating is less than the specified minimum film
thicknesses. The total minimum film thickness for any combination of coats will be the sum total
of the averages of the specified thickness range of the individual coats.
(3) After applying the coating on the steel piles, the Engineer will thoroughly
inspect the surfaces and make film thickness measurements at the approximate rate of one for
each 25 square feet of area unless deficient thickness is found. In this case, the rate of submeasurements will be increased as required to determine the extent of the deficient area.
560-12 Basis of Payment.
No separate payment will be made for coating new structural steel. Include the cost in the
cost of the structural steel.
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SECTION 561
COATING EXISTING STRUCTURAL STEEL
561-1 Description.
Coat existing structural steel in accordance with the requirements of this Section by
removing and replacing the existing coating or overcoating the existing coating as stated in the
Contract Documents.
561-2 Materials.
561-2.1 Coating Systems: For removal and replacement systems, use coating products
and systems meeting the requirements of Section 975 and are listed on the Departments
Qualified Products List (QPL).
For overcoating systems, use products and systems as designated in the Contract
Documents. Submit product data sheets and product Material Safety Data Sheets (MSDS), or in
lieu of MSDS, submit test reports showing percent weight compositional analysis, Chemical
Abstract Number, American Conference of Governmental Industrial Hygienists (ACGIH) time
weighted average and ceiling exposure limits for all components, and lower and upper explosive
limits, flash point, boiling point, amount of volatile organic compounds by weight, and specific
gravity for each component of the coating system.
561-2.2 Thinners, Solvents and Cleaners: Meet the requirements of 560-2.2. In
addition, for overcoating systems, use thinners, solvents, and cleaners that do not damage the
existing coating system.
561-2.3 Caulking: Meet the requirements of 560-2.3.
561-2.4 Soluble Salts Test Kit: Meet the requirements of 560-2.4.
561-2.5 Abrasives: Meet the requirements of 560-2.5.
561-2.6 Rust Preventative Compound: Meet the requirements of 560-2.6.
561-2.7 Storage: Meet the requirements of 560-2.7.
561-3 Equipment.
561-3.1 Compressed Air: Meet the requirements of 560-3.1.
561-3.2 Abrasive Blasting System: Meet the requirements of 560-3.2.
561-3.3 Coating Application System: Meet the requirements of 560-3.3.
561-4 Quality Control.
561-4.1 Field Preparation and Application: Provide a current Corporate Quality
Control Plan approved by SSPC under the SSPC QP1 and SSPC QP2 certifications as
appropriate and a site specific Coating Quality Control Plan to the Engineer at least 14 calendar
days prior to beginning coatings work. Do not begin coatings work until the site specific Coating
Quality Control Plan has been approved by the Engineer.
Prepare a traffic control plan for each phase of construction activities signed and
sealed by the Contractors Engineer of Record in accordance with the Roadway Plans
Preparation Manual. Do not begin work until the traffic control plan is approved by the Engineer.
Maintain traffic in accordance with Section 102.
For work over navigable waters, submit a work plan to the United States Coast
Guard including any scheduled restrictions to navigation channels or marine traffic. Obtain Coast
Guard approval at least 30 days in advance of any restrictions.
561-4.2 Inspection: Meet the requirements of 560-5.3.
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561-5 Qualifications.
561-5.1 Field Contractor: Meet the requirements of 560-6.2.
561-5.2 Quality Control Inspectors: Meet the requirements of 560-6.3.
561-5.3 Certifications: Meet the requirements of 560-6.4.
561-6 Surface Preparation.
561-6.1 General: When portions of the existing coating are designated in the Contract
Documents to be removed and replaced, clean, wash, test and remove soluble salts, and abrasive
blast or hand and power tool clean to remove all existing coating and corrosion in the intended
locations. Feather back the edges of all existing coating to remain a minimum of 3 inches around
the area of existing coating removed to provide a smooth transition. Verify the edges of the
existing coating are intact by probing with a dull putty knife in accordance with SSPC SP 2.
Roughen the existing coating in the feathered area to ensure proper adhesion of the new coating.
Notify the Engineer immediately when any structural steel appears to be defective.
When the existing coating is to remain, clean, wash, and test and remove soluble
salts.
Ensure all surfaces to be coated are clean, dry, and free from oil, grease, dirt, dust,
soluble salts, corrosion, peeling coating, caulking, weld spatter, mill scale and any other surface
contaminants. Sequence the surface preparations and coating operations so that freshly applied
coatings will not be contaminated by dust or foreign matter. Protect all equipment and adjacent
surfaces not to be coated from surface preparation operations. Protect working mechanisms
against intrusion of abrasive. In the event that any rusting or contamination occurs after the
completion of the surface preparation, prepare the surfaces again to the initial requirements.
Perform surface preparation work only when the temperature of the steel surface is at least 5oF
above the dew point temperature.
561-6.2 Mechanical Removal of Surface Defects: Meet the requirements of 560-7.2. In
addition, remove all pack rust prior to solvent cleaning.
561-6.3 Cleaning: Meet the requirements of 560-7.3.
561-6.4 Washing: Meet the requirements of 560-7.4.
561-6.5 Soluble Salts Detection and Removal: Meet the requirements of 560-7.5 except
test five random locations in the first 1000 square feet and one random location for each
subsequent 1000 square feet.
561-6.6 Abrasive Blast Cleaning: Meet the requirements of 560-7.6.
561-6.7 Hand and Power Tool Cleaning: Prepare steel by power and hand tool cleaning
as defined in SSPC SP 11, SSPC SP 3, and SSPC SP 2 as stated in the Contract Documents. Use
SSPC VIS 3 as an aid in establishing cleanliness.
561-7 Surfaces Not to be Coated.
561-7.1 Galvanized Surfaces: Meet the requirements of 560-8.1.
561-7.2 Machine Finished Surfaces: Meet the requirements of 560-8.4.
561-8 Application.
561-8.1 General: Apply a complete coating system to all structural steel surfaces except
surfaces indicated in 561-7.
Prior to the application of any coating, inspect the substrate for contamination and
defects, and prepare the surface in accordance with 561-6 before application of the next coat.
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Apply each coat including a stripe coat in a color that contrasts with the substrate
or preceding coat. For exterior surfaces, apply a finish coat color meeting Federal Standard,
595B, Shade 36622, unless otherwise specified in the Contract Documents.
561-8.2 Weather and Temperature Limitations: Meet the requirements of 560-9.2.
561-8.3 Sealing Using Caulk: Meet the requirements of 560-9.3.
561-8.4 Protection of Adjacent Surfaces: Meet the requirements of 560-9.4.
561-8.5 Mixing and Thinning: Meet the requirements of 560-9.5.
561-8.6 Application Methods: Meet the requirements of 560-9.6.
561-8.7 Stripe Coating: Meet the requirements of 560-9.7.
561-8.8 Thickness of Coats: Meet the requirements of 560-9.8.
561-8.9 Coating Drying, and Curing: Apply coatings within the time specified by the
coating manufacturers product data sheet for drying and recoating. Before handling, test for cure
in accordance with the manufacturers recommended method. Meet the requirements of
ASTM D5402 for organic zinc primers when the manufacturers technical data sheet does not
state a specified cure test. Obtain the acceptance criteria from the coating manufacturer and
report the results to the Engineer.
561-8.10 Coating Finish: Meet the requirements of 560-9.10.
561-9 Touchup and Repair.
Clean and coat all welds, rivets, bolts, and all damaged or defective coating and rusted
areas in accordance with 561-6 and 561-8. Upon approval by the Engineer, aluminum mastic
may be used in accordance with the manufacturers recommendations. Aluminum mastic must
contain aluminum pigment and minimum 80% volume solids.
561-10 Protection of the Environment, Public, and Workers.
561-10.1 General: Establish plans and programs to protect the environment, public,
contractor employees, and other workers from exposure to toxic heavy metals as well as releases
and emissions of hazardous materials and nuisance dusts. Conduct all coating application and
removal operations in compliance with EPA, OSHA, and other applicable Federal, State and
local regulations. Provide a contingency plan for the remediation of water and land in the event
of contamination by solid or liquid paint and contaminated water.
561-10.2 Environmental Protection: Prepare and submit to the Engineer, plans and
programs for the protection of the environment and public based on the applicable EPA
requirements, the requirements of this Section, and the Contract Documents. Include plans and
programs for the protection of the air, soil/ground, and water.
561-10.2.1 Pollution Control: Submit a written pollution control and monitoring
plan at the preconstruction meeting or as directed by the Engineer which clearly describes the
means for complying with all Local, State and Federal regulations including pollution control
provisions specified herein. The written plan must be in accordance with SSPC Project Design:
Industrial Lead Paint Removal Handbook, Volume II, Phase 6, Environmental Monitoring, and
specifically include, but not be limited to, providing a scaled map of the work site layout
showing the proposed number and location of soil sampling, Total Suspended Particulate (TSP)
monitoring sites, waste storage areas, staging areas, temporary waste storage areas, and ambient
air and personnel sampling frequency.
Comply with all applicable Federal, State, and Local rules and regulations.
Immediately cease all operations in the event a violation of any environmental regulation or a
failure to properly execute any pollution control provisions occurs. Resume operations after
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written proposed corrective procedures have been submitted to and approved by the Engineer
and implemented.
561-10.2.2 Permits: Submit all required permits from all applicable regulatory
agencies to the Engineer prior to the commencement of any work. Seek permit determination
from these regulatory agencies to avoid any potential permit non-compliance issues during work
activities. The Contractor is responsible for all liability resulting from non-compliance with
pertinent rules and regulations including permit requirements.
561-10.2.3 Ambient Air Quality Compliance and Protection of the Air:
561-10.2.3.1 Visible Emissions: Assess the visible emissions using EPA
Method 22, Timing of Emissions as defined by 40 CFR 60, Appendix A, Standards of
Performance for New Stationary Sources. During abrasive blasting, do not allow visible
emissions from a containment to exceed a random cumulative duration of more than one percent
of the workday (SSPC Guide 6, Level 1 Emissions). During pressurized water cleaning, do not
allow visible emissions from a containment to exceed a random cumulative duration of more
than ten percent of the workday (SSPC Guide 6, Level 3 Emissions).
561-10.2.3.2 Total Suspended Particulate (TSP) Matter: Control
emissions from the containment area to prevent exceeding the TSP lead of 1.5 g/m3 over a
90 day period, or the daily and adjusted daily allowances of SSPC-TU 7. Conduct TSP Lead
monitoring in accordance with 40 CFR 50, Appendix B, Reference Method for Determination of
TSP Matter in the Atmosphere (high volume sampler required), and 40 CFR 50, Appendix G,
Reference Method for Determination of TSP Matter Collected from Ambient Air. Position the
TSP lead monitoring equipment in general accordance with 40 CFR 58, Ambient Air Quality
Surveillance.
When lead is present in the coating, perform TSP Lead background
monitoring for a period of 3 days prior to the beginning of abrasive blast cleaning operations.
Submit the results from background monitoring and the first week of monitoring during abrasive
blast cleaning to the Engineer for review within 5 calendar days after the first week of work.
Continue monitoring unless otherwise directed by the Engineer.
561-10.2.3.3 Regulated Area: Establish a regulated area around the work
site to prohibit unauthorized persons from areas where exposure to hazardous airborne metals
may exceed the following action levels:
Airborne Metals
Lead
Cadmium
Arsenic
Hexavalent Chromium (Cr6+)
Action Level
30 g/m3
2.5 g/m3
5 g/m3
2.5 g/m3
Conduct monitoring in accordance with the National Institute for
Occupational Safety and Health (NIOSH) procedures upon initiation of dust producing
operations and submit the test results to the Engineer within 72 hours of sampling. Report sample
results as eight-hour Time Weighted Averages (TWA). Reestablish the regulated area and
perform additional sampling when the results exceed the action levels or when directed by the
Engineer. Document all pertinent data in a field logbook. Position air-sampling pumps around
the project perimeter where the public or personnel can approach the work area. Place sampler
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inlets at breathing height. Clearly mark the regulated area by the use of warning signs, rope,
barrier tape, or temporary construction fencing.
561-10.2.4 Soil/Ground Quality: Inspect the ground beneath and in proximity to
the structure in the presence of the Engineer for visible paint chips to establish an initial job site
cleanliness standard. When heavy metals are in the existing coatings, test soil samples prior to
the beginning of operations and after project completion for heavy metals. Document the number
and specific locations where the initial samples are taken as outlined in the SSPC Project DesignIndustrial Lead Paint Removal Handbook, Volume 2 to ensure the post samples are collected
from the same locations. Submit all samples to the Engineer for review. If the project activities
increase the heavy metal content in soil to more than 20% above the pre-job geometric mean or
100% at any one location, return the site to the pre-job levels. Conduct additional soil testing as
necessary to determine the extent of contamination.
For structures less than 14 feet minimum height, take one sample north,
south, east , and west (where soil is present) of the structure. If the structure is longer than
14 feet, take one additional sample for every 14 feet in length.
For structures greater than 14 feet minimum height, take two samples
north, south, east , and west (where soil is present) of the structure. Locate the inner row of
samples within 14 feet of the structure. Locate the outer row of samples at a distance equal to the
height of the structure. If the structure is longer than 14 feet, take one additional sample for every
14 feet in length.
In addition, submit a pre- and post- soil sampling plan for storage areas
identifying the sample location, depth, analyses list, lab certification, and turnaround time. Once
approved by the Engineer, submit sampling results along with a scaled drawing indicating
designated sample locations.
561-10.2.5 Water Quality: Do not release, discharge or otherwise cause
hazardous materials, debris, waste, or paint chips to enter the water. Protect against releases due
to rain and methods of surface preparation from reaching rivers, streams, lakes, storm drains, or
other bodies of water.
561-10.3 Containment System: Submit a written containment system design plan in
accordance with this section and the contract documents at the pre-construction conference or as
directed by the Engineer which clearly describes the proposed containment system applicable to
the intended removal method and in accordance with the requirements outlined herein and
SSPC Guide 6, Guide for Containing Debris Generated During Paint Removal Activities. Ensure
the plan includes, but is not limited to, removal method; methods for collecting debris; and
containment enclosure components. Use fire retardant materials. Provide containment drawings,
calculations, assumptions, ventilation criteria if applicable, and a structural analysis that verifies
the existing structure can withstand the additional dead, live and wind loads imposed by the
containment system, signed and sealed by a Specialty Engineer. However, for more complex
structures incorporating cables stayed, suspension, or truss designs, the analysis must be
performed by the Contractors Engineer of Record qualified in Type Work Category 4.3,
Complex Bridge Design. Provide a contingency plan addressing natural weather events such as
tropical storms and hurricanes. Ensure the lighting inside the containment is in accordance with
SSPC Guide 12, Guide for Illumination of Industrial Painting Projects. Provide lighting to a
minimum intensity of 10 ft-cd for general, 20 ft-cd for work, and 50 ft-cd for inspection. All
drawings and calculations must be submitted and accepted before any work begins. Include a
clear description of the ventilation system components and information including the fan curve
and design point on the proposed dust collector. Design to provide ventilation according to the
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notes provided in SSPC Guide 6: 100 feet per minute for cross draft and 50-60 feet per minute
for downdraft.
Isolate the immediate area of the structure to ensure compliance with current and
permit requirements for air, water, soil, and pollution prevention. Protect the containment system
from vehicular and pedestrian traffic. Ensure paint, paint chips, or other debris will not fall
outside of the containment area under any circumstances. Repair any damage created by
fastening, bracing, or handling the scaffolding and staging. If a suspended platform is
constructed, use rigid or flexible materials as needed to create an air and dust impenetrable
enclosure. Verify that the platform and its components are designed and constructed to support at
least four times its maximum intended load without failure, with wire cables capable of
supporting at least six times their maximum intended load without failure. Strictly comply with
all applicable OSHA regulations regarding scaffolding. The category and class of containment
shall be as required in the Contract Documents.
561-10.4 Protection of Adjacent Areas: Protect all areas adjacent to abrasive blast
cleaning, including machinery and deck grating. Before the commencement of any cleaning and
coating operations, provide a control plan for the protection of adjacent surfaces from damage by
nearby blasting and coating to the Engineer for review. Repair any damage to adjacent areas. The
repair procedure must be submitted to the Engineer for acceptance prior to any remediation.
561-10.5 Worker Protection: Comply with the requirements of OSHA 29 CFR 1926
and applicable portions of 29 CFR 1910. Include specific programs as required by
29 CFR 1926.62 (lead), 29 CFR 1926.1118 (inorganic arsenic), 29 CFR 1926.1126 (hexavalent
chromium), and 29 CFR 1926.1127 (cadmium) when these hazardous agents are present.
Implement appropriate safety procedures for all hazards on the job site whether specifically
identified herein or not.
561-11 Waste Handling and Management.
561-11.1 General: Prepare a waste management program plan which addresses the
applicable requirements from EPA regulations for hazardous waste management and the
Contract Documents. Include provisions for the handling and disposal of non hazardous waste.
Dispose of all waste in accordance with all federal, state, and local laws and regulations.
561-11.2 Collection and Handling of Waste: Properly classify, package, and store all
paint removal debris, both solid and liquid in accordance with SSPC Guide 7, Guide for the
Disposal of Lead-Contaminated Surface Preparation Debris, the Federal Water Pollution Control
Act with amendments, and all other current government regulations and guidelines. Comply with
the Resource Conservation and Recovery Act to include, at a minimum, CFR 40 260 through
CFR 40 268. Prior to identification and storage, separate solid and liquid waste, and separate
individual waste streams.
561-11.3 Testing and Analysis: Laboratory analyses for all waste stream and
environmental samples shall be conducted by an EPA certified, independent laboratory with an
approved Quality Assurance Plan. Laboratory analyses for worker monitoring and regulated area
samples shall be conducted by an American Industrial Hygiene Association (AIHA) metals
accredited laboratory. Provide a copy of all sampling and test reports no later than 72 hours after
collection of samples.
561-11.4 Waste Identification: Collect samples in accordance with EPA SW 846, Test
Methods for Evaluating Solid Waste - Physical/Chemical Methods. Use a random and
representative sampling technique. Collect a minimum of four representative samples of each
waste stream. These waste streams include, but are not limited to, water, paint chips, dust, and
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paint chips mixed with disposable abrasives and debris. Complete the initial sampling of each
waste stream immediately upon filling the first drum, but do not allow waste to accumulate for
longer than 7 days before sampling.
After the representative samples are collected, send them immediately to the EPA
certified laboratory for analysis. Unless otherwise directed by the Engineer, required by State
regulations, or required by the waste recycling or disposal facility, once each waste stream is
sampled, tested, and classified, additional sampling and analysis are not required for subsequent
shipments unless the waste stream changes. Submit samples to an approved laboratory to be
tested for arsenic, barium, cadmium, hexavalent chromium, lead, mercury, selenium, and silver
in accordance with EPA Method 3050 and Method 6010 (content) and EPA Method 1311,
Toxicity Characteristics Leaching Procedures (TCLP).Clearly label each sample with sample
number, date and time of sampling, name of collector, and location of collection.
Maintain chain of custody forms for each sample. Enter each sample on a sample
analysis request form. Enter sample numbers, type of waste, amount of each sample, distribution
of samples, signature and all other information into field logbook.
561-11.5 Waste Storage: Collect waste from the control devices, equipment, and all
work surfaces on a daily basis. Keep hazardous and non-hazardous waste separate. Do not mix
blasting debris with any other type of waste. Place waste in approved storage drums.
Locate all hazardous waste within a regulated area. The maximum weight for
each drum, when filled, is 821 pounds. Properly seal and label all drums. Transport waste storage
drums to a secured, marked, temporary storage area. Locate the temporary storage area on welldrained ground not susceptible to flooding or storm water run-off. Place drums on a pallet and
cover with fiber reinforced, impermeable tarpaulins. Store drums no more than two drums wide
and two drums high. Arrange drums so that labels are easily readable. Do not store waste in the
temporary storage area longer than 90 days.
561-11.6 Waste Disposal: Transport, treat and dispose of all hazardous and nonhazardous waste. Notify the Engineer a minimum of three weeks prior to the date of shipment of
any waste to an off- site facility. Provide the Engineer with documentation that the receiving
disposal facilities are properly licensed. Provide manifests for all hazardous and non-hazardous
waste shipments. Identify any waste disposal subcontractors and provide a copy of their licensing
to perform waste disposal and transport operations.
561-11.7 Permits: The Contractor is responsible for all liability resulting from noncompliance with pertinent rules and regulations including permit requirements.
561-12 Method of Measurement.
The quantity to be paid will be the lump sum quantity coated, completed and accepted.
561-13 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 561- 1Coating Existing Structural Steel - lump sum.
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SECTION 562
REPAIR OF GALVANIZED SURFACES
562-1 Description.
Apply a coating of galvanizing compound over welded areas of galvanized structural
members and over areas of previously galvanized members on which the galvanizing has
become damaged.
562-2 Materials.
562-2.1 Areas 100 Square Inches or Less: Use a cold galvanizing compound containing
at least 92% zinc dust in the dry film.
562-2.2 Areas Greater than 100 Square Inches: Use a galvanizing compound as
specified in 975-2.4.1 and listed on the Qualified Products List (QPL).
562-3 Construction Methods.
Prepare surfaces and apply the galvanizing compound according to ASTM A780 and
manufacturers recommendations. Apply additional coats on rough or pitted surfaces, when in
the opinion of the Engineer it is necessary to obtain acceptable cover. Follow the manufacturers
recommended dry time between coats.
Re-clean the areas not coated on the same day the cleaning is accomplished, or surfaces
that have rusted, prior to coating.
Apply the galvanizing compound to attain a uniform appearance free from all defects or
failures. Submit repair procedures to the Engineer for approval. All deficiencies will be corrected
at no cost to the Department.
562-4 Basis of Payment.
No direct payment will be made for galvanizing compound coating of welded surfaces or
for field repair of damaged galvanized surfaces. Include the cost to perform these operations, in
the Contract price for the item which includes the member being so treated.
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SECTION 563
ANTI-GRAFFITI COATINGS
563-1 Description.
Apply an anti-graffiti coating in accordance with the requirements of this Section
to the areas shown in the Plans.
563-2 Materials.
Use anti-graffiti coating products meeting the requirements of Section 975 that
are recommended for the base substrate by the manufacturer and listed on the
Departments Qualified Products List (QPL). Do not use sacrificial coatings on steel
structures.
563-3 Application.
563-3.1General: Apply anti-graffiti coatings in accordance with the
manufacturers product data sheet.
563-3.2 Protection of Adjacent Surfaces: Consider wind direction, velocity and
geographic location as having a major impact on all cleaning and anti-graffiti coating
operations. Use all necessary precautions to prevent cleaning and anti-graffiti coating
materials from being dispersed outside the work site. If conditions are such that material
is dispersed to areas where vehicles or other property may be damaged, suspend
operations until conditions improve and work can continue without affecting adjacent
property.
Protect all surfaces not intended to be coated, which are adjacent to, or in
close proximity to the surfaces to be coated, during the application of anti-graffiti
coating. Clean surfaces that are to be coated, as per the manufacturers product data
sheet.
563-3.3 Surface Preparation: Remove all graffiti from the substrate. Prior to
applying any anti-graffiti coatings, prepare all surfaces to be coated in accordance with
ASTM D4261 or ASTM D4258 and the manufacturers product data sheet.
When the anti-graffiti coating or coating system is to be applied over an
existing coating, apply a test patch (minimum area of 4 square feet) in accordance with
this Section. Allow the test patch to cure a minimum of 7 days without any defects. No
time extension will be granted as a result of this test requirement.
563-3.4 Correction of Deficiencies: Remove all applied anti-graffiti coatings
identified by the Engineer as damaged, defective, or otherwise not meeting these
Specifications, in accordance with the manufacturers recommendations.
Prepare the surface and reapply the coating in accordance with the
manufacturers recommendations and as specified herein.
Remove and correct all deficiencies at no additional cost to the
Department.
563-4 Method of Measurement.
The quantity to be paid for will be plan quantity, in square feet, of the area of antigraffiti coating completed and accepted.
The area will be based on the surface area shown in the Plans with no allowance
for surface texture or variable depth surface profiles.
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563-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including furnishing and applying all materials to complete the anti-graffiti coating.
Payment shall be made under:
Item No. 563- 3Anti-Graffiti Coating, Sacrificial - per square foot.
Item No. 563- 4Anti-Graffiti Coating, Non Sacrificial - per square
foot.
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SECTION 570
PERFORMANCE TURF
570-1 Description.
Establish a growing, healthy turf over all areas designated in the Plans. Use sod in areas
designated in the Plans to be sodded. Use seed, hydroseed, bonded fiber matrix, or sod in all
other areas. Maintain turf areas until final acceptance of all contract work in accordance with
Section 5-11.
570-2 Materials.
Meet the following requirements:
Turf Materials .................................................................Section 981
Fertilizer ..........................................................................Section 982
Water ...............................................................................Section 983
570-3 Construction Methods.
570-3.1 General: Incorporate turf installation into the project at the earliest practical
time.
Shape the areas to be planted to the plan typical sections and lines and grade
shown in the Contract Documents.
Except in areas where the Contract Documents requires specific types of grass to
match adjoining private property, any species of grass designated in Section 981 may be used.
Use the methods and materials necessary to establish and maintain the initial grassing until
acceptance of the Contract work in accordance with 5-11. All of the permanent grassing material
shall be in place prior to final acceptance.
The Department will only pay for replanting as necessary due to factors
determined by the Engineer to be beyond control of the Contractor.
Complete all grassing on shoulder areas prior to the placement of the friction
course on adjacent pavement.
570-3.2 Seeding: At the Contractors option, wildflower seed may be included in the turf
seeding operation or performed separately from the turf seeding.
Use of compost meeting the requirements of Section 987 as mulch is acceptable
unless otherwise specified.
570-3.3 Sod: Place the sod on the prepared surface, with edges in close contact. Do not
use sod which has been cut for more than 48 hours.
Place the sod to the edge of all landscape areas as shown in the Plans and as
shown in the Design Standards.
Peg sod at locations where the sod may slide. Drive pegs through sod blocks into
firm earth, flush with the sod soil surface, at intervals approved by the Engineer. The work and
materials for pegging of sod as directed by the Engineer will be paid for as Unforeseeable Work.
Place rolled sod parallel with the roadway and cut any exposed netting even with
the sod edge.
Monitor placed sod for growth of pest plants and noxious weeds. If pest plants
and/or noxious weeds manifest themselves within 30 days of placement of the sod during the
months April through October, within 60 days of placement of the sod during the months of
November through March treat affected areas by means acceptable to the Department at no
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expense to the Department. If pest plants and/or noxious weeds manifest themselves after the
time frames described above from date of placement of sod, the Engineer, at his sole option, will
determine if treatment is required and whether or not the Contractor will be compensated for
such treatment. If compensation is provided, payment will be made as Unforeseeable Work as
described in 4-4.
Remove and replace any sod as directed by the Engineer.
570-3.4 Hydroseeding: Use equipment specifically designed for mixing the mulch, seed,
fertilizer, tackifier and dye, and applying the slurry uniformly over the areas to be hydroseeded.
Use mulch that does not contain reprocessed wood or paper fibers. Ensure that
50% of the fibers will be retained on a twenty-five mesh screen.
Mix fertilizer as required into the hydroseeding slurry.
Ensure that the dye does not contain growth or germination inhibiting chemicals.
When polyacrylamide is used as part of hydroseeding mix, only anionic polymer
formulation with free acrylamide monomer residual content of less than 0.05% is allowed.
Cationic polyacrylamide shall not be used in any concentration. Do not spray polyacrylamide
containing mixtures onto pavement. These may include tackifiers, flocculants or moistureholding compounds.
570-3.5 Bonded Fiber Matrix (BFM): Meet the minimum physical and performance
criteria of this Specification for use of BFM in hydroseeding operations or temporary nonvegetative erosion and sediment control methods.
Provide evidence of product performance testing, manufacturers certification of
training and material samples to the Engineer at least 7 calendar days prior to installation.
Provide documentation to the Engineer of manufacturers testing at an
independent laboratory, demonstrating superior performance of BFM as measured by reduced
water runoff, reduced soil loss and faster seed germination in comparison to erosion control
blankets.
Use only BFMs that contain all components pre-packaged by the manufacturer to
assure material performance. Deliver materials in UV and weather resistant factory labeled
packaging. Store and handle products in strict compliance with the manufacturers directions.
When polyacrylamide is used as part of hydroseeding mix, only anionic polymer
formulation with free acrylamide monomer residual content of less than 0.05% is allowed.
Cationic polyacrylamide shall not be used in any concentration. Do not spray polyacrylamide
containing mixtures onto pavement. These may include tackifiers, flocculants or moistureholding compounds.
Meet the following requirements after application of the formed matrix:
Ensure that the tackifier does not dissolve or disperse upon re-wetting.
Ensure that the matrix has no gaps between the product and the soil and
that it provides 100% coverage of all disturbed soil areas after application.
Ensure that the matrix has no germination or growth inhibiting properties
and does not form a water-repelling crust.
Ensure that the matrix is comprised of materials which are 100%
biodegradable and 100% beneficial to plant growth.
Mix and apply the BFM in strict compliance with the manufacturers
recommendations.
Apply the BFM to geotechnically stable slopes at the manufacturers
recommended rates.
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Degradation of BFM will occur naturally as a result of chemical and biological
hydrolysis, UV exposure and temperature fluctuations. Re-application, as determined by the
Engineer, will be required if BFM-treated soils are disturbed or water quality or turbidity tests
show the need for an additional application. The work and materials for re-application, will be
paid for as Unforeseeable Work.
570-3.6 Watering: Water all turf areas as necessary to produce a healthy and vigorous
stand of turf. Ensure that the water used for turf irrigation meets the requirements of Section 983.
570-3.7 Fertilizing: Fertilize as necessary based on soil testing performed in accordance
with Section 162. Refer to Section 982 for fertilizer rates.
For bid purposes, base estimated quantities on an initial application of
265 lbs/acre and one subsequent application of 135 lbs/acre of 16-0-8.
570-4 Turf Establishment.
Perform all work necessary, including watering and fertilizing, to sustain an established
turf until final acceptance, at no additional expense to the Department. Provide the filling,
leveling, and repairing of any washed or eroded areas, as may be necessary.
Established turf is defined as follows:
Established root system (leaf blades break before seedlings or sod can be pulled
from the soil by hand).
No bare spots larger than one square foot.
No continuous streaks running perpendicular to the face of the slope.
No bare areas comprising more than 1% of any given 1,000 square foot area.
No deformation of the turf areas caused by mowing or other Contractor
equipment.
Monitor turf areas and remove all competing vegetation, pest plants, and noxious weeds
(as listed by the Florida Exotic Pest Plant Council, Category I List of Invasive Species, Current
Edition, http://www.fleppc.org). Remove such vegetation regularly by manual, mechanical, or
chemical control means, as necessary. When selecting herbicides, pay particular attention to
ensure use of chemicals that will not harm desired turf or wildflower species. Use herbicides in
accordance with 7-1.7.
If at the time that all other work on the project is completed, but all turf areas have not
met the requirements for established turf set forth in 570-4, continuously maintain all turf areas
until the requirements for established turf set forth in 570-4 have been met.
During the entire establishment period and until turf is established in accordance with this
specification, continue inspection and maintenance of erosion and sedimentation control items in
accordance with Section 104. Take responsibility for the proper removal and disposal of all
erosion and sedimentation control items after turf has been established.
Notify the Engineer, with a minimum of seven calendar days advance notice, to conduct
inspections of the turf at approximate 90-day intervals during the establishment period to
determine establishment. Results of such inspections will be made available to the Contractor
within seven calendar days of the date of inspection. Determination of an established turf will be
based on the entire project and not in sections.
Upon the determination by the Engineer that the requirements of 570-4 have been met
and an established turf has been achieved and all erosion and sedimentation control items have
been removed, the Engineer will release the Contractor from any further responsibility provided
for in this Specification.
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The Contractors establishment obligations of this specification will not apply to
deficiencies due to the following factors, if found by the Engineer to be beyond the control of the
Contractor, his subcontractors, vendors or suppliers:
a. Determination that the deficiency was due to the failure of other features of the
Contract.
b. Determination that the deficiency was the responsibility of a third party
performing work not included in the Contract or its actions.
The Department will only pay for replanting as necessary due to factors determined by
the Department to be beyond the control of the Contractor.
570-5 Responsible Party.
For the purposes of this Specification, the Contractor shall be the responsible party
throughout construction and establishment periods.
Upon final acceptance of the Contract in accordance with 5-11, the Contractors
responsibility for maintenance of all the work or facilities within the project limits of the
Contract will terminate in accordance with 5-11; with the sole exception that the facilities
damaged due to lack of established turf and the obligations set forth in this Specification for
performance turf shall continue thereafter to be responsibility of the Contractor as otherwise
provided in this Section.
570-6 Disputes Resolution.
The Contractor and the Department acknowledge that use of the Statewide Disputes
Review Board is required and the determinations of the Statewide Disputes Review Board for
disputes arising out of the performance turf specification will be binding on both the Contractor
and the Department, with no right of appeal by either party, for the purposes of this
Specification.
Any and all Statewide Disputes Review Board meetings after final acceptance of the
Contract in accordance with 5-11 shall be requested and paid for by the Contractor. The
Department will reimburse the Contractor for all fees associated with meetings.
570-7 Failure to Perform.
Should the Contractor fail to timely submit any dispute to the Statewide Disputes Review
Board, refuse to submit any dispute to the Statewide Disputes Review Board, fail to provide an
established turf in accordance with 570-4 within one year of final acceptance of the Contract in
accordance with 5-11, or fail to compensate the Department for any remedial work performed by
the Department in establishing a turf and other remedial work associated with lack of an
established turf, including but not limited to, repair of shoulder or other areas due to erosion and
removal of sediments deposited in roadside ditches and streams, as determined by the Statewide
Disputes Review Board to be the Contractors responsibility, the Department shall suspend,
revoke or deny the Contractors certificate of qualification under the terms of
Section 337.16(d)(2), Florida Statutes, until the Contractor provides an established turf or makes
full and complete payment for the remedial work performed by the Department. In no case shall
the period of suspension, revocation, or denial of the Contractors certificate of qualification be
less than six months. Should the Contractor choose to challenge the Departments notification of
intent for suspension, revocation or denial of qualification and the Departments action is upheld,
the Contractor shall have its qualification suspended for a minimum of six months or until the
remedial action is satisfactorily performed, whichever is longer.
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570-8 Method of Measurement.
The quantities to be paid for will be plan quantity in square yards based on the area
shown in the Plans, completed and accepted.
570-9 Basis of Payment.
Prices and payments will be full compensation for all work and materials specified in this
Section.
Payment will be made under:
Item No. 570- 1Performance Turf - per square yard.
763
SECTION 571
PLASTIC EROSION MAT
571-1 Description.
Furnish and install plastic erosion mat on areas as shown in the Plans. Conduct this work
in conjunction with the performance turf work as specified in Section 570.
571-2 Materials.
Use a plastic erosion mat consisting of continuous or fused synthetic polymer fibers,
which are entangled to form a three-dimensional matrix (netting or distorted netting may be
included as part of the matrix). Ensure that the mat is capable of maintaining its shape
throughout installation. Ensure that the mat is inert to chemicals encountered in a natural soil
environment, and meets the requirement of Section 985 and the Design Standards, Index
No. 199, according to its application.
571-3 Installation of Plastic Erosion Mat.
Before installing the plastic erosion mat, furnish the Engineer two certified copies of the
test report from the manufacturer certifying that the geotextile to be incorporated into this project
meets the requirements of Section 985 and Design Standards, Index No. 199. Also, provide two
copies of the manufacturers written installation instructions.
Install a plastic erosion mat of uniform thickness, not less than 1/4 inch or more than
3/4 inch on the prepared soil surface in accordance with these Specifications, the manufacturers
recommendations and in conformity with the lines, grades and dimensions as shown in the Plans.
Ensure that all joints are shingle lapped such that the bottom of each section fits over the top of
the section below to prevent uplift of the ends or edges by water flow. Overlap ends of adjacent
rolls a minimum of 3 feet. Overlap edges of adjacent rolls a minimum of 4 inches. Stake all
edges at 3 to 5 feet intervals with staples as recommended by the manufacturer unless otherwise
directed by the Engineer. Ensure that overlaps and anchor trenches are in conformance with the
Plans and the manufacturers installation recommendations.
Ensure that after installation there are no protrusions, projections or exposures of the
plastic erosion mat. Do not compact the installed plastic erosion mat with any type of equipment
employing a foot or grid.
The Engineer will reject any material having defects, tears, punctures, flaws,
deterioration or other damage before, during or after installation. Remove and replace all
rejected plastic erosion mat at no additional expense to the Department.
Fill all voids in the mat with soil meeting the requirements of Section 987. Establish
performance turf meeting the requirements of Section 570.
571-4 Method of Measurement.
The quantity to be paid for will be the surface area of plastic erosion mat installed and
accepted in square yards with no allowance for overlaps.
Performance turf will be paid for separately in accordance with Section 570.
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571-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section,
including furnishing, handling, placement of plastic erosion mat, all labor, equipment, and
miscellaneous materials necessary for a complete and accepted installation.
Payment will be made under:
Item No. 571- 1Plastic Erosion Mat - per square yard.
765
SECTION 580
LANDSCAPE INSTALLATION
580-1 Description.
Install, establish and maintain landscaping as indicated in the Contract Documents.
580-2 Materials.
580-2.1 Plants:
580-2.1.1 Grade Standards and Conformity with Type and Species: Only use
nursery grown plant materials purchased from Florida based Nurseryman Stock that comply with
all required inspection, grading standards, and plant regulations in accordance with the latest
edition of the Florida Department of Agricultures Grades and Standards for Nursery Plants.
Unless otherwise specified, minimum grade for all plants is Florida No. 1
or better. All plants must be the specified size and grade at the time of delivery to the site and the
minimum grade maintained throughout the project construction period and plant establishment
period.
Use only plants that are true to type and species and ensure that the plants
not specifically covered by Florida Department of Agricultures Grades and Standards for
Nursery Plants conform in type and species with the standards and designations in general
acceptance by Florida nurseries. Prior to planting, furnish certification to the Engineer that all
plant materials have been purchased from Florida based Nurseryman Stock.
A minimum of two plants of each species on each shipment must be
shipped with tags stating the botanical nomenclature and common name of the plant. Should
discrepancies between botanical nomenclature and common name arise, the botanical name will
take precedence.
580-2.1.2 Inspection and Transporting: Move nursery stock in accordance with
all Federal and State regulations and accompany each shipment with the required inspection
certificates for filing with the Engineer.
580-2.2 Water: Meet the requirements of Section 983.
580-2.3 Mulching: Use of cypress mulch prohibited.
580-3 Planting Requirements.
580-3.1 Delivery: All materials must be available for inspection before installation and
will be subject to approval or rejection.
580-3.2 Layout: Mark proposed planting beds and individual locations of trees and
palms as shown in the Contract Documents for Engineers review, prior to excavation or
planting. The Engineer may request to review all proposed construction and maintenance
practices before the start of the operations.
Make no changes to the layout, materials or any variations of plant materials from
the Contract Documents without the Engineers written approval.
580-3.3 Soil Drainage: All planting holes and beds must drain sufficiently prior to
installing any plants. Immediately notify the Engineer of drainage or percolation problems before
plant installation.
580-3.4 Installation of Plants: For installation of the plants as identified in the Contract
Documents, comply with the requirements of the Design Standards, Index No. 544.
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Personnel performing these services are under the sole responsibility and
supervision of the Contractor and must be competent, experienced, and skilled in all aspects of
the required landscape installation and establishment practices.
580-3.5 Contractors Responsibility for Condition of the Plantings: Begin
maintenance of all plants immediately after each planting.
Keep all plants watered, fertilized, mulched, pruned, and staked and guyed as
necessary to assure specified minimum grade of Florida No. 1 throughout the duration of the
project construction period and establishment period. During the establishment period, keep the
individual planting locations and planting beds free of litter and undesirable vegetation. Ensure
that the plants are maintained so that they are healthy, vigorous, and undamaged throughout the
duration of the project construction period and establishment period. For the duration of the
establishment period, operate and maintain in good operating condition, all components of any
irrigation system installed in compliance with the Contract Documents.
During the establishment period, replace any plants that fall below specified
minimum grade. Use replacement plants of the same species, size and planting medium as the
plant being replaced and as specified in the Contract Documents.
580-3.6 Inspection Requirements: Certify monthly, on a form provided by the
Department, that the plants have been installed and are being maintained per the Contract
Documents. A Registered Landscape Architect acting as the Contractors Landscape Quality
Control representative will oversee the establishment period.
The Contractors Landscape Quality Control representative must perform
quarterly inspections of planting areas and submit findings in report form to the Department.
Information to be included in inspection report from the Contractors Quality Control
representative must include as a minimum the following:
Date of inspection
Description of project
Location of inspection
Weather conditions
Condition of plants - identify by species, location, and number of plants
that are no longer the specified minimum.
Condition of planting beds (including mulching, mowing, weeding,
fertilizing, watering, and staking and guying), if applicable
Other comments
Signature and seal of Contractors Landscape Quality Control
representative
Submit the certified inspection report to the Engineer within seven calendar days
after performing the inspection. Any corrections to the inspection report must be
revised/corrected and resubmitted within three calendar days after notification by the Engineer.
Any deficiencies noted on the inspection report must be corrected within ten days of notification
from the Department.
Periodic, random verifications will be performed by the Department to ensure the
quality of the plants and correctness of the certified landscape inspection report. Any unresolved
disputes that arise between the quality control reporting and the verifications performed by the
Department will be referred to the Statewide Disputes Review Board.
767
580-4 Disposal of Surplus Materials and Debris.
Remove from the jobsite any surplus excavated material from plant holes unless
otherwise directed by the Engineer. Surplus is defined as material not needed after installation of
plants per Contract Documents. Upon commencement of the plant installation, remove daily all
landscape installation debris from the landscape locations described in the Contract Documents.
Remove all excess staking and guying materials from the jobsite.
580-5 Plant Establishment Period and Contractors Warranty.
Take responsibility for the proper maintenance, survival and condition of all plants for a
period of one year after final acceptance in accordance with 5-11. Notify the Engineer upon
completion of installation of all plants.
Mowing as part of the landscape work will be identified in the Contract Documents.
Continue any mowing of the landscape areas specified in the Contract Documents throughout the
establishment period.
As a condition precedent to final acceptance in accordance with 5-11, provide a
Warranty/Maintenance Bond to the Department in the amount of the total sums bid for all
landscape items as evidence of warranty during this plant establishment period. The cost of the
bond will not be paid separately, but will be included in the costs of other bid items.
In addition to satisfying the provisions of Section 287.0935, Florida Statutes, the bonding
company is required to have an A.M. Best rating of A or better. If the bonding company drops
below the A rating during the Warranty/Maintenance Bond period, provide a new
Warranty/Maintenance Bond for the balance of the establishment period from a bonding
company with an A or better rating. In such event, all costs of the premium for the new
Warranty/Maintenance Bond will be at the Contractors expense.
The Engineer may conduct interim inspections of all landscape items during the plant
establishment period, as well as at the end of the plant establishment period. As part of the
warranty to the Department, and at no cost to the Department, replace all plants found not to
meet minimum specifications as shown in 580-2.1.1 and 580-3.5 within ten days after each
inspection.
Prior to the end of the establishment period and after plant establishment has been
verified, remove all staking and guying from the project.
At the end of the establishment period, the Engineer will release the Contractor from
further warranty work and responsibility provided all plants are established and all previous
warranty and remedial work, if any, has been completed to the satisfaction of the Engineer.
580-6 Method of Measurement.
The quantities to be paid will be the items shown in the Contract Documents, completed
and accepted.
580-7 Basis of Payment.
Prices and payments will be full compensation for all work and materials specified in this
Section.
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TRAFFIC CONTROL SIGNALS AND DEVICES
SECTION 603
GENERAL REQUIREMENTS FOR THE INSTALLATION
AND EVALUATION OF TRAFFIC CONTROL SIGNALS AND
DEVICES
603-1 Description.
The provisions contained in this Section include general requirements for all traffic
control signals and devices.
603-2 Equipment and Materials.
603-2.1 General: Except as provided in 603-2.2, only use traffic control signals and
devices meeting the requirements of the Minimum Specifications for Traffic Control Signals and
Devices (MSTCSD), the Contact Documents, and listed on the Departments Approved Product
List (APL).
Only use new equipment and materials, except as specified in the Contract
Documents.
603-2.2 Exceptions: The Department may grant exceptions to the requirements of
603-2.1 by temporary permit to evaluate new technology or for other circumstances that are
found to be in the public interest.
603-2.3 Uniformity: Only use compatible units of any one item of equipment, such as
signal heads, detectors, controllers, cabinets, poles, signal system or interconnection equipment,
etc.
603-2.4 Hardware and Fittings: Ensure that all bolts and nuts less than 5/8 inch in
diameter are passivated stainless steel, Type 316 or Type 304 and meet the requirements of
ASTM F593 and ASTM F594 for corrosion resistance.
Ensure that all bolts and nuts 5/8 inch and over in diameter are galvanized and
meet the requirements of ASTM A307.
Use high-strength steel anchor bolts and U-bolts, having a minimum yield
strength of 55,000 psi and a minimum ultimate strength of 90,000 psi.
603-2.5 Galvanizing: Meet the requirements of Section 962 when galvanizing for fittings
and appurtenances for all structural steel (including steel poles).
603-3 Definitions.
Traffic Control Signals and Devices: Any signal or device, manually, electrically or
mechanically operated by which traffic is alternately directed to stop and permitted to proceed or
controlled in any manner. Traffic control signals and devices regulate, warn, or guide traffic on,
over or adjacent to a street, highway, pedestrian facility, or bikeway by authority of a public
agency having jurisdiction. Traffic control signals and devices include, but are not limited to,
controller assemblies (controller cabinets and their contents); signal heads including their
hanging or mounting devices; vehicle detection systems (loops, sealant, amplifier, lead-in wire,
or cable); pedestrian detection systems (push button, push button housing, lead-in wires, and
signal); motorist information systems, video equipment, network devices, dynamic message
signs, highway advisory radios, cameras, vehicle detection systems, and other equipment used
within a traffic control system.
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Minimum Specifications for Traffic Control Signals and Devices (MSTCSD): The
minimum specifications used for the evaluation, certification, and approval of official traffic
control signals and devices and ancillary devices for use on the streets and highways of Florida.
The specifications are available on the Traffic Engineering and Operations web site.
Approved Product List (APL): A listing of approved traffic control signals and devices,
and ancillary devices or system equipment that the Department has reviewed for compliance to
specifications and authorized for use on the streets and highways of Florida. The APL is
available on the Traffic Engineering and Operations web site.
Temporary Permit: A permit issued by the Traffic Engineering and Operations Office to a
public or private entity for the purpose of evaluating the operational effectiveness and safety of a
device for a specified time period at specific locations. This permit is issued only when the
limited use of the device is in the best interest of the public.
603-4 Systems Approval Requirement.
The Engineer will review and approve any system design plan of traffic control signals
and devices, that is controlled or operated from a remote location by computers or similar
devices, and which affects the movement of traffic on any portion of the State Highway System,
prior to installation. Within such system, only use traffic control signals and devices that meet all
certification or approval requirements contained herein.
603-5 Device Approval Process.
The Departments APL certification and approval process is described in the FDOT
Traffic Engineering Manual, Section 7.1
603-6 Marking of Approved Equipment.
Ensure that traffic control signals and devices are marked in accordance with Section
A601 of the MSTCSD.
603-7 Submittal Data Requirements.
Prior to the installation of equipment and within 30 days after the preconstruction
conference, submit a completed listing of all traffic control signals, devices, or hardware with
Department APL approval numbers to the Engineer for approval on the form provided by the
Department. For non-structural equipment or materials that do not have a Department APL
approval number, submit one copy of the manufacturers descriptive literature and technical data
fully describing the equipment to the Engineer for approval.
Develop shop drawings for all structural support materials and other special designs, such
as non-electrical, non-mechanical, or other fabricated items, which may not be specifically
detailed in the Plans. Have the Specialty Engineer approve all shop drawings. Do not submit
shop drawings for those items that have been previously evaluated and approved. Meet the
requirements of 5-1.4 for shop drawings. Send two copies of the shop drawings signed and
sealed by the Specialty Engineer to the Engineer.
Provide a complete operable signal installation as specified in the Contract regardless of
any failure of the Department to discover or note any unsatisfactory material. Meet the
requirements of Section 608.
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603-8 Documentation for Electronic Equipment.
Prior to final acceptance, furnish the Engineer with two copies of the following
documentary items obtained from the manufacturer for the electronic equipment listed below:
1. Operation Manual
2. Troubleshooting and Service Manual
3. Assembly and installation instructions
4. Pictorial layout of components and schematics for circuit boards
5. Parts list, including the location
6. Diagram of the field installation wiring (not applicable to the detectors)
7. Warranty information
Furnish documentary items for the following equipment:
1. Controllers
2. Vehicle detectors
3. Load switches
4. Flasher units
5. Preemption units
6. Conflict monitors
7. Special sequence relays
8. Cameras
9. Dynamic message signs
10. Highway advisory radios
11. Road weather information systems
12. Any other equipment which has a logic, timing, or communications function
13. Other equipment specified in the Contract Documents
603-9 Department-Furnished Equipment Installed By Contractor.
Where the Contract includes installation of Department-furnished equipment, the
Department will turn over such equipment to the Contractor when the construction progress
allows or as designated in the Contract Documents. The Department will test and certify the
equipment to be in proper condition and ready to use and will bear the costs of correcting any
defects in the equipment prior to pick-up by the Contractor. The Engineer will coordinate the
pick-up and installation of the equipment. Maintain the equipment in proper operational
condition after pick-up at no cost to the Department, until either final acceptance or the
equipment is returned to the Department.
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SECTION 608
MANUFACTURERS WARRANTIES FOR TRAFFIC CONTROL SIGNALS AND
DEVICES
608-1 Description.
This Section sets forth manufacturers warranty requirements for traffic control signals
and devices furnished to the Department. Manufacturer and Contractor costs associated with
transferring, providing, and delivering equipment warranties, requirements, terms, and conditions
are part of the Work and are included in the pay item for the equipment or construction feature
utilizing the equipment.
608-2 Manufacturers Warranty Provisions.
608-2.1 General: Secure all warranties provided by the equipment manufacturer for the
specific equipment included in the Contract. Ensure that all warranties are fully transferable from
the Contractor to the owner of the equipment within the project limits. Ensure that warranties
cover defects for at least the duration specified in the Contract Documents from the date of final
acceptance in accordance with 5-11. Transfer warranties upon final acceptance in accordance
with 5-11. Document all warranties and warranty transfers and provide a copy to the Engineer.
In accordance with 611-5, the Contractors responsibility for warranty repairs, warranty
replacement, troubleshooting, or other costs associated with repair or replacement of traffic
control signals and devices within the contracts project limits will terminate 90 days after final
acceptance in accordance with 5-11.
608-2.2 Terms and Conditions: Ensure that the terms and conditions of warranties are
documented by the manufacturer for equipment submittals on construction projects. Include
terms for a specified service performance with provisions for repair parts and labor, or for
replacement.
When a warranty is available, ensure that a written warranty accompanies the
manufacturers billing invoice. Ensure warranties require the manufacturer to furnish
replacements for any part or equipment found to be defective during the manufacturers warranty
period at no cost to the owner of the equipment within the project limits.
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SECTION 611
ACCEPTANCE PROCEDURES FOR TRAFFIC CONTROL SIGNALS AND DEVICES
611-1 Description.
This Section sets forth Contract acceptance procedures for installations of traffic control
signals and devices and for equipment purchase contracts.
611-2 Acceptance of Traffic Control Signal and Device Installations.
611-2.1 Partial Acceptance: The Engineer may make inspection for partial acceptance
under the Contract in accordance with 5-10 of a complete traffic control signal and device
installation upon its completion in accordance with the Contract Documents and at such time that
other parts of the total Contract are at a stage of completion that either require or allow the
installation to operate in a manner which is in accordance with the Contract Documents. Before
inspection for partial acceptance, the Engineer will require the satisfactory completion of all field
tests of completed installations in accordance with the requirements of 611-4. The Engineer will
make inspection for partial acceptance in accordance with 5-10 in company with a Contractor's
representative and, when applicable, a representative of the agency designated to accept
maintenance responsibility.
611-2.2 Final Acceptance: The Engineer will make inspection for final acceptance of
traffic control signal and device installations as part of all work under the Contract in accordance
with 5-11, only after satisfactory completion of all field tests of completed installations in
accordance with the requirements of 611-4 and on the basis of a comprehensive final field
inspection of all equipment installations. Submit three copies of Form 750-010-02, Submittal
Data - Traffic Control Equipment to the Engineer. The Engineer will make the final inspection
with a Contractor's representative and, when applicable, a representative of the agency
designated to accept maintenance responsibility. Transfer warranties and guarantees on
equipment to the Department in accordance with Section 608. For traffic signal installations,
submit three completed copies of Form 700-010-22, Final Acceptance of Traffic Signal
Installation(s) and Transfer of Maintenance, to the Engineer.
611-2.3 As-Built Drawings: As a condition precedent to acceptance under 611-2.1 or
611-2.2, furnish as-built drawings of all installations in accordance with the following
requirements:
611-2.3.1 Submittal Requirements: Submit three sets of as-built plans for
review by the Engineer on reproductions of the original 11 inch by 17 inch sheets. Record all asbuilt information using block lettering or typed text to ensure legibility. Signing and pavement
marking plan sheets may be used instead of signalization plan sheets, if a substantial number of
changes from the original plans must be recorded. Intelligent transportation system (ITS) as-built
plans must include an accurate table (spreadsheet) that provides the true final location of devices
by mile post to three decimal places, plus an offset dimension given for each above-ground
structure. Global positioning system (GPS) coordinates can be utilized as supplemental
information in the table. Aerial photographs may be furnished with the table to provide
supplementary information. The aerials should not include the extra features of the right of way,
baseline, or roadway edges being drawn in. The aerials may be used as a base for the as-built
plans with mile post and offset dimensions. If, in the opinion of the Engineer, the changes can
not be clearly delineated on reproductions of the original 11 inch by 17 inch sheets, clearly
delineate all changes on 11 inch by 17 inch detail sheets, enlarged 200% from the reproductions.
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Make any corrections resulting from the Engineers review, and resubmit three sets of the
completed as-built plans as a condition precedent to acceptance of the installation.
611-2.3.2 Components: Include as-built information for all components of the
installation. As a minimum, identify the following components in the format indicated below.
611-2.3.2.1 Conduit and Cable: Identify all conduit and cable with
unique linestyles for routing (overhead, conduit, saw cut, etc.) that are clearly identified in a
legend on each sheet. Identify the type of cable (example - 7 conductor signal cable) and label
the number of conductors, fiber strands or other identifying features of the cable. For conduit,
clearly note conduit size and number of runs.
611-2.3.2.2 Loops and Detection Zones: Identify the location of all
installed loops (including the distance from the stop bar for the advance loops), the path of each
loop to the pull box, the loop window and the path of the loop lead-in to the controller cabinet.
Identify the device location and the approximate detection area for detection systems that are not
embedded in or under pavement.
611-2.3.2.3 Pull Boxes: Label unused and out of service pull boxes
clearly. Show distances to each pull box from the nearest edgeline, stop bar, or other permanent
feature. If an edgeline is not near a pull box or would not clearly identify its location; a fixed
monument may be used (example - FDOT pole or structure).
611-2.3.2.4 Poles: Locate Poles from the nearest edgeline of both
approaches. If an edgeline is not near a pole or would not clearly identify its location, a fixed
monument may be used.
611-2.3.2.5 Signal Heads: Locate all signal heads with respect to the
pavement markings. Each signal head shall be identified by its corresponding movement number.
611-2.3.2.6 Cabinet: Clearly locate all cabinets. The type of cabinets and
inventory of internal components must be documented. Controller manufacturer along with the
controller model number shall be provided for all traffic signal cabinets. A cabinet corner blow
up shall be provided detailing pull box locations with all conduit and cable per 611-2.3.2.1 and
611-2.3.2.3.
611-2.3.2.7 Preemption: Clearly locate all preemption equipment. The
type of preemption equipment and the manufacturer along with the model number shall be
provided. Additionally, the type of communication medium (example - closed loop) shall be
identified. Any underground conduit and cable as well as pull boxes shall be per 611-2.3.2.1 and
611-2.3.2.3.
611-2.3.3 Compensation: All costs involved with providing as-built drawings are
incidental to the other items of work associated with traffic control signals and devices.
611-2.4 Installation Inspection Requirements: Meet the requirements of Section 105.
611-3 Signal Timing.
Set the timing of a traffic signal or system of traffic control devices in accordance with
the Contract Documents, unless approved otherwise in writing by the Engineer.
611-4 Field Tests of Installations.
Perform the following tests in the presence of the Engineer and, when applicable, a
representative of the agency designated to accept maintenance responsibility.
Continuity: Test each signal head circuit, pedestrian detector circuit, vehicle detector loop
circuit, and interconnect signal circuit for continuity.
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Functional: Perform a functional test that demonstrates that each and every part of the
installation functions as specified.
Induced Voltage on traffic signal connections: Measure the voltage between each signal
head indication field terminal and the AC neutral circuit in the controller cabinet during the off
(dark) state of each signal head indication. Ensure that the voltage does not exceed 2 V AC, RMS . If
this value is exceeded, take the following action to reduce the value to 2 V AC, RMS :
(1) Check for loose or broken connections in the signal head circuit from the
controller cabinet to the signal heads.
(2) If (1) above does not correct the problem, connect additional neutral circuits
between the signal head and the controller cabinet.
Inductive Loop Assembly: An inductive loop assembly is defined as a loop plus the leadin cable. Measure and record the series resistance of each inductive loop assembly. Ensure that
the resistance does not exceed 10 . Perform an insulation resistance megger test, at 500 V DC ,
for each inductive loop assembly at the cabinet in which the inductive loop assembly is
terminated. Do not connect the inductive loop assembly to the cabinet terminal strips during the
test, except for the drain wire of a shielded lead-in cable. Insulation resistance is defined as the
resistance between one wire of the lead-in cable and a ground rod or bussbar. Record the
insulation resistance of each inductive loop assembly. Ensure that the resistance is equal to or
greater than 100 M.
Perform the 48 hour test only after achieving acceptable results from the other tests listed
in 611-4.
48 Hour Test for Traffic Signal installations:
(a) Before beginning the 48 hour test, place all new signal installations (no
existing signals) in flash for 48 to 336 hours. The length of the flash period will be determined
by the Engineer.
(b) Continuously operate each new or modified traffic signal installation or
system for not less than 48 hours. If unsatisfactory performance of the system develops, correct
the condition, and repeat the test until obtaining 48 hours of satisfactory continuous operation.
(c) During the 48 hour test period, the Contractor is fully responsible for the
signal or signal systems. Provide a responsible representative (technically qualified) who can
monitor signal operation and troubleshoot any malfunctions within a one hour period.
When coordination is specified in the Contract Documents, provide a two hour training
session on the operation and programming of the coordination features of the controller units
during the 48 hour test. Arrange the time and place of the training session with the Engineer.
(d) Perform a 48 hour test for flashing beacon installations in the same manner as
for traffic signal installations.
(e) Start the 48 hour test on a Monday, Tuesday, or Wednesday. Ensure the
48 hour test does not include weekends, Holidays, or Special Events.
(f) Start the 48 hour test between 9:00 AM and 2:00 PM.
(g) Before the 48 hour test, install and have standing by all equipment specified in
the Contract Documents.
611-5 Contractors Warranty Period for Installations.
611-5.1 General Requirements: After satisfactory completion of all field tests in
accordance with 611-4, repair or replace any defective components or work of the installations
for a 90 day period after final acceptance in accordance with 5-11.
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611-5.2 Contractors Responsibilities: During the warranty period, the Contractor is
responsible for the following:
(a) Repair or replacement of equipment that fails to function properly due to
defective materials or workmanship.
(b) Upon notification by the Engineer of a malfunction, restore the equipment to
proper operating condition within 12 hours after notification by the Engineer.
If the Contractor fails to restore the equipment to proper operating condition
within 12 hours after notification, the Engineer has the authority to have the remedial work
performed by other forces. The Contractor is responsible for all incurred costs of the work
performed by other forces. Remedial work performed by other forces does not alter any of the
requirements, responsibilities or obligations of this warranty.
(c) In the event that the equipment does not function or malfunctions due to
defective materials or workmanship, the Contractor is liable for any impairment to the safety of
pedestrian and vehicular traffic resulting from such malfunction.
611-5.3 Departments Responsibilities: During the warranty period, the Department is
responsible for the following:
(a) Electrical energy costs which are paid for by the local maintaining agency.
(b) All adjustments, such as timing, necessary for the normal operations of
equipment.
(c) Documentation of the individuals involved and the time of Contractor
notification upon failure or malfunction of equipment.
(d) Repair or replacement of any part of the installation damaged as a result of
natural causes or those resulting from vehicular or pedestrian traffic not associated with
Contractor activities.
611-6 Manufacturers Tests and Certifications.
For materials which may not require formal testing, the Engineer reserves the right to
require certifications from the manufacturer of such equipment and material, to the effect that
they meet all Specification requirements, and, in the event of questionable equipment or material,
to require that such material or equipment be tested at no expense to the Department.
The Engineer reserves the right to withhold any payments which may be due; if the
Engineer determines that the equipment does not meet the Specifications or evaluation criteria.
611-7 Contracts for Purchase of Equipment.
611-7.1 Acceptance Tests Required: For each unit of equipment furnished under
purchase contracts (furnish only), the Engineer will perform the following tests:
(a) Visual inspection within 5 days after delivery.
(b) Operational tests which determine whether the equipment performs in
accordance with the requirements of the Contract Documents. The Engineer will complete such
tests within 15 days after delivery. If the equipment is listed on the Departments APL, the
Engineer may verify the APL Certification number in lieu of the operational tests.
611-7.2 Eligibility for Payment:
The Department will base payment for equipment furnished under purchase
contracts on satisfactory completion of the visual inspection and operational tests required by
611-7.1.
Before any payment will be made for each functional group, deliver to the
Engineer and receive from the Engineer acceptance of all units of each functional group of
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equipment required to be furnished by the Contract Documents. The Department will make
separate payment for a staged delivery of each functional group of equipment only when staged
delivery is specified in the Contract Documents.
611-7.3 Equipment Failing to Pass Acceptance Tests:
When any unit of equipment fails to pass the acceptance tests, correct the
deficiencies (by repair or replacement), at no expense (including all freight costs) to the
Department, to attain compliance. If the original Contract Time has expired, the Department will
charge and continue to assess liquidated damages in accordance with 8-10 until final acceptance
of the equipment. Upon compliance with such correction requirements, the Engineer will
perform tests on the equipment as specified above and will determine their eligibility for
payment.
The Department will not assess liquidated damages during the acceptance test
period in 611-7.1. The Department will allow only one acceptance test exclusion with regard to
liquidated damages assessment per lot of units required to be delivered.
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SECTION 620
TRAFFIC CONTROL SIGNAL AND DEVICE
INSTALLATION GROUNDING
620-1 Description.
Install grounding for traffic signal and device installations to provide personnel and
equipment protection against faults, surge currents and lightning transients.
620-2 Materials.
620-2.1 Ground Rods: Use ground rods made of copper-clad steel with a minimum
diameter of 5/8 inches. Ground rod sections must be a minimum of 8 feet in length and
manufactured for the sole purpose of providing electrical grounding.
620-2.2 Grounding Conductors: Use solid No. 6 AWG copper insulated (green)
conductor for electrical or lightning protection ground from the system ground bus or barrier
plates to the grounding electrode assembly. Use either solid or stranded No. 6 AWG copper
insulated (green) conductor for all ground connections.
620-2.3 Exothermic Grounding Bond: Use materials from the same source, meeting the
requirements of the Institute of Electrical and Electronics Engineers Standards 80 and 837.
620-2.4 Ground Rod Coupling Devices: Use a coupling device for grounding electrode
to grounding electrode connections approved by the Engineer.
620-3 Requirements for Grounding.
620-3.1 General: Meet all local electrical codes which exceed these Specifications.
Install all grounding conductors, which bond grounding electrode assemblies, 18 inches below
finished grade. Accomplish grounding for any element of a traffic control signal and device
installation by installing either a grounding electrode assembly or a grounding electrode array,
unless otherwise specified in the Contract Documents.
Bond all grounding electrode assemblies and arrays together and place in a
location that minimizes the length of the grounding conductor between the assembly or array and
the element being grounded.
Install 40 feet of ground assembly or array for each of the following elements:
(a) Electric power service
(b) Pole with electrical power service installed
(c) Pole mounted cabinet with electrical power service installed
(d) Controller or detector cabinet
Install 20 feet of ground assembly or array for each of the following elements:
(a) Pole
(b) Pedestals for pedestrian signals
(c) Metal cover used with pull boxes with AC power
Ensure that all separately grounded elements at an intersection are bonded
together to form an intersection grounding network.
For span wire assemblies, use the span wire to connect the grounding electrode
assemblies or arrays of the poles.
Do not install a grounding electrode assembly or array for a base mounted cabinet
within 6 feet of a grounding electrode assembly or array installed for a pole.
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Make all bonds between ground wires and grounding electrode assemblies or
arrays with an exothermic bond with the following exception: do not exothermically bond
grounding electrode to grounding electrode connections or the system ground bussbar or barrier
plate connections located within a cabinet.
620-3.2 Grounding Electrode Assembly: Provide a grounding electrode assembly
consisting of one or more grounding electrodes coupled together, such that the total length of the
electrodes in the assembly is a minimum of 20 feet, driven into the earth at a single point,
without disrupting the electrical continuity of the assembly.
Install the grounding electrode assembly so that the final elevation at the top is
6 inches below finished earth grade. Mark the location of the assembly with a stake and keep
uncovered until the Engineer performs a final inspection of the installation.
620-3.3 Grounding Electrode Array: Provide a grounding electrode array consisting of
two or more grounding electrode assemblies, bonded together and spaced a minimum of 6 feet
apart.
620-3.4 Grounding Poles: Ground all poles, including pedestals for pedestrian signals,
in accordance with the details for grounding and connections shown in the Design Standards.
For non-metallic traffic signal poles, including pedestals for pedestrian signals,
accommodate the ground connection from signal heads and span wires to the ground electrode
assembly or array located at the pole base in accordance with the details in the Design Standards,
Index No. 17727.
When erecting new metal poles within 10 feet of existing metal poles or
structures, bond the new and existing poles or structures together.
620-3.5 Grounding Electric Power Service: Ground all electric power services in
accordance with the details for grounding and connections shown in the Design Standards, Index
No. 17736.
620-3.6 Grounding Controller or Detector Cabinets: Ground controller or detector
cabinets to the bussbar located in the cabinet. Place the grounding electrode assembly or array as
close to the cabinet as possible.
620-3.7 Grounding Span Wire Mounted Signal Heads and Electrically Powered
Signs: Ground span wire mounted signal heads and electrically powered signs through the span
wire assembly in accordance with the details shown in the Design Standards, Index No. 17727.
Do not use guy wires for grounding purposes, however bond any guy wire to the
span wire as part of the intersection grounding network.
620-4 Basis of Payment.
The work specified in this Section will not be paid for directly, but will be considered as
incidental work.
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SECTION 630
CONDUIT
630-1 Description.
Install conduit for traffic control signals and devices, and other electrically powered or
operated devices as shown in the Plans and Design Standards.
630-2 Materials.
Use materials that have been tested and listed as defined in the National Electrical Code
(NEC) for the specific use to meet the following industry standards:
Schedule 40 and 80 Polyvinyl Chloride (PVC)1 ........................................... UL 651
Fiberglass Reinforced Epoxy2..................................................................... UL 2420
Intermediate Metal3................................................................ ASTM A135/A135M,
........................................................................... ASTM A513,ASTM A568/A568M
Rigid Galvanized Metal3 ................................................................................... UL 6
Rigid Aluminum4 ........................................................................................... UL 6A
PVC Coated Intermediate Metal4.................... ASTM A135/A135M, ASTM A513,
................................................................. ASTM A568/A568M, NEMA RN1-2005
High Density Polyethylene (HDPE) Standard Dimension
Ratio (SDR) 9-115 ............................................................................... ASTM F2160
1 Use conduit with solvent type slip-fit plastic couplings unless approved by the
Engineer.
2 Use conduit having a minimum stiffness value of 250. Ensure that each section has a
duct bell with an integral gasket on one end and a duct spigot on the other end.
3 Use conduit that is hot-dipped galvanized, with both ends reamed and threaded.
4 Use conduit with both ends reamed and threaded.
5 Can be used with preassembled cable and rope-in-conduit.
630-3 Installation Requirements.
630-3.1 General: Install the conduit in accordance with NEC or National Electrical
Safety Code (NESC) requirements. Consider the locations of conduit as shown in the Plans as
approximate. Construct conduit runs as straight as possible, and obtain the Engineers approval
of all major deviations in conduit locations from those shown in the Plans.
Do not place more than the equivalent of four quarter bends or 360 degrees of
bends, including the termination bends, between the two points of termination in the conduit,
without a pullbox. Obtain the Engineers approval to use corrugated flexible conduits for short
runs of 6 feet or less.
Use only intermediate metal conduit, rigid galvanized metal conduit, rigid
aluminum conduit or PVC coated intermediate metal conduit for above-ground electrical power
service installations. Meet the requirements of Section 562 for coating all field cut and threaded
galvanized pipe.
Use Schedule 80 PVC or fiberglass reinforced epoxy conduit on bridge decks.
Use HDPE with an SDR number less than or equal to 11, Schedule 80 PVC or
Schedule 40 PVC, for underground installations in earth or concrete for traffic control signal and
device applications.
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Install underground conduit as shown in the Design Standards, Index No. 17721.
Install conduit on bridges and approach slabs as shown in Design Standards, Index No. 21210.
When a conduit installation changes from underground to above-ground, make
the change a minimum of 6 inches below finished grade.
Install a No. 12 AWG pull wire or polypropylene cord inside the full length of all
conduits. Ensure that a minimum of 24 inches of pull wire/cord is accessible at each conduit
termination.
Ensure the conduit includes all required fittings and incidentals necessary to
construct a complete installation.
When earth backfill and tamping is required, place backfill material as per
Section 120 in layers approximately 12 inches thick, and tamp each layer to a density equal to or
greater than the adjacent soil.
When backfilling trenches in existing pavement, use a commercially available
sand-cement (approximately 10:1 mix ratio).
Provide a standard clearance between underground control cable and electrical
service cable or another parallel underground electrical service cable that meets NESC
requirements.
Prevent the ingress of water, dirt, sand, and other foreign materials into the
conduit prior to, during, and after construction. Exclude water and debris from buried conduit
and from the top riser assembly of above-ground conduit using a foam-sealing material, rubber
plug, or other device designed for this application and approved by the Engineer.
Ensure the conduit fill ratio (outer cable diameter to inner conduit/duct diameter)
does not exceed 50%.
630-3.1.1 Fiber Optic Cable Conduit: Install the conduit system so the fiber
optic cable maintains a minimum bend radius of 20 times the cable diameter. Use approved
methods for connecting inner duct or conduit within or between plowed portions, trenched
portions, and bored portions. Submit the conduit manufacturers coupling method and material to
the Engineer for approval.
630-3.1.2 Fiber Optic Cable Locate Wire: Ensure that the locate wire is a single
copper conductor with a minimum gauge of #12 AWG. Furnish locate wire that is insulated
using a 45 mil minimum thickness polyethylene sheath that is orange in color and marked to
identify the manufacturer and the conductor size. Bury locate wire along the centerline of the top
outer surface of installed conduit, as shown in the Plans, or as directed by the Engineer. Install
locate wire in the trench or bore with all underground conduits to provide end-to-end electrical
continuity for electronically locating the underground conduit system. Do not install locate wire
in a conduit with fiber optic cable.
Do not run locate wires into field cabinets. Terminate locate wires at the
first and last pull boxes in the conduit run or as shown in the Plans. Ensure that wire termination
occurs only at the top of a pull box.
In a trenching operation, install the locate wire no more than 3 inches
above the conduit. Ensure that the locate wire enters all pull boxes and splice boxes, and that a
minimum of 10 feet of slack locate wire is coiled and neatly stored in each box.
In a boring operation, install the locate wire in an encasement.
Drill a hole in the pull box or splice box for wire entry as shown in the
Plans. Fill any gaps between the locate wire and the hole it passes through with nonshrink grout
or a similar sealant suitable for the application and approved by the Engineer.
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Perform continuity tests and insulation resistance tests on all locate wires.
Provide the Engineer with all test results. Replace or repair defective locate wire at no additional
cost.
Make locate wire splices in a flush grade-level box. Ensure that locate
wire splices are waterproof and suitable for direct burial. Ensure that locate wire splices at the
pull box meet NEC requirements. Ensure that locate wire splices are constructed of and in the
following order: a mechanical crimp connection with a butt sleeve, an oxide-preventing aerosol
lacquer, mastic electrical splicing tape, and standard electrical tape using methods and materials
approved by the Engineer. At the completion of the installation, provide the Engineer with asbuilt drawings that document all splice locations.
630-3.2 Conduit Sizes: Size the conduit to be used on all installations, unless otherwise
shown in the Contract Documents. Use conduit of sufficient size to allow the conductor to be
installed without any damage and meeting NEC requirements. Use conduit that is at least 1 inch
in diameter, except for the conduit protecting the ground wire on the side of a pole, use conduit
that is at least 1/2 inches in diameter.
630-3.3 Conduit Joints: Make conduit joints using materials as specified by the
manufacturer. When conduit crosses an expansion joint of a structure and where shown in the
Plans, install an expansion or expansion/deflection fitting as specified by the manufacturer.
Certify that expansion/deflection fittings are rated to accommodate a minimum rotation of 30
and that both the expansion and expansion/deflection fittings are rated to accommodate the
anticipated longitudinal movement (minimum 2 inches for deflection fittings and 0.7 inches for
expansion/deflection fittings). Ensure that all installed joints are waterproof. As an exception to
the threaded coupling for intermediate metal conduit, at locations where it is not possible to
screw the threaded coupling properly, the Contractor may use a waterproof slip-joint coupling
approved by the Engineer. Secure the joint, and tighten threaded connections.
Prior to insertion into the coupling; clean, prime and coat the ends of PVC conduit
with a solvent-type cement as specified by the manufacturer.
630-3.4 PVC Coating: Apply the PVC coating to the entire surface of the conduit,
except for the threads, to attain a nominal thickness of 40 mils. Ensure that the coating is free of
sags or drips.
Attach the coupling to the conduit prior to the application of the coating for
conduit of 1 inch diameter or less.
Use a coupling with sleeve extensions on conduit larger than 1 inch. Ensure that
the sleeve extensions on all threaded female openings have a length equal to the diameter of the
conduit up to and including size number 53.
630-3.5 Conduit Terminations: Fit the terminating ends of all metal conduit and metal
conduit sleeves with an appropriate bushing.
For conduit to be encased in concrete, wrap with tape or otherwise protect all
terminations to prevent the entrance of concrete.
Connect new underground conduits to existing underground conduits with a pull
box.
Install conduit terminating in a concrete strain pole through the cable entry hole
and up the center of the pole to a location approximately 6 inches below the handhole.
Seal conduits terminating in a controller base, pole, pull box, junction box, or
pedestal base with duct seal , or an equivalent moisture resistant sealant approved by the
Engineer.
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For a controller base, pole or pedestal base, and junction boxes, terminate conduit
runs into the center of the base or box at least 2 inches above the surface of the base.
630-3.6 Existing Underground Facilities: Coordinate with any potential conflicting
underground utilities prior to starting all excavating, boring or jacking operations at the project
site.
630-3.7 Restoration of Trench Areas: Restore the conduit trench construction area to an
acceptable condition. Such work includes repair or replacement of all pavement areas, sidewalks,
curbs, structures, landscaping or grass areas disturbed by the conduit trench.
630-3.8 Jacking Conduit: Use either intermediate metal conduit or rigid galvanized
metal conduit as the sleeve when installation of a conduit requires jacking under paved surfaces,
railroads, etc., with either PVC or fiberglass reinforced epoxy conduit installed in the jacked
sleeve. Do not disturb any pavement without the approval of the Engineer.
630-3.9 Above-Ground Installation: Use conduit designed and manufactured for use in
long-term above-ground applications with UV stabilization to prevent material deterioration.
Securely attach above-ground conduit installations to the surface of the supporting structure
using conduit straps. As a minimum, use conduit straps located on 5 foot centers. Use galvanized
metal conduit straps when installing intermediate metal conduit, fiberglass reinforced epoxy
conduit, rigid galvanized conduit, rigid aluminum conduit or PVC coated intermediate metal
conduit above ground.
Use the same PVC coating for the metal straps as the conduit, when using PVC
coated intermediate metal conduit.
630-3.10 Elbows: Use only preformed or field constructed conduit elbows. The radius of
curvature of the inner edge of any bend shall not be less than shown below:
Size
1/2 inch
3/4 inch
1 inch
1 1/4 inches
1 1/2 inches
2 inches
2 1/2 inches
3 inches
3 1/2 inches
4 inches
5 inches
6 inches
Standard Radius
4 inches
4 1/2 inches
5 1/2 inches
7 1/4 inches
8 1/4 inches
9 1/2 inches
10 1/2 inches
13 inches
15 inches
16 inches
24 inches
30 inches
630-4 Method of Measurement.
630-4.1 General: Measurement for payment will be in accordance with the following
work tasks.
630-4.2 Furnish and Install: The Contract unit price per foot of conduit, furnished and
installed, will include furnishing all hardware and materials as specified in the Contract
Documents, and all labor, trenching, backfilling, and restoration materials necessary for a
complete and accepted installation.
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Payment for conduit placed in the ground or attached to bridges will be based on
the horizontal path of the installed conduit measured in a straight line between the centers of pull
boxes, cabinets, poles, etc. No allowance will be made for sweeps or vertical distances above the
ground or within the structure, or below the ground.
Furnishing, installing, and testing the locate wire is included in the cost of the
conduit. Furnishing and installing pull wire/cord is included in the cost of the conduit.
630-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 630- 1Conduit - per foot.
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SECTION 632
SIGNAL AND INTERCONNECT CABLE
632-1 Description.
Install underground and aerial signal and interconnect cable.
632-2 Materials.
Use materials meeting the requirements of Section A632 of the current Minimum
Specifications for Traffic Control Signal Devices (MSTCSD), except as provided in 603-2.2.
632-3 Installation Requirements.
632-3.1 Number of Conductors: Determine the number of conductors required for each
signal and interconnect cable unless specified in the Contract Documents.
Provide two spare conductors within the interconnect cable. Terminate conductors
within controller cabinets as specified below.
Provide three spare conductors for each signal cable used at all signal
installations. Install the three spare conductors from the controller cabinet through each signal
head disconnect hanger to the furthermost disconnect hanger.
For non-span wire installations, install the three spare conductors from the
controller cabinet through each signal to the furthermost signal.
Ground spare signal cable conductors in the controller cabinet. In the disconnect
hanger, terminate spare wires at the terminal strip. Individually cap or tape any additional spares
in the disconnect hanger.
Identify all spare conductors in a controller cabinet as spare signal conductors or
spare interconnect conductors, and ground them to the controller cabinet ground bus bar. Provide
spare conductors within the controller cabinet of sufficient length to reach the furthermost field
wiring terminals in the cabinet.
632-3.2 Number of Cables: Do not install more than four separate cables at any point on
a single support wire.
632-3.3 Protection of Cable: Ensure cable drawn through conduit, ducts, drilled holes
protected by a rubber grommet, or support structures is installed in such a manner as to prevent
damage to conductors or insulation.
632-3.4 Cabling for Mast Arm Assembly: Continuous lengths of cable between the
traffic signal controller cabinet, signal heads (or disconnect hangers), pedestrian signal heads and
pedestrian detectors will be allowed only when specified in Contract Documents.
Attach strain relief approved by the Engineer to the J hook inside the mast arm
pole.
632-3.5 Cable Terminations: Terminate signal cable in the terminal by inserting the
bared conductors into a compression type terminal block and tightening the appropriate screws.
When barrier terminal blocks are specified in the Contract Documents, crimp
insulated forks or ring terminals to the bared conductors using a calibrated ratchet-crimping tool
and connect the forks or ring terminals to the barrier terminal block by tightening the appropriate
screws.
Neatly form and tie wrap all cable terminations.
Ground spare signal cable conductors in the controller cabinet. If disconnect
hangers are specified in the Contract Documents, terminate spare wires at the terminal strip
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located inside the disconnect hangers. Individually cap or tape any additional spares in the
disconnect hanger.
Ensure all cable terminations for a mast arm assembly are terminated in the
terminal compartment at the base of the mast arm pole.
632-4 Signal Cable.
Install underground and aerial signal cable in accordance with the Design Standards,
Index No. 17727.
Except for mast arm assemblies, install signal cable in continuous lengths between the
traffic signal controller cabinets, disconnect hangers (or signal heads for non-span wire
installations), pedestrian signal heads, and pedestrian detectors.
Do not use the neutral return conductor for pedestrian detectors as a neutral return for any
other device.
632-5 Interconnect Cable.
Install underground and aerial interconnect cable in accordance with the Design
Standards, Index Nos. 17733 and 17841.
Install aerial interconnect cable in continuous lengths to and between traffic signal
controller cabinets and aerial junction boxes.
Except for mast arm assemblies, install underground interconnect cable in continuous
lengths to and between traffic signal controller cabinets and above-ground junction boxes.
Install terminations between controller cabinets at above-ground interconnect junction
boxes. The Contractor may install terminations at intervals less than shown in the Plans;
however, the Contractor must provide the above-ground junction box, materials, and labor for
these terminations at no expense to the Department. Obtain the Engineers approval of the
location of additional junction boxes.
632-6 Method of Measurement.
632-6.1 General: Measurement for payment will be in accordance with the following
work tasks.
632-6.2 Furnish and Install: The Contract unit price per intersection for cable (signal)
and per foot for cable (interconnect), furnished and installed, will include furnishing all material,
hardware, support wire, cable ties, cable clamps, lashing wire, terminal connectors, cable
grounding and labor necessary for a complete and accepted installation.
Payment for cable (signal) will be based on the number of intersections at which
signal cable is furnished and installed.
Payment for cable (interconnect) will be based upon the length installed between
cable terminations, as determined by the manufacturers sequential markings printed on the cable
jacket, recorded to the nearest foot.
632-6.3 Furnish: The Contract unit price of cable, furnished, will include the cost of the
required cable as specified in the Contract Documents, plus all shipping and handling costs
involved in delivery as specified in the Contract Documents.
632-6.4 Install: The Contract unit price per intersection for cable (signal) and per foot
for cable (interconnect), installed, will include all labor, cable ties, cable clamps, lashing wire,
and cable grounding necessary for a complete and accepted installation. The Engineer will
supply all cable.
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Payment for cable (signal) will be based on the number of intersections at which
signal cable is installed.
Payment for cable (interconnect) will be based upon the length installed between
cable terminations, as determined by the manufacturers sequential markings printed on the cable
jacket, recorded to the nearest foot.
632-7 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 632- 7Cable (Signal) - per intersection.
Item No. 632- 8Cable (Interconnect) - per foot.
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SECTION 634
SPAN WIRE ASSEMBLY
634-1 Description.
Install a span wire assembly for supporting traffic signals, signs, and other traffic control
devices. Provide fiberglass insulators when required.
634-2 Materials.
634-2.1 General Requirements: For a single point attachment, use only a catenary wire
to support the imposed dead and wind load from the attached signs and traffic signals. For a
single point attachment, the catenary wire also supports the signal conductor cables and
interconnect cables.
For a two point attachment, the catenary wire is used to support the imposed dead
load and a portion of the imposed wind load from the attached signs and traffic signals. The two
point attachment also includes a messenger wire to resist a significant portion of the imposed
wind load and to support the signal conductor cables and interconnection cables.
Use a tether wire for maintaining the alignment of signal heads when specified in
the Plans.
634-2.2 Wires: For span wire assemblies, only use wire cables of seven-wire strands
manufactured and provided with a Class A zinc coating in accordance with ASTM A475.
Provide Utility Grade catenary or messenger wires. The Contractor may use
Siemens-Martin Grade tether wires. Meet the following additional requirements for span wire
assembly strands:
Span Wire Assembly
Strand Type
Nominal Diameter
Inch
Catenary Wire or
Messenger Wire *
3/8
7/16
1/2
3/16
Tether Wire
Required Minimum
Breaking Strength
Pounds
11,500
18,000
25,000
1,900
*Supply catenary or messenger wire of the nominal diameter as specified in the contract documents.
634-2.3 Hardware and Fittings: For Utility or Siemens-Martin Grade wires, use the
connection hardware as specified herein. For installations that use other grades of wire, provide
the hardware and fittings indicated in the Plans. Provide only hardware and fittings made of
galvanized steel or non-corrosive metal unless the fiberglass insulators specified in 634-2.4 are
also required. Provide hardware and fittings of sufficient strength to resist the breaking strength
of the wire with which they are used.
Use an alloy steel eyebolt (ASTM F541, Type 2) and a matching heavy hex nut
(ASTM A563, Grade C or D), both zinc coated in accordance with ASTM A153, Class C, to
connect the automatic compression dead-end clamp of the catenary wire or messenger wire to
the wood or concrete strain poles. Sizes of eyebolts, supplied with nuts and washers, are as
following: Use a 3/4 inch diameter bolt for maximum of one 7/16 inch diameter catenary (or
messenger) wire, or maximum of two 3/8 inch diameter catenary (or messenger) wires. Use a
1 inch diameter bolt for maximum of one 1/2 inch diameter catenary (or messenger) wire, or
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maximum of two 7/16 inch diameter catenary (or messenger) wires. Use 1-1/4 inch diameter bolt
for maximum of two 1/2 inch diameter catenary (or messenger) wires. For two point
attachments, connect the messenger wire at the lower attachment location. Do not use thimble
eye bolts for these connections.
Only use thimble eye and eye bolts, 3/4 inch in diameter, minimum, to connect
the automatic compression dead-end clamps of tether wires to wood or concrete strain poles.
Only use S hooks, 5/16 inch in diameter, minimum, when connecting the tether
wire to all poles.
Ensure that other hardware and fittings, as required for the attachment of a span
wire assembly to support poles or structures, are in accordance with the details shown in the
Design Standards.
634-2.4 Fiberglass Insulators: Install fiberglass insulators of the length specified in the
Plans on span wire assemblies located within 6 feet of overhead electric power lines.
Use a fiberglass insulator of a cylindrical shape, fabricated from epoxy-resin
impregnated fiberglass strands and having a breaking strength 50% greater than that of the
structural support wire to which it is to be attached. Equip the insulator with thimble eye fittings
on each end for attachment of the wire. Furnish all fittings and hardware necessary for the
complete installation with the insulator and ensure that such fittings and hardware are of at least
equal strength to the insulator.
634-3 Installation Requirements.
634-3.1 Span Wire Assembly Types: Use either of the following span wire assemblies
as shown in the contract documents:
(a) Single Point Attachment Assembly: This type of assembly requires a catenary
wire with an optional tether wire (if specified in the Plans).
(b) Two Point Attachment Assembly: This type of assembly requires a catenary
wire, a messenger wire and an optional tether wire (if specified in the Plans).
634-3.2 Span Types: Install span wire assemblies on the following span types:
(a) Perpendicular Span: Use this type span at an intersection to support a single
span wire assembly upon which traffic signals, signs, and other traffic control devices are
attached. Attach the span wire assembly to two support poles or structures, located on opposite
sides of the roadway, and extend the assembly across the roadway at an angle of approximately
90 degrees to the roadway approach.
(b) Diagonal Span: Use this span type at an intersection to support a single span
wire assembly upon which traffic signals, signs, and other traffic control devices are attached.
Attach the span wire assembly to two poles, located in opposite quadrants of the intersection,
and extend the assembly across the intersection at an angle of approximately 45 degrees to the
approach lanes of the intersection. Locate traffic control devices for all approaches at appropriate
locations on the span wire assembly.
(c) Box Span: Use this span type at an intersection to support a perimeter system
of four span wire assembly upon which traffic signals, signs and other traffic control devices for
each approach to the intersection are attached. Attach the span wire assembly to four poles, one
located in each quadrant of the intersection, and extend each span wire between two poles at an
angle of approximately 90 degrees to the roadway approaches. Place traffic control devices for
an approach on the span wire on the far side of the intersection.
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(d) Special Design Span: Use this span type to support two or more span wire
assembly upon which traffic signals, signs and other traffic control devices for one or more
roadway approaches are attached. Attach the span wire assembly to three or more poles.
634-3.3 General Requirements:
(a) Provide a span wire assembly with catenary, messenger and tether wires of
one continuous length of wire cable with no splices except when an insulator is required by 6342.4. Connect the insulator, if required, to the cable with automatic compression dead-end clamps.
(b) Attach the span wire assemblies to the support poles or structures by means of
automatic compression clamps and accessory hardware.
(c) Assemble the washer and nut on the oval eye bolt with the flat washer next to
the pole. Tighten the nut sufficiently to prevent the oval eye bolt from rotating.
(d) For two point attachments, install the messenger wire with the following
tensions per 100 feet. Linearly prorate cable tensions for other lengths from these values:
Cable Size Inch
3/8
7/16
1/2
sag.
Wire Tension Lbs.
340.0
500.0
645.0
(e) The catenary wire shall be tensioned to provide a 5% , plus or minus 0.5%
(f) Install the span wire assemblies in accordance with the Design Standards,
Index No. 17727, and at a height on the support poles which will provide a clearance from the
roadway to the bottom of the signal head assemblies as shown in Index 17727.
(g) Connect all span wires to the pole grounding system in accordance with
Section 620.
(h) Obtain and meet all provisions of the National Electric Safety Code (ANSIC2) regarding clearance from electric lines, contacting of utility owners, and safety requirements
prior to span wire installation.
(i) Prior to installation of the two point attachment span wire assembly, submit the
method of providing the required tension in the messenger wire to the Engineer for approval.
634-4 Method of Measurement.
634-4.1 General: Measurement for payment will be in accordance with the following
work tasks.
634-4.2 Furnish and Install: The Contract unit price per intersection for Span Wire
Assembly and per foot of Fiberglass Insulator, furnished and installed, between supporting poles
and structures will include furnishing all materials and hardware as required in 634-2, and all
labor, equipment, and miscellaneous materials necessary for a complete and accepted
installation.
634-4.3 Furnish: The Contract unit price per intersection for Span Wire Assembly and
per foot of Fiberglass Insulator, furnished, will include the cost of the required materials and
hardware as required in 634-2, and all handling and delivery of these items to the site designated
by the Department in the Contract Documents.
790
634-4.4 Install: The Contract unit price per intersection for Span Wire Assembly and per
foot of Fiberglass Insulator, installed, will include all labor, equipment, and miscellaneous
materials necessary for a complete and accepted installation.
The Engineer will supply all materials and hardware as required in 634-2 for the
span wire assembly.
634-5 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section.
When a tether wire is specified in the Plans, the payment of the tether wire shall be included in
the compensation for the span wire assembly.
Payment will be made under:
Item No. 634- 4Span Wire Assembly - per intersection.
Item No. 634- 5Fiberglass Insulator - per foot.
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SECTION 635
PULL AND JUNCTION BOXES
635-1 Description.
Install pull and junction boxes for traffic signals.
635-2 Materials.
Use Pull and Junction Boxes listed on the Departments Approved Product List (APL).
Ensure that all Pull and Junction Boxes are marked in accordance with Section 603 and the
markings are visible after installation.
635-3 Pull Boxes Installation.
Install pull boxes in accordance with the Design Standards, Index No. 17700. Ensure that
the pull box cover is flush with the finished grade or sidewalk. Do not install pull boxes in
roadways, driveways, parking areas, ditches or public sidewalk curb ramps.
635-4 Junction Boxes Installation.
635-4.1 Aerial Junction Boxes: Install aerial junction boxes in accordance with the
Design Standards, Index No. 17733.
635-4.2 Mounted Junction Boxes: Install mounted junction boxes in accordance with
the Design Standards, Index No. 17841. Ensure that the bottom surface of pole mounted junction
boxes is a minimum of 4 feet above the finished grade.
635-4.3 Cable Terminations: Make cable terminations in junction boxes in accordance
with Section 632. Rout and form the cable to allow access to the terminal screws. Do not cover
the terminal identification numbers with the cable.
635-5 General Requirements.
Do not pull signal or interconnect cable through a pull box used for loop termination. Use
separate pull boxes for signal and interconnect cables.
Use embedded junction boxes that include junction boxes, conduit, conduit expansion
couplings, and miscellaneous hardware to make a complete and accepted installation.
Ground all metal covers in accordance with Section 620.
When specified in the Contract Documents, disregard the grounding requirements for
metal covers for pull and junction boxes powered strictly by battery or a combination of battery
and solar energy or used exclusively for vehicle loop wires where signal or 120V interconnect
power is not present.
635-6 Method of Measurement.
635-6.1 General: Measurement for payment will be in accordance with the following
work tasks:
635-6.2 Furnish and Install: The Contract unit price each for pull and junction boxes,
furnished and installed, will consist of the pull and junction boxes including all required
hardware for the type of box and location as specified in the Contract Documents, and all labor
and materials necessary for a complete and accepted installation.
635-6.3 Furnish: The Contract unit price each for pull and junction box, furnished, will
include the cost of the pull and junction box including covers, doors, locks and keys, and any
792
necessary miscellaneous hardware specified in the Contract Documents, plus all shipping and
handling costs involved in delivery as specified in the Contract Documents
635-6.4 Install: The Contract unit price each for pull and junction box, installed, will
include the cost of all labor, equipment, miscellaneous hardware and materials necessary to make
a complete and accepted installation of the type box and at locations as shown in the Plans. The
Engineer will supply a complete box as specified in the Contract Documents.
635-7 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section, except
grounding. Payment for embedded junction boxes will not be made separately.
The Contractor shall include the cost of embedded junction boxes in the Contract unit
price for the concrete substructure or superstructure items.
Payment will be made under:
Item No. 635- 1Pull and Junction Boxes - each.
793
SECTION 639
ELECTRICAL POWER SERVICE ASSEMBLIES
639-1 Description.
Install electrical power service assemblies for either overhead service or underground
service in accordance with the details shown in the Design Standards, Index No. 17736.
639-2 Definitions.
(a) Overhead Service: A service assembly which is supplied electrical power from an
overhead power company source. Include with an overhead electrical power service assembly
the following components:
(1) Weatherhead
(2) Conduit
(3) Electrical Service wire
(4) Meter base (when required)
(5) Service disconnect
(6) Surge Protective Device
(b) Underground Service: A service assembly which is supplied electrical power from an
underground power company source. Include with an underground electrical power service
assembly the following components:
(1) Conduit
(2) Electrical Service wire
(3) Meter base (when required)
(4) Service disconnect
(5) Surge Protective Device
639-3 Materials.
639-3.1 Weatherhead: Use a weatherhead made of a copper free aluminum alloy with
three electrical service wire entrance holes, meeting National Electric Code (NEC) requirements.
639-3.2 Conduit: Use conduit meeting the requirements of Section 630. Meet the
requirements of Section 562 for coating all field cut and threaded galvanized pipe.
639-3.3 Electrical Service Wire: Use No. 6 AWG stranded copper wire with XHHW
(cross-linked polyethylene (XLPE) high heat-resistant, water-resistant) insulation, rated at 600 V
in dry and wet condition.
639-3.4 Meter Base: Use meter bases approved by the local electric power company.
639-3.5 Service Disconnect:
639-3.5.1 Enclosure (Cabinet): Use an enclosure conforming to National
Electrical Manufacturers Association (NEMA) Standards for Type 3R, Type 3S or Type 4, made
of galvanized steel, aluminum, stainless steel or other materials approved by the Engineer.
Ensure that the enclosure has a hinged door which can be locked with a padlock. Provide
padlock and two keys. Do not use external handles or switches. Ensure that the inside
dimensions meet NEC requirements.
639-3.5.2 Circuit Breaker: Use a manually resettable circuit breaker which has a
current rating above the current rating of the circuit breaker to which electrical power is
provided. Do not use less than a 40A circuit breaker.
794
639-3.6 Surge Protective Device: Use a lightning arrester rated for a maximum
permissible line to ground voltage of 175 VAC.
639-3.7 Attachment Hardware: Use attachment hardware that meets the requirements
of Section 603.
639-4 Installation Requirements.
639-4.1 General: Meet the following requirements for the installation of individual
components of the electrical power service assembly:
Use extreme care and caution in the installation of all components of the electrical
power service assembly.
Follow installation procedures recommended by NEC and National Electrical
Safety Code (NESC).
Consider the location of electrical power service assemblies as shown in the Plans
to be approximate, and coordinate with the appropriate electrical power company authority to
determine the exact locations of each assembly.
639-4.2 Weatherhead: Securely attach the weatherhead to the upper end of the conduit
which extends upward from the meter base (or service disconnect if a meter base is not required)
to a minimum height of 22 feet above grade.
639-4.3 Conduit: Securely attach all conduit to the pole or cabinet with a maximum
distance of 5 feet between conduit attachment hardware.
639-4.4 Electrical Service Wire: Install the electrical service wire in a manner which
will ensure that damage to the installation will not occur.
Ensure that the service wire is of sufficient length after installation in the conduit
to provide for attachment to the power company service and for termination within the cabinet
for which power is required.
639-4.5 Meter Base: When a meter base is required, securely fasten the meter base to the
pole or cabinet. Install pole mounted meter bases at a minimum height of 5-1/2 feet above grade
when measured from the center of the meter base or meet the local electric power company
requirement, whichever is greater.
639-4.6 Service Disconnect: Securely fasten the service disconnect to the pole (or
cabinet with the Engineers approval), and electrically position the service disconnect between the
service meter and the traffic control device cabinet to which electrical service is being supplied.
Install pole mounted service disconnects a minimum of 4 feet above grade when measured from
the bottom of the disconnect. For cabinet installations, mount the service disconnect at a height
approved by the Engineer or as shown in the Plans.
639-5 Method of Measurement.
639-5.1 General: Measurement for payment will be in accordance with the following
work tasks.
Payment for Electrical Service Wire is based upon the distance of the cable run
and includes payment for all conductors used in the run.
Payment for conduit and electrical service wire which is vertically attached to the
electrical power assembly is considered incidental and paid under item 639-1.
639-5.2 Furnish and Install: The Contract unit price per foot of electrical service wire,
or the Contract unit price each for electrical service disconnect, furnished and installed, will
include furnishing all materials and hardware as specified in the Contract Documents, and all
795
labor, equipment, and miscellaneous materials necessary for a complete and accepted
installation.
639-5.3 Furnish: The Contract unit price per foot of electrical service wire, or the
Contract unit price each, for electrical service disconnect, furnished, will include the cost of the
required materials and hardware as specified in the Contract Documents, plus all shipping and
handling costs involved in delivery as specified in the Contract Documents.
639-5.4 Install: The Contract unit price per foot of electrical service wire, or the Contract
unit price each, for electrical service disconnect, installed, will include all labor, equipment, and
miscellaneous materials necessary for a complete and accepted installation. The Engineer will
supply electrical service wire or electrical service disconnect.
639-5.5 Electrical Power Service: The Contract unit price per assembly for electrical
power service will include furnishing and installing all material and hardware as specified in the
Contract Documents, and all labor and equipment necessary to make a complete and accepted
installation.
639-6 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 639- 1Electrical Power Service - per assembly.
Item No. 639- 2Electrical Service Wire - per foot.
Item No. 639- 3Electrical Service Disconnect - each.
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SECTION 641
PRESTRESSED CONCRETE POLES
641-1 Description.
Furnish and install prestressed concrete poles for service pole applications, luminaire
support, and strain poles for span wire support of traffic signals, signs, and other devices
(multiple types). Obtain precast, prestressed concrete poles from a manufacturing plant that is
currently on the Departments list of Producers with Accepted Quality Control Programs.
Producers seeking inclusion on the list shall meet the requirements of 105-3.
Ensure that each pole is constructed and permanently and legibly marked in accordance
with Design Standards, Index No. 17725, including the date cast. The marking shall be visible
after installation.
Ensure that the shipment of the products to the job site meets the requirements of 45016.3 and 105-3.2.
641-2 Materials.
Meet the following requirements:
Portland Cement Concrete ......... Section 346 Class V Special
............................................................................ or Class VI
Reinforcing Steel ......................................................... 931-1
Prestressed Strands....................................................... 933-1
Spiral Reinforcing ..............................................ASTM A 82
641-3 Concrete Pole Construction.
Construct concrete poles in accordance with Section 450. Assume responsibility for
performance of all quality control testing and inspections required by Sections 346 and 450,
however; the PCI personnel and plant certifications are not required.
641-4 Installation Requirements.
641-4.1 General: Furnish poles of the type and length shown in the Plans. Provide
catenary cable of the size shown in the Plans. Ground poles in accordance with Section 620.
Install span wire assemblies in accordance with Section 634.
Do not consider the poles acceptable for use if the camber of the pole, measured
as the maximum deviation between the centerline of the pole and a straight line connecting the
centroids of the cross-sections at each end of the pole, is greater than the total pole length in
inches divided by 140.
641-4.2 Footings: Provide footings 3 feet 6 inches in diameter and of the depth specified
in the Plans for strain poles used for span wire support of traffic signals. Provide footings for all
other pole applications as specified in the Plans. Construct the footings with concrete as specified
in Section 347.
For the excavation and backfill of the footing, meet the requirements specified in
125-4 and 125-8.2 with the exception of the backfill density. In lieu of the requirements for
obtaining the specified density, the Contractor may hand tamp the backfill in 4 inch maximum
layers or machine tamp the backfill in 6 inch maximum layers. When performing such
operations, ensure that the material is neither dry nor saturated. The Contractor may backfill with
concrete.
797
Use forms, when required, meeting the requirements of 700-7.3. If the footing is
cast in an oversize hole, place the concrete in the top 6 inches in a form. Trowel all exposed
surfaces to a smooth finish.
641-4.3 Orientation of Poles: For poles supporting one catenary wire, orient the pole so
that the load face is perpendicular to the catenary wire. For poles supporting two catenary wires,
orient the pole so that the load face is perpendicular to a line bisecting the angle between the two
catenary wires.
Rake pole back from the span wire as necessary to achieve a final rake of 1/2 inch
per foot, plus or minus 1/4 inch.
641-5 Method of Measurement.
641-5.1 General: Measurement for payment will be in accordance with the following
work tasks.
641-5.2 Furnish and Install: The Contract unit price for prestressed concrete poles,
furnish and install, will consist of the pole plus all labor, concrete for the foundation and other
materials necessary for a complete and accepted installation as specified in the Contract
Documents.
641-5.3 Furnish: The Contract unit price for prestressed concrete poles, furnish, will
include the cost of the pole and shipping, handling, and delivery of the pole to the site designated
in the Contract Documents.
641-5.4 Install: The Contract unit price for prestressed concrete poles, install, will
include all labor, concrete for the foundation and other materials necessary for a complete and
accepted installation as specified in the Contract Documents. The Engineer will supply the poles.
641-6 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 641Prestressed Concrete Poles - each.
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SECTION 649
GALVANIZED STEEL STRAIN POLES, MAST
ARMS AND MONOTUBE ASSEMBLIES
649-1 Description.
The work in this Section consists of furnishing and installing galvanized steel
strain poles, galvanized steel mast arms and galvanized steel monotube assemblies in
accordance with the details shown in the Contract Documents, subject to a five year
warranty period as defined herein. The warranty period will apply only when strain poles,
mast arms or steel monotube assemblies are painted as called for in the Contract
Documents.
649-2 Materials.
Use pole assemblies as shown in the Design Standards when standard mast arm
assemblies or standard strain pole assemblies are required by the Contract Documents.
Obtain strain poles, mast arm, and monotube assemblies from a fabrication
facility that is listed on the Departments list of Metal Producers with Accepted Quality
Control Program, meeting the requirements of 105-3.
Provide shop drawings and signed and sealed calculations, as needed, in
accordance with Section 5 for configurations shown in the Plans.
Use coating products meeting the requirements of Section 975.
Use grouts meeting the requirements of Section 934 and listed on the QPL.
Use water meeting the requirements of Section 923.
Use membrane curing compounds meeting the requirements of Section 925.
649-3 Fabrication.
Fabricate strain poles, mast arm and monotube assemblies and miscellaneous
hardware in accordance with the Contract Documents. Cut all materials to the final
dimensions and complete all welding prior to galvanizing. Obtain all components for
individual strain poles, mast arm and monotube assemblies from the same fabricator.
Obtain the luminaire and bracket from other sources, when necessary.
Affix an aluminum identification tag which will be visible from the handhold or
located inside the terminal box containing the information described in the Design
Standards.
Before shipping, assemble mast arm and monotube assemblies including
luminaire and bracket, to assure proper fit. The mast arm and monotube assemblies may
be separated for shipment.
Ensure all components are protected from damage during shipping and handling
by wrapping or other effective methods. Replace any component, which the Engineer
determines is damaged beyond repair, at no additional cost to the Department. If
components are wrapped for shipment, remove wrappings no later than five days after
receipt of components or immediately if the wrappings become saturated. Post these
instructions in brightly colored wording on the wrapper. Failure to comply with these
instructions may lead to damage of the coating system and will be cause for the rejection
of the component.
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649-4 Coatings.
649-4.1 Galvanizing: Galvanize all components in accordance with
ASTM A123, except galvanize all fastener assemblies in accordance with ASTM A153.
Use galvanizing methods which provide surfaces suitable for painting.
649-4.2 Surface Preparation: Prepare all galvanized surfaces to be painted in
accordance with ASTM D6386 and the manufacturer of the coating systems
specifications. Provide a clean and suitable galvanized surface that maximizes coating
system adhesion.
Measure the thickness of the zinc coating after completion of surface
preparation using a magnetic thickness gage in accordance with ASTM A123. Ensure
sufficient galvanizing remains on the substrate to meet the requirements of ASTM A123
and the Contract Documents. Correct any deficient areas to the satisfaction of the
Engineer at no additional cost to the Department.
649-4.3 Painting:
649-4.3.1 General: When required by the Contract Documents, provide
painted strain poles, mast arms and monotube assemblies. Provide products from a
fabricator on the Departments list of Prequalified Fabricators of Painted Galvanized
Steel Strain Poles, Mast Arms and Monotube Assemblies. Provide products that will meet
specification requirements throughout the warranty period. Meet the color requirement as
specified in the Contract Documents. Provide the Engineer with two metal sample
coupons, a minimum of 2 inches x 4 inches, painted concurrently and with the same
paint as was used on the first lot of any strain poles, mast arms and monotube assemblies
delivered to the jobsite. Provide sample coupons and manufacturer product data sheets to
the Engineer along with the delivery of the first shipment of any painted strain poles,
mast arms or monotube assemblies delivered to the jobsite. At the time of their delivery,
the sample coupons described in this paragraph shall match the color of the strain poles,
mast arms and monotube assemblies to within 1E measured as specified in 975-4. If the
delivered sample coupons exhibit a difference in color from the strain poles, mast arms
and monotube assemblies greater than 1E then the sample coupons will be considered
unacceptable and no payment shall be made for the materials which the sample coupons
represent. Those materials shall not be accepted by the Department until acceptable
representative sample coupons in accordance with the requirements of this Section have
been delivered to the Engineer.
649-4.3.2 Responsible Party Warranty: When the Contract Documents
call for painted galvanized steel strain poles, mast arms or monotube assemblies, the
Contractor shall designate a responsible party to accept responsibility. The responsible
party designated by the Contractor must execute and deliver to the Department a form,
provided by the Department, prior to the first delivery to the jobsite of any painted strain
poles, mast arms or monotube assemblies, stipulating that the responsible party accepts
responsibility for ensuring the coating system adhesion and color retention requirements
as specified in 975-4 are met for a period of five years after final acceptance in
accordance with 5-11. The responsible party shall also bear the continued responsibility
for performing all remedial work associated with repairs of any adhesion or color
retention failure as defined in Section 975, as to which notice was provided to the
responsible party within the five year warranty period. Failure to timely designate the
responsible party will result in the Contractor being the responsible party unless
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otherwise agreed to in writing by the Department. The responsible party shall be either
the Contractor or the fabricator. When the responsible party is the fabricator, the
responsible party shall be one of the fabricators listed on the Prequalified Fabricators of
Painted Galvanized Steel Strain Poles, Mast Arms and Monotube Assemblies. This list
may be viewed on the Departments website at the following URL:
http://www.dot.state.fl.us/construction/ .
Upon final acceptance of the Contract in accordance with 5-11, the
Contractors responsibility to ensure that the coating system adhesion and color retention
requirements specified in 975-4 will terminate. The obligations of the responsible party
set forth in this Section shall start at final acceptance of the Contract in accordance with
5-11 and continue thereafter until expiration of the five year warranty period.
649-5 Installation.
Install foundations for strain poles, mast arm and monotube assemblies in
accordance with Section 455. Do not install the mast arm pole, strain poles or monotube
pole until the foundation has achieved 70% of the specified 28-day concrete strength and
verifying test results have been provided to the Engineer. Determine concrete strength
from tests on a minimum of two test cylinders prepared and tested in accordance with
ASTM C31 and ASTM C39. Before erecting the pole, clean the top of the foundation of
any laitance, oils, grease or any other deleterious materials. Erect strain poles in an
orientation which considering the rake and the application, cable forces will produce a
plumb pole. Erect monotubes plumb at the time of installation. Plumb the pole supporting
mast arms after the mast arms, traffic signals or sign panels have been placed.
If the traffic signals and/or sign panels are not in place within two working days
after the mast arm is erected, furnish and install a 3 foot by 2 foot blank sign panel on the
bottom of each mast arm within 6 feet of the mast arm tip and plumb the pole. Re-plumb
the pole supporting mast arms after installation of traffic signals and sign panels.
Install ASTM A325 bolt, nut and washer assemblies in accordance with the
following. Use bolt, nut and washer assemblies that are free of rust and corrosion and that
are lubricated properly as demonstrated by being able to easily hand turn the nut on the
bolt thread for its entire length. Tighten nuts to the full effort of an ironworker using an
ordinary spud wrench to bring the faying surfaces of the assembly into full contact which
is referred to as snug-tight. After bringing the faying surfaces to a snug-tight condition,
tighten nuts in accordance with the turn-of-nut method in 460-5, Table 460-7. Maintain
uniform contact pressure on the faying surfaces during snugging and turn-of-nut process,
by using a bolt tightening pattern that balances the clamping force of each bolt, as closely
as possible, with the equal clamping force of a companion bolt.
Use ASTM F1554 anchor bolt assemblies that are free of rust and corrosion, and
lubricate these assemblies prior to installation so that the nut turns easily by hand the
entire length of the bolt thread. Install nuts on anchor bolts in accordance with the
sequence that follows. Ensure that the base plate is level by incrementally adjusting the
leveling nuts all of which must be in direct contact with the bottom surface of the base
plate at the conclusion of the leveling process. The distance from the bottom of leveling
nuts to the top of the concrete foundation must not exceed one anchor bolt diameter.
Tighten all the anchor bolt nuts so they are in direct contact with the top surface of the
base plate and are snug-tight. Snug-tight is attained by applying the full tightening effort
of an ironworker using an ordinary spud wrench. If the top surface of the base plate has a
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slope that exceeds 1:40, use a beveled washer under the anchor bolt nut. Tighten the
leveling nuts until they are snug-tight. Match mark the anchor bolt nut relative to the
anchor bolt to ensure that the anchor bolt nut is rotated by the fraction of a turn specified
in Table A and apply the turn to the nut. Do not exceed the Table A value by more than
20 degrees. Tighten each retainer or jam nut until it is in firm contact with the top surface
of the anchor bolt nut then while preventing the anchor bolt nut from rotating, tighten the
jam nut until it is snug-tight. During each stage of leveling nut, anchor bolt nut and jam
nut tightening, use a pattern of tightening that, as nearly as possible, produces a balanced
distribution of clamping forces on the base plate as tightening progresses.
Anchor Bolt Diameter (in.)
1 1/2
> 1 1/2
Table A
Nut Rotation from Snug-Tight Condition
1/3 turn
1/6 turn
649-6 Screen Installation.
Install a screen that will prevent vermin and debris from entering the gap between
the bottom of the base plate and the top of the concrete foundation. Cover the entire gap
with a wire screen, the bottom horizontal wire of which shall be in full contact with the
surface of the concrete foundation and the top horizontal wire of which shall not extend
beyond the top surface of the base plate. For the screen, use standard grade plain weave
galvanized steel wire cloth with 1/2 inch x1/2 inch mesh and 0.063 inch diameter wires.
Vertical screen wires shall not extend beyond the top and bottom horizontal wires of the
screen. Use one continuous section of screen with only one overlapping splice where the
ends come together and overlap the layers 3 inches minimum. Attach the screen to the
vertical side of the base plate with self-tapping stainless steel screws (#8-1/2 inch long)
with stainless steel washers (1/4 inch inside diameter). Drill pilot holes into the base plate
to facilitate screw installation. Install screws on 9 inch centers maximum and at least one
screw shall be installed through the overlapping splice to clamp the layers together. Also
clamp the overlapping splice layers together just above the concrete foundation with an
all stainless steel fastener assembly consisting of a machine screw (#8-5/8 inch long), nut
and two flat washers (1/4 inch inside diameter) and lock washer. Tightly clamp the screen
layers between the flat washers.
649-7 Remedial Work.
During the warranty period, the responsible party shall perform all remedial work
necessary to meet the requirements of this Specification at no cost to the Department.
Such remedial work shall be performed within 180 days of notification of a failure by the
Department. Failure to perform such remedial work within the time frame specified will
result in the work being performed by other forces at the responsible partys cost.
If the responsible party is the fabricator, the fabricator will be removed from the
list of Prequalified Fabricators of Painted Galvanized Steel Strain Poles, Mast Arms and
Monotube Assemblies for a minimum of six months or until payment in full for the
correction of the deficiencies or defects has been made, whichever is longer.
If the responsible party is the Contractor, the Department will suspend, revoke or
deny the responsible partys certificate of qualification under the terms of
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Section 337.16(d)(2), Florida Statutes, for a minimum of six months or until payment in
full for the correction of the deficiencies or defects has been made, whichever is longer.
649-8 Statewide Disputes Review Board.
A Statewide Disputes Review Board will resolve any and all disputes that may
arise involving administration and enforcement of this Specification. The responsible
party and the Department acknowledge that use of the Statewide Disputes Review Board
is required, and the determinations of the Statewide Disputes Review Board for disputes
arising out of this Specification will be binding on both the responsible party and the
Department, with no right of appeal by either party.
649-9 Method of Measurement.
649-9.1 General: Measurement for payment will be in accordance with the
following work tasks.
649-9.2 Furnish and Install: The Contract unit price each for strain poles, mast
arm and monotube assemblies, furnished and installed, will include all materials specified
in the Contract Documents, including the foundation, cover plates, caps, clamps, blank
sign panel, luminaire bracket, all labor, equipment, miscellaneous materials and hardware
necessary for a complete and acceptable installation.
649-9.3 Furnish: The Contract unit price each for strain poles, mast arm and
monotube assemblies, furnished, will include all materials, all shipping and handling
costs involved in delivery as specified in the Contract Documents.
649-9.4 Install: The Contract unit price each for strain poles, mast arm and
monotube assemblies, installed, will include the foundation, blank sign panel, all labor,
equipment, miscellaneous materials and hardware necessary for a complete and
acceptable installation. The Engineer will supply materials as specified in the Contract
Documents.
649-10 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Sign panels and signal assemblies will be paid for separately.
Payment will be made under:
Item No. 649Steel Mast Arm Assembly - each.
Item No. 649Steel Monotube Assembly - each.
Item No. 649Steel Strain Pole - each.
803
SECTION 650
VEHICULAR SIGNAL ASSEMBLIES
650-1 Description.
Install vehicular traffic signal assemblies. For additional requirements related to the
installation of the signals, refer to the appropriate Sections for the installation of related elements
of the overall traffic signal system.
650-2 Materials.
Use signal housings, light emitting diode (LED) modules, backplates, and signal
auxiliaries currently listed on the Departments Approved Product List (APL). Ensure that all
equipment is marked in accordance with Section 603.
650-3 Installation.
650-3.1 Preassembly: Pre-assemble the signal heads when more than one signal section
is required prior to installation at the site. Furnish signal heads with LED modules, backplates,
and visors. Use tunnel visors unless otherwise specified in the Contract Documents. Install the
LED ball module in the door so that the UP arrow or the word UP or TOP is in the up orientation
of the signal housing. Install the LED arrow modules in the signal housing door in the direction
of the intended use.
650-3.2 Positioning of Signals: Consider the locations of the installed signals as shown
in the Plans as sufficiently flexible as to allow for unanticipated field conditions at the site. The
Engineer will direct any variations from the locations shown. Position adjacent signal faces no
closer than 8 feet apart measured horizontally at 90 degrees to the traffic flow between centers of
faces.
Regardless of the results of any scaled dimensions, consider the location shown in
the Plans to be approximate. Position a signal face mounted on a span wire or mast arm as near
as practical to the line of the drivers normal view.
Ensure that all sections are of the same manufacturer and the section assemblies
are uniform in appearance and alignment.
650-3.3 Clearances: Unless directed otherwise by the Engineer for unusual
circumstances at the site, provide a vertical clearance of not less than 17 feet-6 inches and not
more than 19 feet for traffic signals placed over the roadway. Measure such clearance for each
span directly under the most critical signal assembly (in regards to clearance) for that span. Place
signal assemblies on each span as near as practical to the same elevation as the critical signal
assembly.
Ensure that the lowest point on pedestal-mounted and side-mounted signal heads
is 12 feet above finished grade at the point of their installation.
650-3.4 Aiming of Signal Indication: For proper lateral orientation, aim signals after
installing and before locking them in position.
650-3.5 Wiring Connections: Do not splice signal cable. Connect the proper signal
cable to the terminals in each signal head in order to provide the proper signal indication display
when the cables are connected to the controllers. Wire a separate neutral circuit and return it to
the controller cabinet from each vehicular movement as shown in the Contract Documents.
650-3.6 Special Installation Requirements for Optically Programmed Signals:
Install, direct (aim), and conceal optically programmed signals in strict accordance with the
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instructions of the manufacturer, using the materials furnished by the signal manufacturer with
the signals, and with the directions of the Engineer.
Position the signals for maximum performance in accordance with the
requirements shown in the Plans, and install them with rigidly firm mounts, using elbows and
plumbizers of such type as will provide for stability of the position of the signals. Do not use
clevises in the supporting attachments.
Seal the cable routing to the signals to provide permanent water tightness.
650-3.7 Vertically Mounted Polycarbonate (Light-Weight) Signal Head Assemblies:
The top section of all multi-section (5-section, 3-section), vertically mounted, light-weight signal
heads must be constructed of die cast aluminum, unless the entire 3-section polycarbonate signal
head assembly is specifically approved and listed on the APL as a 12 inch polycarbonate 3section vehicle assembly. Ensure that all sections of multi-section assemblies are from the same
manufacturer.
Single section signals may be constructed of die cast aluminum or polycarbonate
construction.
650-3.8 Backplates: Install louvered backplates on all signal head assemblies. On posted
speed limits of 45 mph or greater, provide backplates with a reflectorized border.
650-3.9 Sealing Installed Signal Head Assembly: Ensure that the installed signal head
assembly is sealed to exclude dust and moisture. Drill two, 1/4 inch drain holes in the bottom of
the installed signal head assembly.
650-3.10 Concealing Signals Not in Use: Where traffic signals are installed and not put
into service immediately, conceal the signal head assembly by placing burlap bags or other
covering approved by the Engineer over a weather resistant covering of non-transparent material
open at the bottom to prevent condensation buildup.
650-3.11 Installation Sequence: Install all traffic signal assemblies at any intersection as
a single operation unless a staged operation is approved by the Engineer.
650-4 Method of Measurement.
650-4.1 General: Measurement for payment will be in accordance with the following
work tasks.
650-4.2 Furnish and Install: The Contract unit price per assembly for traffic signal,
furnished and installed, will consist of the traffic signal assembly, including all attachment
hardware necessary to make a complete unit, all mounting brackets, drop-pipe, disconnect
hangers, backplates, visors, LED modules, labor, and materials necessary for a complete and
accepted installation.
650-4.3 Furnish: The Contract unit price per assembly for traffic signal, furnished, will
include the cost of all components of a traffic signal assembly plus all shipping and handling cost
involved in delivery as specified in the Contract Documents.
The Contractor shall deliver the assembly in an unassembled state, with the
following exception, deliver signal sections assembled in the required number of sections for one
direction so that with minimum effort they may be combined into a multiple direction assembly
as specified in the Contract Documents. The Contractor shall include all hardware specified in
this Section in the components of the assembly which are to be furnished and used in the
installation of the assembly. The Contractor shall package and ship component parts of the
assembly in accordance with manufacturers instructions in order to minimize the potential for
damage during shipment.
805
650-4.4 Install: The Contract unit price per assembly for traffic signal, installed, will
consist of all labor necessary to assemble all traffic signal components for a complete and
accepted installation.
The Engineer will supply all traffic signal assembly components. The Contractor
shall furnish any required minor miscellaneous standard hardware items, such as nuts and bolts,
as part of the installation task.
650-4.5 Relocate: The Contract unit price per assembly for traffic signal, relocate, will
include the removal of the signal head and installation at the location shown in the Plans. This
includes signal cable and all other materials necessary for a complete and accepted relocation.
650-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 650- 5Traffic Signal - per assembly.
806
SECTION 653
PEDESTRIAN SIGNAL ASSEMBLIES
653-1 Description.
Install pedestrian signal assemblies as shown in the Plans and Design Standards,
Index No. 17764.
653-2 Materials.
Use only pedestrian signals currently listed on the Departments Approved Product List
(APL). Ensure that all equipment is marked in accordance with Section 603.
653-3 Installation.
653-3.1 General: Use pedestrian signal assemblies capable of being maintained,
adjusted, or disassembled with ordinary hand tools. Pre-assemble the pedestrian signal (not
mounting hardware) prior to installation at the site. Connect the proper signal cable wires to the
proper connections in the pedestrian housing in order to provide the proper signal indication
display. Conceal all conductors. Construct the pedestrian signal assembly (including the
mounting hardware) to be a weather-tight unit.
653-3.2 Placement: Install the pedestrian signals at a location and mount them in the
manner as shown in the Plans. Consider the Plans to be sufficiently flexible as to allow for
unanticipated field conditions at the site. The Engineer will direct all variation from the locations
shown. Mount pedestrian signals with bottom of housing not less than 8 feet (standard) or more
than 10 feet above the sidewalk level. Position pedestrian signals and all mounting assembly
members as either plumb or level, and symmetrically arranged. Properly aim the signals in the
line of the pedestrians vision for the crosswalk being used.
653-3.3 Installation Sequence: Install all pedestrian signal assemblies at any
intersection as a single operation unless a staged operation is approved by the Engineer. Do not
install signals at any intersection until all other signal equipment, including the controller, and
pedestrian detectors, are in place and ready for operation, unless completely covered, in
accordance with 650-3.8. Ensure that the cover remains in place until the pedestrian signal is
placed into operation.
653-4 Method of Measurement.
653-4.1 General: Pedestrian signal assemblies will include any hardware necessary to
make a complete installation and may include one or more pedestrian signals, as specified in the
Contract Documents, including the appropriate mounting hardware.
Measurement for payment will be in accordance with the following work tasks.
653-4.2 Furnish and Install: The Contract unit price per assembly for pedestrian signal,
furnished and installed, (including mounting hardware but not including pedestals) will include
all materials and equipment as specified in the Contract Documents, and all labor and materials
necessary for a complete and accepted installation.
653-4.3 Furnish: The Contract unit price per assembly for pedestrian signal, furnished,
will include the cost of the assembly including all mounting hardware as specified in the
Contract Documents, plus all shipping and handling costs involved in delivery as specified in the
Contract Documents.
807
The Contractor shall deliver the pedestrian signal assembly in a pre-assembled
state. The Contractor shall package and ship component parts of the assembly in accordance with
the manufacturer's instructions to minimize the potential for damage during shipment.
653-4.4 Install: The Contract unit price per assembly for pedestrian signal, installed, will
consist of all labor necessary to assemble all components for complete and accepted installation.
The Engineer will supply pedestrian signal assembly (including all mounting hardware) as
specified in the Contract Documents. The Contractor shall furnish all conduit, risers, lead-inwires, posts or miscellaneous materials needed to complete the installation as specified in the
Contract Documents.
653-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 653- Pedestrian Signals - per assembly.
808
SECTION 660
INDUCTIVE LOOP DETECTORS
660-1 Description.
Install inductive loop detectors, harnesses, and loop assemblies.
660-2 Materials.
Use inductive loop detectors, pre-formed loop assemblies and loop sealant currently
listed on the Departments Approved Products List (APL). Ensure that all loop detectors are
marked in accordance with Section 603 and the markings are visible after installation.
660-3 Installation Requirements.
660-3.1 Inductive Loop-Detector Units: Install inductive loop detector units and cable
harnesses in accordance with the manufacturers instructions and the Design Standards,
IndexNo. 17781. Adjust the operating frequency of each detector unit, if required, to prevent
crosstalk of the units.
660-3.2 Saw Cuts: Use a chalk line or equivalent method to outline the perimeter of the
loop on the pavement and routes for lead-in cables. Do not allow the saw cut in the pavement to
deviate by more than 1 inch from the chalked line. Ensure that all saw cuts are free of any dust,
dirt or other debris and completely dry prior to the installation of the loop wire, loop wire twisted
pair lead or lead-in cable.
Make saw cuts in accordance with the Design Standards, Index No. 17781.
Ensure that the top conductor of the loop wire or lead-in cable is a minimum of 1 inch below the
final surface of the roadway.
660-3.3 Loop Wire: Ensure that all loops are wound in a clockwise manner and the first
turn of the loop wire is placed in the bottom of the saw cut, with each subsequent turn placed on
top of the preceding turn. Push the loop wire to the bottom of the saw cut with a non-metallic
tool which will not damage the insulation.
Tag and identify the clockwise lead of each loop.
Use alternate polarity on adjacent loops.
Ensure that the hold down material is non-metallic and is not longer than 1 inch
and that the distance from the top of the hold down material to the final surface of the roadway is
not less than 3/4 inch.
Twist the loop wire a minimum of five turns per 1 foot to form a loop wire
twisted pair lead from the edge of the loop to the pull box.
Splice the loop wire twisted pair lead to the lead-in cable in the pull box. Place
only one loop wire twisted pair lead in a saw cut.
Ensure that the distance between a twisted loop wire pair lead within the roadway
is a minimum of 6 inches from any other twisted loop wire pair lead or loop, until they are within
1 foot of the edge of pavement or curb, at which point they may be placed closer together.
Prepare and apply the loop sealant in accordance with the manufacturers
instructions. Ensure that the loop sealant has cured completely before allowing vehicular traffic
to travel over the sealant.
660-3.4 Lead-In Cable: Place the lead-in cable in the bottom of the saw cut. Do not
damage the insulation.
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Install no more than four lead-in cables in a saw cut. Ensure that the hold down
material is not longer than 1 inch and that the distance from the top of the hold down material to
the final surface of the roadway is not less than 3/4 inch.
Prepare and apply the loop sealant in accordance with the manufacturers
instructions. Ensure that the loop sealant has cured completely before allowing vehicular traffic
to travel over the sealant.
660-4 Splicing and Termination Requirements.
660-4.1 Splicing: Splice lead-in cable to the loop wire in accordance with Design
Standards, Index No. 17781. Perform the splicing in a pull box located off the roadway, not in
the roadway itself.
Splice the black conductor of the lead-in cable to the clockwise lead of the
loop.
Ensure that the ends of the cable jackets, twisted pair and lead-in, are encased in
the loop splice material.
Ensure that each loop has an individual return to the cabinet and series splicing is
performed on a separate terminal block in the cabinet.
660-4.2 Terminations: Using insulated terminal lugs, terminate lead-in cables or twisted
pair loop wire on a terminal strip which is located in the controller or detector cabinet. Use a
calibrated ratchet type crimping tool to attach the lugs to the conductors of the lead-in cable or
twisted loop wire.
660-5 Loop Assembly Identification.
Identify and tag each loop assembly in the controller or detector cabinet by lane and
movement number.
Example:
Outside lane - Movement 6
Center lane - Movement 6
Inside lane - Movement 6
660-6 Testing Requirements.
660-6.1 Series Resistance: Obtain Department of Transportation Traffic Signal
Resistance Measurement Data Sheets from the Engineer. Measure and record the series
resistance of each loop assembly on these data sheets. Leave a copy in the controller cabinet.
If the series resistance of a loop assembly is greater than 10 , inspect the loop
assembly to find the cause of the excessive resistance. Correct the cause of the excessive
resistance at no additional cost to the Department.
660-6.2 Insulation Resistance: Measure and record the insulation resistance of each
loop assembly, and verify that the resistance is greater than 100 M. Use a 500 V DC insulation
megger to measure the resistance. Reference all measurements to a good earth ground (ground
rod, metallic water pipe, etc.). Disconnect the transient suppression devices from the loop
assemblies before taking any measurements. If the insulation resistance is less than 100 M,
determine if the lead-in cable or the loop wire is causing the problem, and replace the defective
cable or loop wire at no additional cost to the Department.
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660-7 Turn On Requirements.
Connect the loop assemblies to the appropriate inductive loop vehicle detectors and tune
the detectors in accordance with the manufacturers instructions. Separate the operating
frequencies of vehicle detectors, in adjacent lanes, by at least 2 kHz.
660-8 Method of Measurement.
660-8.1 General: Measurement for payment will be in accordance with the following
tasks.
660-8.2 Furnish and Install: The Contract unit price each for inductive loop detector
and per assembly for loop assembly, furnished and installed, will include all equipment,
materials as specified in the Contract Documents and all labor, equipment, and miscellaneous
materials necessary for a complete and accepted installation.
660-8.3 Furnish: The Contract unit price each for inductive loop detector, per assembly
for loop assembly, per gallon for loop sealant, per foot for loop material and for each inductive
loop detector accessories, furnished, will include all equipment and materials as specified in the
Contract Documents, plus all shipping and handling costs involved in delivery as specified in the
Contract Documents.
660-8.4 Install: The Contract unit price each for inductive loop detector and per
assembly for loop assembly, installed, will include all loop sealant, miscellaneous materials,
labor, and equipment necessary for a complete and accepted installation.
The Engineer will supply the inductive loop detector, harness, lead-in cable, and
loop wire.
660-8.5 Modify: The Contract unit price per assembly for loop assembly, modified, will
include all lead-in cable, saw cuts, miscellaneous materials as specified in the Contract
Documents, connecting new lead-in cable to an existing loop and installing and terminating the
lead-in cable to the location designated in the Contract Documents, and all labor and equipment
necessary for a complete and accepted installation.
660-9 Basis of Payment.
660-9.1 Inductive Loop Detector: Price and payment will be full compensation for all
work specified in this Section.
Payment will be made under:
Item No. 660- 1Inductive Loop Detector - each.
660-9.2 Loop Assembly: Price and payment will be full compensation for all work
specified in this Section.
Payment will be made under:
Item No. 660- 2Loop Assembly - per assembly.
811
SECTION 665
PEDESTRIAN DETECTOR ASSEMBLY
665-1 Description.
Install pedestrian detector assembly.
665-2 Materials.
Use only an ADA (Americans with Disabilities Act) compliant pedestrian detector
assembly listed on the Departments Approved Product List (APL). Ensure that all pedestrian
detectors are marked in accordance with Section 603 and the markings are visible after
installation.
665-3 Installation.
Meet the requirements of 653-3.1, except as follows. Connect the lead-in wires to the
detector in order to provide proper operation when connected to the controller.
Install the pedestrian detector assembly at the location and mounted in a manner as
shown in the Plans and Design Standards, Index No. 17784. Ensure that all detectors used are of
the same manufacturer and model.
Consider the Plans to be sufficiently flexible as to allow for unanticipated field
conditions at the site. The Engineer will direct any variation from the locations shown. When
mounting, place the detector housing or saddle in complete contact with the pole or controller
cabinet. When a post is required in the installation of the pedestrian detector assembly, restore
the area around the post to its original condition or as required by the Plans.
665-4 Method of Measurement.
665-4.1 General: Measurement for payment will be in accordance with the following
tasks.
665-4.2 Furnish and Install: The Contract unit price each for pedestrian detector
assembly, furnished and installed, will include all mounting hardware, lead-in wires, materials
and equipment, as specified in the Contract Documents, and all labor and miscellaneous
materials necessary for a complete and accepted installation.
665-4.3 Furnish: The Contract unit price each for pedestrian detector assembly,
furnished, will include the cost of the assembly (including all mounting hardware) plus all
shipping and handling costs involved in delivery as specified in the Contract Documents.
Risers, lead-in wires, or posts are not included in furnish items.
The Contractor shall deliver the pedestrian detector assembly in a pre-assembled
state. The Contractor shall package and ship component parts of the assembly in accordance with
the manufacturers instructions in order to minimize the potential for damage during shipment.
665-4.4 Install: The Contract unit price each for pedestrian detector assembly, installed,
will include all materials, equipment, labor and miscellaneous materials necessary to assemble
and install all components for a complete and accepted installation. The Engineer will supply the
pedestrian detector assembly, including mounting hardware.
665-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
812
Item No. 665- Pedestrian Detector - each.
813
SECTION 670
TRAFFIC CONTROLLER ASSEMBLY
670-1 Description.
Install traffic controller assembly or flashing beacon controller assembly.
670-2 Materials.
Use a traffic controller assembly or flashing beacon controller assembly listed on the
Departments Approved Product List (APL). Ensure that the traffic controller assembly or
flashing beacon controller assembly is marked in accordance with Section 603 and the markings
are visible after installation.
670-3 Installation Requirements.
670-3.1 Controller Cabinets: Meet the requirements of Section 676.
670-3.2 Field Wiring: Meet the requirements of Sections 632 and 676.
670-3.3 Grounding: Meet the requirements of Sections 620 and 676.
670-3.4 Equipment Placement: Install all equipment in the cabinet in accordance with
the manufacturers recommendations.
670-4 Method of Measurement.
670-4.1 General: Measurement for payment will be in accordance with the following
work tasks.
670-4.2 Furnish and Install: The Contract unit price per assembly for traffic controller
assembly or flashing beacon controller assembly, furnished and installed, will include all
equipment specified in the Contract Documents, and all labor, equipment, and miscellaneous
materials necessary for a complete and accepted installation.
670-4.3 Furnish: The Contract unit price per assembly for traffic controller assembly or
flashing beacon controller assembly, furnished, will include all equipment specified in the
Contract Documents, plus all shipping and handling costs involved in delivery as specified in the
Contract Documents.
670-4.4 Install: The Contract unit price per assembly for traffic controller assembly or
flashing beacon controller assembly, installed, will include all labor, equipment, and
miscellaneous materials necessary for a complete and acceptable installation. The Engineer will
supply the equipment specified in the Contract Documents.
670-5 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 670- 5Traffic Controller Assembly - per assembly.
814
SECTION 671
TRAFFIC CONTROLLERS
671-1 Description.
This Section specifies the provisions for the measurement and payment for NEMA
Types D4-4, and D8 and Model 170 controller units.
671-2 Materials.
Use traffic controllers listed on the Departments Approved Product List (APL). Ensure
that all traffic controllers are marked in accordance with Section 603 and the markings are
visible after installation.
671-3 Method of Measurement.
671-3.1 General: Measurement for payment will be in accordance with the following
work tasks.
671-3.2 Furnish and Install: The Contract unit price each for traffic controller unit,
furnished and installed, will include furnishing a controller unit and harness cable as specified in
the Contract Documents, and all labor and miscellaneous materials necessary for a complete and
accepted installation.
671-3.3 Furnish: The Contract unit price each for traffic controller unit, furnished, will
include the controller unit and harness cable as specified in the Contract Documents, plus all
shipping and handling costs involved in delivery as specified in the Contract Documents.
671-3.4 Install: The Contract unit price each for traffic controller unit, installed, will
include all labor, equipment, and miscellaneous materials necessary for a complete and accepted
installation. The Engineer will supply all materials as specified in the Contract Documents.
671-3.5 Modify: The Contract unit price each for traffic controller unit, modified as
specified in the Contract Documents, will include all labor, equipment, and miscellaneous
materials necessary for a complete and accepted installation.
671-4 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 671- 2Traffic Controller - each.
815
SECTION 676
CONTROLLER CABINETS
676-1 Description.
Install NEMA cabinets Types 1, 2, 3, 4, 5, and cabinets types used for Model 170
controller assemblies.
676-2 Materials.
Use Controller Cabinets listed on the Departments Approved Product List (APL).
Ensure that all Controller Cabinets are marked in accordance with Section 603 and the markings
are visible after installation.
676-3 Installation Requirements.
676-3.1 General: Install controller cabinets in accordance with the Design Standards,
Index No. 17841. Ensure that all conduit entrance holes or other holes which are field drilled are
reamed and free of burrs. Make all conduit connections to the cabinet watertight by the use of
clear silicone rubber sealant.
676-3.2 Pole Mounted Cabinets (Types 1, 2, 3, and 4):
(a) Fasten the pole mounted hardware which is furnished with the cabinet to the
cabinet, making all connections watertight.
(b) Use stainless steel bands for mounting cabinets onto steel strain poles.
(c) Use stainless steel bands or lead anchors (or equivalent) for mounting cabinets
onto concrete strain poles.
(d) Use stainless steel bands or lag bolts for mounting cabinets onto wood poles.
676-3.3 Base Mounted Cabinets (Types 4, 5, and types used for Model 170
Controller Assemblies):
(a) Use anchor bolts to fasten base mounted cabinets to the concrete base.
(b) Seal the joint between the bottom of the cabinet and the concrete base (inside
and outside of cabinet) with a clear silicone rubber sealant.
(c) Construct the base for the cabinets with concrete in accordance with
Section 347. Make the concrete base for the cabinet level, free of honeycombs and as smooth as
possible. Temporarily seal the end of conduit risers located in the base before placing the
concrete. Position the end of the conduit risers a minimum of 2 inches above the finished surface
of the concrete base.
676-3.4 Field Wiring:
(a) Terminate signal cable, interconnect cable, and loop lead-in wires on the
appropriate terminal strips in the controller cabinet with insulated terminal lugs. Use a calibrated
ratchet type crimping tool to install the insulated terminal lugs onto the field wires.
(b) Label spare circuits of the signal and interconnect cables and connect them to
the cabinet ground bussbar.
(c) Neatly bundle and identify all field wiring cables in the controller cabinet.
676-3.5 Grounding: Ground all controller cabinets in accordance with the requirements
of Section 620. Keep the ground wire from the controller cabinet ground bussbar to the ground
rod assembly or array as short as possible. Ensure the ground wire is not in contact with any
other part of the cabinet.
816
676-4 Method of Measurement.
676-4.1 General: Measurement for payment will be in accordance with the following
work tasks.
676-4.2 Furnish and Install: The Contract unit price each for controller cabinet,
furnished and installed, will include all materials specified in the Contract Documents, and all
labor, equipment, and miscellaneous materials necessary for a complete and acceptable
installation.
676-4.3 Furnish: The Contract unit price each for controller cabinet, furnished, will
include all materials and all shipping and handling costs involved in delivery as specified in the
Contract Documents.
676-4.4 Install: The Contract unit price each for controller cabinet, installed, will include
all labor, equipment, and miscellaneous materials necessary for a complete and acceptable
installation. The Engineer will supply all materials as specified in the Contract Documents.
676-4.5 Modify: The Contract unit price each for controller cabinet, modified as
specified in the Contract Documents, will include all labor, equipment, and miscellaneous
materials necessary for a complete and acceptable installation.
676-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 676- 1Controller Cabinet - each.
817
SECTION 678
CONTROLLER ACCESSORIES
678-1 Description.
Install controller accessories.
678-2 Materials.
Use traffic controller accessories listed on the Departments Approved Product List
(APL). Ensure that all traffic controller accessories are marked in accordance with Section 603
and the markings are visible after installation.
678-3 Time Switch.
Mount time switches on the inside wall of the controller cabinet in such a manner as to
allow easy access for programming the switch. Ensure that the load current on the output circuits
of the time switch does not exceed 3 A at 115 V AC. Whenever time switches are used for
transferring a controller assembly to and from flashing operation, wire the controller cabinet for
uniform code flashing as specified in the Contract Documents.
678-4 Method of Measurement.
678-4.1 General: Measurement for payment will be in accordance with the following
work tasks.
678-4.2 Furnish and Install: The Contract unit price each for controller accessory,
furnished and installed, will include furnishing all materials, equipment, and hardware specified
in the Contract Documents, and all labor and miscellaneous materials necessary for a complete
and acceptable installation.
678-4.3 Furnish: The Contract unit price each for controller accessory, furnished, will
include the cost of the equipment and materials and all shipping and handling costs involved in
delivery as specified in the Contract Documents.
678-4.4 Install: The Contract unit price each for controller accessory, installed, will
include all labor, equipment, and miscellaneous materials necessary for a complete and
acceptable installation. The Engineer will supply all materials as specified in the Contract
Documents.
678-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 678- 1Controller Accessories - each.
818
SECTION 690
REMOVAL OF EXISTING TRAFFIC CONTROL SIGNALS AND DEVICES
690-1 Description.
Remove existing traffic control signals and devices including electrical and electronic
equipment, supporting hardware and structures, electrical wiring, conduit, and all other elements
specified and required to clear the areas of concern for new installations.
When removing existing traffic signals and devices , salvage and protect all equipment
and materials designated for removal in the Contract Documents.
690-2 Ownership.
The Department retains ownership of the equipment removed unless otherwise stated in
the Contract Documents.
690-3 General Removal Operations.
Remove and salvage all equipment, appurtenances, and materials designated in the Plans
to remain the property of the Department or other owner.
Where the removals require excavation, backfill, compact, and level the excavated areas
(unless to be used as areas for other installations) so as to form a smooth contour, uniform in
density with adjacent ground areas.
Where the removal operations require the removal or disturbance of overlying pavement,
curb, grass, or sidewalk, remove such pavement and subsequently replace it in kind (or
equivalent).
Remove, handle, and transport electronic equipment to be removed with all due care.
Correct any damage to such equipment caused by negligence at no expense to the Department
regardless of whether the damage occurs before or after removal of the equipment.
When removing all electronic equipment, also remove all attaching devices and all other
devices and auxiliaries related to the electronic unit which the Department does not require to
remain in place for use with replacing equipment.
Perform all removals in such a manner as to not damage or disturb adjacent property,
utilities, or other equipment.
When replacing existing functioning installations with new installations, do not remove
the existing installations until the new installations are in place and operating or until temporary
traffic control approved by the Engineer is in place.
Notify the proper authorities or the owners of affected adjacent installations at least
24 hours in advance of any removal operations which might endanger or otherwise affect the
operations of their facilities.
When the Contract Documents indicate that owners (or others) will remove their own
poles, carefully remove and handle all equipment from such poles prior to such removal of the
poles.
690-4 Specific Removal Operations.
690-4.1 Removal of Poles: Remove direct burial, strain poles, steel strain poles, mast
arm and monotube assemblies and associated foundations as specified in the Plans. Obtain the
Engineers approval for the removal process before beginning any removal work. These
requirements do not apply to poles used for highway lighting, unless they are jointly used to
support traffic control signals and devices, signal mast arm, or span wire assemblies.
819
Accomplish the removal process of each pole/foundation in such a manner as not
to result in a safety hazard to motorists or adjacent property or damage to existing utilities.
Ensure that all utilities have been located prior to removal.
When shallow pole removal is specified in the Plans, ensure the remaining
pole/foundation and any protrusions, such as pole keys, dead men, guying apparatus, conduit,
anchor bolts, or reinforcing steel, are removed to a minimum depth of 4 feet below existing
grade.
When deep pole removal is specified in the Plans completely remove each pole
including the foundation and all accessories or attachments, such as pole keys, dead men, guying
apparatus, conduit, anchor bolts, and reinforcing steel.
Do not remove or disturb utility poles located within the right-of-way.
690-4.2 Removal of Signal Pedestal: Remove each signal pedestal and associated
foundations as specified in the Plans. Obtain the Engineers approval for the removal process
before beginning any removal work.
Accomplish the removal process of each pedestal/foundation in such a manner as
not to result in a safety hazard to motorists, pedestrians or adjacent property or damage to
existing utilities. Ensure that all utilities have been located prior to removal.
Completely remove each pedestal including the foundation and all accessories or
attachments, such as pole keys, conduit, anchor bolts, and reinforcing steel.
690-4.3 Removal of Controllers and Cabinets: When removing controller assemblies,
also remove the cabinet. For base mounted cabinets, completely remove the concrete base and
technician pad.
Prior to removal, conduct an inventory of the cabinet and all cabinet contents,
including identification of the model number and serial numbers of each item. Submit the
inventory list to the Engineer for retention by the Department and provide a copy of the list to the
equipment owner.
690-4.4 Removal of Signal Heads (Vehicular and Pedestrian): Remove all signal head
assemblies and attachment hardware in such a manner as to avoid unnecessary damage.
690-4.5 Removal of Detectors (Vehicular and Pedestrian): Divide the removal of
detector assemblies into the following categories:
(a) Vehicular detector assemblies: When the removal of vehicular detector
assemblies is specified in the Contract Documents, remove the amplifier from the controller
cabinet, the loop, and the lead-in wiring that is in the conduit and pull boxes.
When removing pressure type vehicular detector assemblies, remove the
amplifier and the detector pad and its framework from the roadway pavement. After removing
such detector assemblies, repair the roadway areas by backfilling and tamping with an approved
asphalt concrete mix or concrete pavement mix so as to restore the roadway to the satisfaction of
the Engineer.
When removing non-intrusive detectors that are not embedded in or under
pavement, remove the roadside detector assembly, cabling, mounting hardware, and detector
electronics in cabinet.
(b) Pedestrian detector assemblies: Include in the removal of pedestrian detector
assemblies the removal of the push button detector, sign, and all mounting hardware, including
the supporting post and foundation.
690-4.6 Removal of Mast Arms and Span Wires: Disconnect the mast arms and span
wires carefully at the pole, and salvage all usable hardware and attachment devices as
820
determined by the Engineer. Remove all devices supported by the mast arm or span wire
(including wiring) prior to the removal of the mast arm or span wire.
For integrally installed mast arms and mast arm poles, remove the pole and mast
arm combination as a unit after removing the devices supported by the mast arms.
690-4.7 Removal of Cabling and Conduit: After removing the conductor cable and
conduit, carefully stub, or protect with other appropriate procedures, the remaining conductor
cable and conduit at the point of removal.
If the removal of any cables and conduit requires excavation, restore disturbed
areas compatible with adjacent ground areas.
690-5 Transporting and Storing Removed Equipment.
When the Contract Documents specify special handling, deliver equipment and materials
that are not stipulated to be reused in the new installations to the locations designated in the
Contract. When the Contract Documents note no special handling, stockpile or dispose of the
removed materials as approved by the Engineer. The Engineer will determine ownership of
removed equipment and will approve of the removal of any salvaged equipment from the project
in advance.
Provide disposal areas, and dispose of removed concrete strain poles in such areas.
690-6 Method of Measurement.
690-6.1 General: The quantities to be paid for will be measured in accordance with the
different work tasks required in this Section. The Contract unit price for each different work task
as specified in the Contract Documents will include all labor and equipment required to remove
the specified items specified by the pay item numbers.
690-6.2 Remove Poles:
690-6.2.1 Pole Removal Shallow: The quantity to be paid for will be the removal
of each pole including the foundation and all accessories or attachments to a depth not less than
4 feet below existing grade.
690-6.2.2 Pole Removal Deep: The quantity to be paid for will be the complete
removal of the pole and foundation including all accessories or attachments.
690-6.3 Remove Signal Pedestal: The quantity to be paid for will be the complete
removal of each pedestal including the foundation and all accessories or attachments.
690-7 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 690- 10Remove Traffic Signal Head Assembly - each.
Item No. 690- 20Remove Pedestrian Signal Assembly - each.
Item No. 690- 31Remove Signal Pedestal - each.
Item No. 690- 32Pole Removal Shallow - each.
Item No. 690- 34Pole Removal Deep - each.
Item No. 690- 50Remove Controller or Cabinet - each.
Item No. 690- 60Remove Vehicular Detector Assembly - each.
Item No. 690- 70Remove Pedestrian Detector Assembly - each.
Item No. 690- 80Remove Span Wire Assembly - each.
Item No. 690- 90Remove Cabling and Conduit - per intersection or
interchange.
821
Item No. 690-100-
Remove Miscellaneous Traffic Control Signals and
Devices - per site.
822
SECTION 699
INTERNALLY ILLUMINATED SIGNS
699-1 Description.
The work in this Section consists of furnishing and installing an internally
illuminated street name sign in accordance with the details specified in the Contract
Documents.
699-2 Materials.
699-2.1 General: Use internally illuminated street name sign assemblies and
associated mounting hardware meeting the requirements of the Minimum Specifications
for Traffic Control Signal Devices (MSTCSD) and listed on the Departments Approved
Product List (APL). Ensure all internally illuminated street name signs are marked in
accordance with Section 603 and the markings are visible after installation.
Replace any component which the Engineer determines is damaged
beyond repair at no additional cost to the Department.
699-2.2 Hardware: Meet the requirements of 603-2.4.
699-2.3 Clamp-On Cantilever Arm: Use only clamp-on cantilever arms which
meet all design and wind loading requirements as specified in the Contract Documents.
Ensure the clamp is adjustable to accommodate various size poles.
699-3 Submittal Requirements.
699-3.1 General: Free-swinging, internally illuminated signs and clamp-on
cantilever arms mounted on the upright poles of mast arm assemblies or monotube signal
structures may be accepted either by certification or by shop drawing submittal and
approval as stipulated in this Section.
699-3.2 Acceptance of signs by Certification: Meet all of the following
requirements:
1.699-2,
2. Are not more than 18.0 square feet in area, and
3. Weigh no more than 8 lbs. per square foot.
699-3.3 Acceptance of signs by Shop Drawing Approval: Submit Shop
Drawings in accordance with Section 5 for internally illuminated street name signs not
meeting all of the requirements of 699-3.2. Signs submitted for acceptance by shop
drawing approval must be manufactured by a vendor with an approved internally
illuminated sign listed on the APL.
699-3.4 Acceptance of Clamp-On Cantilever Arms: For cantilever arms
supporting signs meeting the requirements of 699-3.2, certify to the Engineer that the arm
meets the criteria in this Section. For cantilever arms supporting signs which do not meet
the requirements of 699-3.2, submit shop drawings and design calculations for the arm
design in accordance with Section 5.
699-4 Installation.
699-4.1 General: Secure the brackets to the street name sign housing in
accordance with the manufacturers instructions.
699-4.2 Single Sided Sign Assembly: Install as specified in the Contract
Documents.
823
699-4.3 Double Sided Sign Assembly: Use a free swinging mounting method.
699-4.3.1 Two Point Support Assembly: Use a two point support
assembly when the street name sign assembly is attached to a mast arm that is
perpendicular to the street on which the sign is viewed.
Use a two point mast arm mounting assembly consisting of the
following:
1. Stainless steel band or cable type clamp,
2. Clevis,
3. Span wire adapter,
4. Tri-stud hanger body.
Ensure one of the hangers has a mechanism for the horizontal
adjustment of the sign.
699-4.3.2 One Point Support Assembly: Use a one point support
assembly consisting of an articulated horizontal stainless steel band or cable type mast
arm clamp, sign bracket and mounting hardware, when the street name sign assembly is
attached to a mast arm that is diagonal to the street on which the sign is viewed. Do not
use a one point support assembly for internally illuminated street name sign assemblies
exceeding 4 feet in width.
Ensure the band or cable clamp is capable of horizontal rotation of
360 degrees.
699-4.4 Clamp-On Cantilever Arm: Attach the arm perpendicular to the street
on which the street name sign assembly is viewed. Use a clamp and arm that are
galvanized in accordance with ASTM A123 unless otherwise specified in the Contract
Documents. Ensure the arm has a cap secured in place.
699-4.5 Electrical Wiring: Install dedicated 14 AWG conductors to supply
power to the sign. Connect the conductors to a dedicated 15 amp circuit breaker located
either inside the controller cabinet or inside the electrical service disconnect. Using the
same conduit system for both signal cables and internally illuminated sign conductors is
permitted, unless otherwise specified.
Install conductors in such a manner as to prevent damage to conductors or
conductor insulation. Remove and replace all damaged conductors /insulation at no
additional cost to the Department.
Ensure drilled hole(s) through which conductors pass through are fitted
with a tight fitting rubber grommet.
Install continuous lengths of conductors between the dedicated circuit
breaker and internally illuminated street name signs.
Do not splice conductors unless specified in the Contract Documents.
Provide one photoelectric cell to turn on/off all internally illuminated
street name sign at each intersection. Use an L bracket to mount the photoelectric cell as
specified in the Contract Documents. Connect the photoelectric cell to a contactor
assembly inside the controller cabinet to provide switching of the internally illuminated
street name signs.
699-5 Method of Measurement.
699-5.1 General: Measurement for payment will be in accordance with the
following tasks.
824
699-5.2 Furnish and Install: The Contract unit price each for internally
illuminated street name sign, furnished and installed, includes the internally illuminated
street name sign and clamp-on cantilever arm as specified in the Contract Documents, all
support and hanger hardware, photoelectric cell, relay assembly, field wiring to both the
sign assembly, photoelectric cell, all miscellaneous materials, and labor necessary for a
complete and accepted installation.
699-5.3 Furnish: The Contract unit price each for internally illuminated street
name sign, furnished, includes the internally illuminated street name sign, and clamp-on
cantilever arm, and materials as specified in the Contract Documents, plus all shipping
and handling costs involved in the delivery as specified in the Contract Documents.
699-5.4 Install: The Contract unit price each for internally illuminated street
name sign, installed, includes all miscellaneous materials and labor necessary for a
complete and accepted installation as specified in the Contract Documents. The Engineer
will supply the internally illuminated street name sign and clamp-on cantilever arm, as
specified in the Contract Documents.
699-6 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 699- 1
Internally Illuminated Street Name Sign - each.
825
SIGNING, PAVEMENT MARKING AND LIGHTING
SECTION 700
HIGHWAY SIGNING
700-1 Description.
Furnish and erect roadway signs, at the locations shown in the Plans, in accordance with
the details shown in the Plans. All overhead cantilever and truss mounted signs are to be lighted
and retroreflective unless otherwise noted in the Plans.
The Department designates ground traffic signs as signs erected on the shoulders, slopes,
or medians, but not extending over the traveled roadway.
The Department designates signs erected partially or completely over the traveled
roadway or mounted on bridges as overhead traffic signs, and may further classify some of these
signs as overhead cantilever or span traffic signs.
The Department designates signs that include certain electronic display components as
Electronic Display Signs (EDS) and may further classify them as Electronic Warning Signs
(EWS), Electronic Regulatory Signs (ERS), Electronic Speed Feedback Signs (ESFS), or Blank
Out Signs (BOS). EDS may be erected on the shoulders, slopes, or in the medians, or installed on
mast arms, monotube assemblies, or span wires.
Obtain multi-post and overhead sign structures from a fabrication facility that is listed on
the Departments list of metal producers with an accepted quality control program, meeting the
requirements of 105-3.
700-2 Sign Assembly Design Requirements.
700-2.1 General: Sign assemblies as specified in the Plans fall into three general
categories: ground sign assemblies, overhead sign assemblies, and electronic display signs.
700-2.2 Sign Panels: All sign panels shall be aluminum. Fabricate standard sign panel
messages in accordance with details included in the Standard Highway Signs Manual published
by the U.S. Department of Transportation. The Engineer will not require the submittal of shop
drawings for these signs or for non-standard sign panels and messages fabricated in accordance
with details shown in the Plans. Submit seven copies of shop drawings indicating detailed layout
of the sign legend, spacing, and border for all other signs to the Engineer prior to fabrication.
If the size of a sign is not specified in the Plans, provide the size sign for
conventional roadways as shown in the MUTCD.
700-2.3 Breakaway Support Mechanisms for Ground Traffic Signs:
700-2.3.1 Frangible Supports: Provide posts for all frangible sign assemblies
consisting of aluminum tubes up to 3 1/2 inches outside diameter with 3/16 inch wall thickness
in accordance with the requirements in the Design Standards.
700-2.3.2 Slip Bases: For posts with slip base assemblies, use galvanized steel in
accordance with the requirements in the Design Standards.
700-2.4 Overhead Sign Structures:
700-2.4.1 Shop Drawings: Submit shop drawings to the Department for approval
as specified in Section 5. Prior to the submittal of the shop drawings, determine the actual length
of support columns for all sign structures on the basis of existing field conditions and include
these lengths on the shop drawings.
826
700-2.4.2 Installation: Install nuts on anchor bolts in accordance with 649-5 and
649-6. Use ASTM A325 bolt, nut and washer assemblies for all installations other than anchor
bolts as follows. Use bolt, nut and washer assemblies that are free of rust and corrosion and that
are lubricated properly as demonstrated by being able to easily hand turn the nut on the bolt
thread for its entire length. Tighten nuts to the full effort of an ironworker using an ordinary spud
wrench to bring the faying surfaces of the assembly into full contact which is referred to as snug
tight condition. After bringing the faying surfaces of the assembly into full contact and to a snug
tight condition, tighten nuts to achieve the minimum torque as specified in Table 700-1 unless
the connection is an alternate splice connection of a span sign structure, in which case, tighten
nuts in accordance with the turn-of-nut method of Table 460-7 of Section 460. Maintain uniform
contact pressure on the faying surfaces during snugging and the subsequent final tightening
process, by using a bolt tightening pattern that balances the clamping force of each bolt, as
closely as possible, with the equal clamping force of a companion bolt. Within 24 hours after
final tightening, the Engineer will witness a check of the minimum torque using a calibrated
torque wrench for 3 bolts or a minimum of 10% of the bolts, whichever is greater, for each
connection; however, do not perform this check on alternate splice connections of span sign
structures.
Table 700-1
Bolt Diameter
(in.)
3/8
1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
Minimum Torque
(ft.-lbs.)
15
37
74
120
190
275
375
525
700-2.5 Sign Retroreflective Sheeting: Meet the requirements of Section 994. Use
Type III, VII or XI sheeting for background sheeting, white legends, borders and shields on all
signs with the following exceptions:
a. Use Type VII sheeting for STOP, DO NOT ENTER and WRONG WAY signs.
b. Use Type III or greater prismatic material for white sheeting for overhead
signs.
Use Type III, VII or XI yellow-green fluorescent sheeting for S1-1 school advance signs and
supplemental panels used with S1-1, S3-1 and S4-5 school signs. Do not mix signs having
fluorescent yellow-green sheeting with signs having yellow retroreflective sheeting. Use
fluorescent orange Type VI or VII for all orange work zone signs. Mesh signs shall meet the
color, daytime luminance and nonreflective property requirements of Section 994, Type VI.
700-2.6 Breakaway Support Mechanisms for Electronic Display Signs: Provide posts
or posts with slip bases as shown in the Plans.
827
700-3 Materials.
700-3.1 General: Meet the materials requirements shown below and any additional
requirements which the Plans might show.
700-3.2 Concrete: Use concrete meeting the requirements of Section 346.
700-3.3 Reinforcing Steel: For reinforcing steel in footings, meet the requirements of
Section 415.
700-3.4 Aluminum Materials:
700-3.4.1 General: For aluminum materials, meet the general provisions of 9651.
700-3.4.2 Sheets and Plates: For aluminum sheets and plates for sign panels,
meet the requirements of ASTM B 209, Aluminum Association Alloy 6061-T6, 5154-H38 or
5052-H38 and those shown in the Plans.
700-3.4.3 Extruded Tubing: For extruded aluminum tubing, meet the
requirements shown in the Plans.
700-3.4.4 Castings: Provide aluminum castings of the alloys shown in the Plans.
For aluminum alternates the Engineer will allow a cast base, provided the Contractor submits test
reports giving evidence that the base to be used for each pole size is as strong as the pole with
which it is to be used. Perform physical tests and submit certified reports for one base to be used
with each pole size. Use Alloy A 356-T6 for the castings. Use aluminum bolts for connecting
parts of the cast base.
700-3.4.5 Channels: For aluminum channels, meet the requirements of
ASTM B 308 for the alloys shown in the Plans.
700-3.4.6 Bolts, Nuts, and Lockwashers: For aluminum bolts, nuts, and
lockwashers, meet the requirements shown in the Plans. Ensure that finished bolts and washers
are given an anodic coating of at least 0.0002 inch in thickness and are chromate-sealed.
700-3.5 Steel:
700-3.5.1 General: Only use structural steel, including bolts, nuts, and washers,
that have been hot dip galvanized or metalized after fabrication. Perform hot dip galvanizing in
accordance with ASTM A 123 or ASTM A 153 and metalizing in accordance with Section 562.
For galvanized steel members meet the general requirements of Section 962 and the specific
requirements of 962-9.
700-3.5.2 Specific Uses of Aluminum and Galvanized Steel: Use aluminum
bolts, nuts, and hardware to connect parts of the cast base.
Use galvanized steel anchor bolts for anchoring base plates to concrete
bases and for the nuts and washers.
For all other metal parts of the cast base, the Engineer will allow
galvanized steel as an alternate to aluminum.
700-3.6 Bearing Pads: For bearing pads, meet the requirements of 932-2.
700-3.7 Retroretroreflective Sheeting: All retroreflective sheeting must be listed on the
QPL and meet the retroreflective sheeting requirements of Section 994.
700-3.8 Process Colors: Use transparent and black opaque process colors listed on the
QPL meeting the requirements of 994-4 on retroreflective and nonreflective sheeting.
700-3.9 Electronic Display Signs: Use electronic display signs and mounting hardware
that meet the requirements of the MSTCSD and are listed on the Departments Approved
Products List.
Use only new signs and mounting hardware.
828
Provide signs marked in accordance with Section 603 and ensure the markings are
visible after installation.
Provide installation guides and operators manuals for each EDS. Ensure the
manuals include functional block diagrams and wiring diagrams; with information required to
operate, maintain, troubleshoot, and repair the EDS; and with recommended maintenance and
calibration procedures.
Ensure signs have a manufacturers warranty covering defects in assembly,
fabrication, and materials for a minimum of three years from the date of final acceptance in
accordance with 5-11. Ensure Guaranties on EDS comply with Section 608.
700-4 Preparation of Sign Blanks.
700-4.1 De-greasing and Etching for Aluminum Sign Blanks:
700-4.1.1 General: Prior to the application of retroreflective sheeting, use any of
the methods shown below to de-grease and etch the aluminum sign blanks.
700-4.1.2 Hand Method: Under this method, de-grease and etch the blanks in
one operation, using steel wool (medium grade) with any of the following combinations of
materials:
(1) An abrasive cleanser of a commercial grade kitchen scouring powder.
(2) Acid and a suitable detergent solution.
(3) An alkaline solution.
Thoroughly rinse the blanks with clean water following all hand degreasing operations.
700-4.1.3 Power-Washer Method: Under this method, de-grease the blanks with
an inhibited alkaline cleanser, by spraying for 90 seconds with the solution between 135 and
249F, the exact temperature to be as recommended by the manufacturer of the cleanser. After
the spraying, rinse the blanks with clean water. Then etch the blanks by immersing them in a 6 to
8% solution of phosphoric acid at a temperature of 100 to 180F for 60 seconds. After
immersion, rinse the blanks in clean water.
700-4.1.4 Immersion Method: Under this method, de-grease the blanks by
immersing them in a solution of inhibited alkaline cleanser at a temperature between 160 and
180F for three to five minutes, and then rinsing with clean water. Then etch blanks by
immersing them in a 6 to 8% solution of phosphoric acid at a temperature of 100F for three
minutes. After immersion, rinse the blanks in clean water.
700-4.1.5 Vapor De-greasing Method: Under this method, de-grease the blanks
by totally immersing them in a saturated vapor of trichloroethylene. Remove trademark printing
with lacquer thinner or a controlled alkaline cleaning system.
700-4.1.6 Alkaline De-greasing Method: De-grease the blanks by totally
immersing them in a tank containing an alkaline solution, controlled and titrated in accordance
with the solution manufacturers directions. Adapt immersion time to the amount of soil present
and the thickness of the metal. After immersion, thoroughly rinse the blanks with running water.
700-4.1.7 Etching Method when De-greasing is Separate Operation: If using
either of the de-greasing methods described under 700-4.1.5 and 700-4.1.6, accomplish etching
by one of the following alternate methods:
(1) Acid Etch: Etch well in a 6 to 8% phosphoric acid solution at 100F, or
in a proprietary acid etching solution. Rinse thoroughly with running cold water, which may be
followed by a hot water rinse.
829
(2) Alkaline Etch: Etch aluminum surfaces in an alkaline etching material
that is controlled by titration. Meet the time, temperature, and concentration requirements
specified by the solution manufacturer. After completing etching is complete, rinse the panel
thoroughly.
700-4.2 Drying: Dry the panels using a forced-air drier. Use a device or clean canvas
gloves, to handle the material between all cleaning and etching operations and the application of
retroreflective sheeting. Do not allow the metal to come in contact with greases, oils or other
contaminants prior to the application of retroreflective sheeting.
700-4.3 Fabrication of Sign Blanks: Fabricate all metal parts to ensure a proper fit of all
sign components. Complete all fabrication, with the exception of cutting and punching of holes,
prior to metal de-greasing and applying the retroreflective sheeting. Cut metal panels to size and
shape and keep free of buckles, warp, dents, burrs, and defects resulting from fabrication.
Provide all sign panels with a flat surface.
700-5 Fabrication of Retroreflectorized Sign Faces.
700-5.1 Application of Sheeting: Apply retroreflective sheeting to the base panels with
mechanical equipment in a manner specified for the manufacture of traffic control signs by the
sheeting manufacturer. Ensure that sheeting applied to extruded aluminum sections adheres over
and around the side legs of all panels to a minimum distance of 1/16 inch beyond the radius of
top edge.
Match sign faces comprising two or more pieces of retroreflective sheeting for
color and retroreflectivity at the time of sign fabrication. Reverse and apply consecutively
alternate successive width sections of either sheeting or panels to ensure that corresponding
edges of sheeting lie adjacent on the finished sign. The Engineer will not accept nonconformance
that may result in non-uniform shading and an undesirable contrast between adjacent widths of
applied sheeting.
700-5.2 Finish: Seal retroreflective sheeting splices and sign edges with materials the
sheeting manufacturer supplies in a manner the sheeting manufacturer specifies for traffic control
signs.
700-5.3 Screening-on Message: Screen message and borders on retroreflective sheeting
in accordance with the recommendations of the ink or overlay manufacturer. Process either
before or after applying the sheeting to the base panels.
700-5.4 Finished Sign Face: Provide finished signs with clean cut and sharp messages
and borders. Ensure that finished background panels are essentially a plane surface.
700-5.5 Stenciling: For permanent roadway signs, mark the back of all finished panels at
the bottom edge with FDOT, the date of fabrication, the date of installation, and the
fabricators initials. Make the markings unobtrusive, but legible enough to be easily read by an
observer on the ground when the sign is in its final position. Apply the markings in a manner that
is at least as durable as the sign face.
700-6 Acceptance of Signs.
700-6.1 Manufacturers Certification and Recommendations: Ensure that the sign
manufacturer certifies that the delivered signs conform to this Section and provides
recommendations for storing and repairing signs.
700-6.2 Packaging and Shipping: Have the manufacturer package and ship the signs in
a manner which will minimize possible damage.
830
700-6.3 Storage of Signs: If signs are stored prior to installation, store them in
accordance with the manufacturers recommendations.
700-6.4 Sign Inspection: Do not install signs until the Engineer inspects them for
conformance with this Section. Provide all manufacturer certifications and recommendations
prior to the Engineers inspection. The Engineer will inspect the signs upon delivery to the
storage or project site and again at the final construction inspection. Repair and replace signs
deemed unacceptable by the Engineer at no expense to the Department.
700-6.5 Imperfections and Repairs: Repair and replace signs containing imperfections
or damage regardless of the kind, type, or cause of the imperfections or damage. Make repairs
according to the manufacturers recommendations and to the satisfaction of the Engineer. Ensure
that completed repairs provide a level of quality necessary to maintain the service life warranty
of the sign and are satisfactory in appearance to the Engineer.
700-6.6 Electronic Display Signs: In addition to the requirements of this Section, meet
the requirements of Section 611.
700-7 Foundations.
700-7.1 Footings:
700-7.1.1Excavation and Backfilling: Perform excavation and backfilling for the
footings in accordance with Section 125, with the exceptions that no specific density is required
and that the backfill may be tamped in 4 inches maximum layers. Use material that is at near
optimum moisture and neither dry or saturated, and tamp to the extent directed by the Engineer.
The Department may require that the backfilling be done with poured concrete.
Install spread footings which support sign structures overhanging the roadway as
required in 455-25 through 455-37.
700-7.1.2 Mixing and Placing Concrete: For batching and mixing of concrete
for footings, meet the requirements of Section 346, except that the Engineer will allow hand
mixing by approved methods where the quantity to be mixed does not exceed 1/2 yd3. Use castin-place or precast concrete for the footings. Obtain precast concrete footings from a plant that is
currently on the list of Producers with Accepted Quality Control Programs. Producers seeking
inclusion on the list shall meet the requirements of 105-3.
700-7.1.3 Forms: The Engineer will not require forms when the ground is
sufficiently firm, in which case, sufficiently moisten the adjacent earth to prevent it from
absorbing the moisture from the concrete. Where forms are required and the soil is not moist,
place sufficient water, as directed by the Engineer, in the hole, and pour the concrete as soon as
the water has been absorbed. Place at least 4 inches of loose earth, free from clods or gravel, over
the top of the footing to effect curing.
700-7.1.4 Finishing Concrete: Trowel the top of the concrete to a smooth finish.
700-7.2 Drilled Shafts: Meet the requirements of Section 455.
700-8 Erection of Signs and Sign Supports.
Do not erect overhead sign supports until the concrete strength in the support footing is at
least 2,500 psi. Determine concrete strength from tests on a minimum of two test cylinders
sampled and tested in accordance with ASTM C 31 and ASTM C 39 and verifying test results
have been provided to the Engineer.
Erect the signs and sign structures in accordance with the details shown in the Plans. The
Contractor may fabricate the structural steel sign trusses in sections that will fit into available
831
galvanizing vats. Prior to galvanizing, weld the joints as specified in 460-6 and in accordance
with the details shown in the Plans. Re-galvanize damaged parts as specified in Section 562.
Weld aluminum structures in accordance with 965-3.
Attach electronic display signs to the supporting structure in accordance with the
manufacturers recommendations using the mounting hardware provided by the manufacturer.
700-9 Removal or Relocation of Signs.
Relocation of signs shall consist of removing the existing sign assembly and installing the
sign on a new foundation.
When the Plans call for existing ground-mounted signs to be relocated or removed,
immediately remove supports and footings that project more than 6 inches above the ground
surface after removing the sign panel from the assembly. Remove existing footings to a depth at
least 12 inches below the ground surface. Restore the area of the sign removal or relocation to
the condition of the adjacent area. The costs will be included in the Contract unit price of the
item to which it is incidental.
Notify the Engineer a minimum of 30 days prior to removal of existing Logo sign
structures.
700-10 Overlay Existing Sign Panels.
Use 0.040 inch thick aluminum sheeting for overlays larger than 3 square feet placed on a
sign panel. Replace hex head bolts on the sign surface using stainless steel flat head machine
screws with nuts and lock washers to give a flat surface for the overlay panel. Install the overlay
panels starting at the edge away from traffic. Place each panel against the sign using a clamp at
the top to hold the panel in place. Drill 1/8 inch holes 1 inch inside the panel edge every 6 inches
to 8 inches and install 1/4-inch to 3/8 inch length pop rivets. Install additional rivets along the
outer edge 6 inches to 8 inches. Place the remaining panels using the same procedure with the
overlap in the direction away from the traffic and with rivets along the overlap on 12 inch
centers.
700- 11 Method of Measurement.
The quantities to be paid for will be:
(1) The number of ground traffic signs of each designated class of assembly,
complete.
(2) The number of lighted overhead traffic signs of each designated class of
assembly, complete.
(3) The number of existing signs removed, relocated, modified of each designated
class of assembly, complete.
(4) The number of overhead signs span wire mounted, bridge mounted, and
lighted sequential, of each designated class of assembly, complete.
(5) The number of electronic display signs, of each designated class of assembly,
complete.
(6) The number of flashing beacon signs, of each designated class of assembly,
complete.
For the purpose of payment, a sign assembly consists of all the signs mounted on
a single structure (one, two or three posts, or overhead structure) or all the signs on a bridge
mounted sign structure and the sign structure.
832
700-12 Basis of Payment.
Price and payment will be full compensation for furnishing and installation of all
materials necessary to complete the signs in accordance with the details shown in the Plans;
including sign panels complete with sheeting, painting, and message; sign posts and supports,
foundations, excavation, etc.; for lighted signs, include all costs of the electrical installation for
lighting, up to the point of connection by others; for flashing beacon signs, include all costs of
beacons, controllers, and electrical installation, up to the point of connection by others; and all
other work specified in this Section, including all incidentals necessary for the complete item.
833
SECTION 701
AUDIBLE AND VIBRATORY PAVEMENT MARKINGS
701-1 Description.
Apply audible and vibratory pavement markings in accordance with the Contract
Documents.
701-2 Materials.
701-2.1 Thermoplastic: Use thermoplastic material meeting the requirements of 971-1
and 971-9 and listed on the Qualified Products List (QPL) as an approved system. The Engineer
will take random samples of the materials in accordance with the Departments Sampling,
Testing and Reporting Guide schedule.
701-2.2 Retroreflective Elements: Use reflective elements recommended by the
manufacturer that meet the requirements of 971-1.7 and are part of the system listed on the QPL.
701-3 Equipment.
Use equipment capable of providing continuous, uniform heating of the striping material
to temperatures exceeding 390F, mixing and agitating the material in the reservoir to provide a
homogenous mixture without segregation. Use equipment that will maintain the striping material
in a plastic state, in all mixing and conveying parts, including the line dispensing device until
applied. Use equipment which is capable of producing a consistent pattern of transverse bumps
positioned at regular and predetermined intervals. Use equipment which meets the following
requirements:
(a) capable of traveling at a uniform rate of speed, both uphill and downhill, to
produce a uniform application of striping material and capable of following straight lines and
making normal curves in a true arc.
(b) capable of applying reflective elements to the surface of the completed stripe
by automatic dispensers attached to the striping machine such that the reflective elements are
dispensed closely behind the installed line. Use reflective element dispensers equipped with an
automatic cut-off control that is synchronized with the cut-off of the thermoplastic material and
applies the reflective elements uniformly on the entire traffic stripe surface with 50 to 60%
embedment.
(c) equipped with a special kettle for uniformly heating and melting the striping
material. The kettle must be equipped with an automatic temperature control device and material
thermometer for positive temperature control and to prevent overheating or scorching of the
thermoplastic material.
(d) meets the requirements of the National Fire Protection Association (NFPA),
State and Local authorities.
701-4 Application.
701-4.1 General: Before applying traffic stripes and markings, remove any material that
would adversely affect the bond of the traffic stripes by a method approved by the Engineer.
Before applying traffic stripes to any portland cement surface, apply a primer,
sealer or surface preparation adhesive of the type recommended by the manufacturer. Offset
longitudinal lines at least 2 inches from construction joints of portland cement concrete
pavement.
834
Apply traffic stripes or markings only to dry surfaces, and when the ambient air
and surface temperature is at least 50F and rising for asphalt surfaces and 60F and rising for
concrete surface.
Apply striping to the same tolerances in dimensions and in alignment specified in
710-5. When applying traffic stripes and marking over existing markings, ensure that no more
than 2 inches on either end and not more than 1 inch on either side of the existing line is visible.
Conduct field tests in accordance with FM 5-541. Take test readings
representative of the striping performance. Remove and replace markings not meeting the
requirements of this Section.
701-4.2 Thickness: Apply flat base lines having a thickness of 0.100 to 0.150 inches,
exclusive of the audible bumps, when measured above the pavement surface.
As an alternative to the flat baseline, a profiled baseline meeting the following
dimensions may be applied. For profiled thermoplastic markings make profile measurements
above the pavement surface. Provide a baseline thickness not to exceed 0.050 inches. Provide
individual profiles across the full width of the marking on approximately 1.0 inch centers with a
space between profiles of approximately 0.25 inches and an average thickness of at least
0.110 inches above the baseline profile.
Measure, record and certify on a Department approved form and submit to the
Engineer, the thickness of white and yellow pavement markings in accordance with FM 5-541.
701-4.3 Dimensions of Audible Bumps: Apply the raised bumps with a profile such that
the leading and trailing edges are sloped at a sufficient angle to create an audible and vibratory
warning.
Bumps on shoulder and centerline markings shall be at least 0.45 inches at the
highest point of the bump, above the pavement surface, including the base line. The height shall
be measured after application of drop-on reflective elements. Bumps shall have a minimum
baseline coverage dimension of 2.5 inches in both transverse and longitudinal directions. The
bumps may have a drainage channel, the width of each drainage channel will not exceed 1/4 inch
at the bottom of the channel. The longitudinal distance between bumps shall be approximately
30 inches.
701-4.4 Retroreflectivity: Apply white and yellow audible and vibratory markings that
will attain an initial retroreflectance of not less than 300 mcd/lxm2 and not less than
250 mcd/lxm2, respectively. Measure, record and certify on a Department approved form and
submit to the Engineer, the retroreflectivity of white and yellow pavement markings in
accordance with FM 5-541.
701-4.5 Color: Use pavement marking materials that meet the requirements of 971-1.
701-4.6 Reflective Elements: Apply reflective elements to all markings at the rates
determined by the manufacturers recommendations as identified for the QPL System.
701-4.7 Loss: If more than 1% of the bumps or more than three consecutive bumps are
missing or broken (less than half a bump remaining) within the first 45 days under traffic,
replace all failed bumps at no expense to the Department. If more than 2% of the bumps fail
within the first 45 days under traffic, the replacement period will extend an additional 45 days
from the date all replacement bumps were installed. If, at the end of the additional 45 days, more
the 2% of all bumps (initial and replacement) fail, replace all failed bumps at no expense to the
Department. Measure, record and certify on a Department approved form and submit to the
Engineer, the loss of bumps.
835
701-5 Contractors Responsibility for Notification.
Notify the Engineer prior to the placement of audible and vibratory markings. Furnish the
Engineer with the manufacturers name and batch numbers of the thermoplastic materials and
reflective elements to be used. Ensure that the batch numbers appear on the thermoplastic
materials and reflective elements packages.
701-6 Protection of Newly Applied Audible and Vibratory Markings.
Do not allow traffic onto or permit vehicles to cross newly applied pavement markings
until they are sufficiently dry. Remove and replace any portion of the pavement markings
damaged by passing traffic or from any other cause.
701-7 Observation Period.
Longitudinal pavement markings are subject to a 180 day observation period under
normal traffic. The observation period will begin with the satisfactory completion and
acceptance of the pavement marking work.
The longitudinal pavement markings shall show no signs of failure due to blistering,
excessive cracking, chipping, discoloration, poor adhesion to the pavement, loss of reflectivity or
vehicular damage. The retroreflectivity shall meet the initial requirements of 701-4.4. The
Department reserves the right to check the color and retroreflectivity anytime prior to the end of
the observation period.
Replace, at no expense to the Department, any longitudinal pavement markings that do
not perform satisfactorily under traffic during the 180 day observation period.
701-8 Corrections for Deficiencies.
Correct all deficiencies by removal and reapplication of a one mile section centered
around the deficiency at no cost to the Department.
701-9 Submittals.
701-9.1 Submittal Instructions: Prepare a certification of quantities, using the
Departments current approved form, for each project in the Contract. Submit the certification of
quantities and daily worksheets to the Engineer. The Department will not pay for any disputed
items until the Engineer approves the certification of quantities.
701-9.2 Contractors Certification of Quantities: Request payment by submitting a
certification of quantities no later than Twelve Oclock noon Monday after the estimate cut-off
date or as directed by the Engineer, based on the amount of work done or completed. Ensure the
certification of quantities consists of the following:
(a) Contract Number, FPID Number, Certification Number, Certification Date and
the period that the certification represents.
(b) The basis for arriving at the amount of the progress certification, less
payments previously made and less any amount previously retained or withheld. The basis will
include a detailed breakdown provided on the certification of items of payment.
701-10 Method of Measurement.
The quantities to be paid for under this Section will be as follows:
(a) The length, in net miles, of 6 inches solid traffic stripe, authorized and
acceptably applied.
836
(b) The total traversed distance in gross miles of 10-30 skip line. The actual
applied line is 25% of the traverse distance for a 1:3 ratio. This equates to 1,320 feet of marking
per mile of single line.
701-11 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including, all cleaning and preparing of surfaces, furnishing of all materials, application, curing
and protection of all items, protection of traffic, furnishing of all tools, machines and equipment,
and all incidentals necessary to complete the work. Final payment will be withheld until all
deficiencies are corrected.
Payment will be made under:
Item No. 701- 1
Audible and Vibratory Pavement Markings.
837
SECTION 702
WET WEATHER PAVEMENT MARKINGS
702-1 Description.
Apply wet weather pavement markings in accordance with the Contract Documents.
702-2 Materials.
702-2.1 Thermoplastic: Use thermoplastic material meeting the requirements of 971-1
and 971-10 and listed on the Qualified Products List (QPL) as an approved system. The Engineer
will take random samples of the materials in accordance with the Departments Sampling,
Testing and Reporting Guide schedule.
702-2.2 Retroreflective Elements: Use reflective elements recommended by the
manufacturer that meet the requirements of 971-1.7 and are part of the system listed on the QPL.
702-3 Equipment.
Use equipment capable of providing continuous uniform heating of the striping material
to temperatures exceeding 390F, mixing, and agitation of the material reservoir to provide a
homogenous mixture without segregation. Use equipment that will maintain the striping material
in a plastic state in all mixing and conveying parts, including the line dispensing device until
applied. Use equipment which meets the following requirements:
(a) capable of traveling at a uniform rate of speed, both uphill and downhill, to
produce a uniform application of striping material and capable of following straight lines and
making normal curves in a true arc.
(b) capable of applying reflective elements to the surface of the completed stripe
by automatic dispensers attached to the striping machine such that the reflective elements are
dispensed closely behind the installed line. Use reflective element dispensers equipped with an
automatic cut-off control that is synchronized with the cut-off of the thermoplastic material and
applies the reflective elements uniformly on the entire traffic stripe surface with 50 to 60%
embedment.
(c) equipped with a special kettle for uniformly heating the striping material. The
kettle must be equipped with an automatic temperature control device and material thermometer
for positive temperature control and to prevent overheating or scorching of the thermoplastic
material.
(d) meets the requirements of the National Fire Protection Association, state and
local authorities.
702-4 Application.
702-4.1 General: Before applying traffic stripes and markings, remove any material that
would adversely affect the bond of the traffic stripes by a method approved by the Engineer.
Before applying traffic stripes over portland cement concrete surface, apply a
primer, sealer or surface preparation adhesive recommended by the manufacturer. Offset traffic
stripes a minimum of 2 inches from any longitudinal joints of portland cement concrete
pavement.
Apply traffic stripes and markings only to dry surfaces and when the ambient air
and surface temperature is at least 50F and rising for asphalt surfaces and 60F and rising for
concrete surfaces.
838
Apply striping to the same tolerances in dimensions and in alignment specified in
710-5. When applying traffic stripes and marking over existing markings, ensure that not more
than 2 inches on either end and not more than 1 inch on either side of the existing line is visible.
Conduct field tests in accordance with FM 5-541 and ASTM E2177 (Bucket
Method).Take test readings representative of the striping performance. Remove and replace
traffic stripes not meeting the requirements of this Section.
702-4.2 Thickness and Dimensions of Markings: For flat thermoplastic markings
provide a thickness of 0.100 to 0.150 inches when measured above the pavement surface.
As an alternative to the flat baseline, a profiled baseline meeting the following
dimensions may be applied. For profiled thermoplastic markings make profile measurements
above the pavement surface. Provide a baseline thickness not to exceed 0.050 inches. Provide
individual profiles across the full width of the marking on approximately 1.0 inch centers with a
space between profiles of approximately .25 inches and an average thickness of at least
0.110 inches above the baseline profile.
Measure, record and certify on a Department approved form and submit to the
Engineer, the thickness of white and yellow pavement markings in accordance with FM 5-541.
702-4.3 Dimensions of Audible Bumps: Apply the raised bump with a profile such that
the leading and trailing edge are sloped at a sufficient angle to create an audible and vibratory
warning.
Bumps on shoulder and centerline markings shall be at least 0.45 inches at the
highest point of the bump, above the pavement surface, including the base line. The height shall
be measured after application of reflective elements. Bumps shall have a minimum baseline
coverage dimension of 2.5 inches in both transverse and longitudinal directions. Bumps may
have a drainage channel, the width of each drainage channel will not exceed 1/4 inch at the
bottom of the channel. The longitudinal distance between bumps shall be approximately
30 inches.
702-4.4 Retroreflectivity: Apply white and yellow traffic stripes and markings that will
attain an initial dry retroreflectivity of not less than 300 mcd/lxm2 and not less than
250 mcd/lxm2, respectively, and also attain an initial wet recovery retroreflectivity of not less
than 150 mcd/lxm2 and not less than 125 mcd/lxm2, respectively.
Measure, record and certify on a Department approved form and submit to the
Engineer, the retroreflectivity of white and yellow pavement markings in accordance with
Florida Method FM 5-541 for dry and ASTM E2177 (Bucket Method) for wet recovery.
702-4.5 Color: Use pavement marking materials that meet the requirements of 971-1.
702-4.6 Reflective Elements: Apply reflective elements to all pavement markings, at the
rates determined by the manufacturers recommendations as identified for the QPL System.
702-4.7 Loss: If more than 1% of the bumps or more than three consecutive bumps are
missing or broken (less than half a bump remaining) within the first 45 days under traffic,
replace all failed bumps at no expense to the Department. If more than 2% of the bumps fail
within the first 45 days under traffic, the replacement period will extend an additional 45 days
from the date all replacement bumps were installed. If, at the end of the additional 45 days, more
the 2% of all bumps (initial and replacement) fail, replace all failed bumps at no expense to the
Department. Measure, record and certify on a Department approved form and submit to the
Engineer, the loss of bumps.
839
702-5 Contractors Responsibility for Notification.
Notify the Engineer prior to the placement of the thermoplastic materials. Furnish the
Engineer with the manufacturers name and batch numbers of the thermoplastic materials and
reflective elements to be used. Ensure the approved batch numbers appear on the thermoplastic
materials and reflective elements packages. Submit a certified test report to the Engineer
indicating the striping materials meet all requirements specified.
702-6 Protection of Newly Applied Traffic Stripes.
Do not allow traffic onto or permit vehicles to cross newly applied pavement markings
until they are sufficiently dry. Remove and replace any portion of the pavement markings
damaged by passing traffic or from any other cause, at no additional cost to the Department.
702-7 Observation Period and Contractors Warranty.
Longitudinal pavement markings are subject to a 180 day observation period under
normal traffic. The observation period will begin with the satisfactory completion and
acceptance of the pavement marking work.
The longitudinal pavement markings shall show no signs of failure due to blistering,
excessive cracking, chipping, discoloration, poor adhesion to the pavement, loss of reflectivity or
vehicular damage. The retroreflectivity shall meet the initial requirements of 702-4.4. The
Department reserves the right to check the color and retroreflectivity anytime prior to the end of
the observation period.
Replace, at no expense to the Department, any longitudinal pavement markings that do
not perform satisfactorily under traffic during the 180 day observation period.
702-8 Corrections for Deficiencies.
Correct all deficiencies by removal and reapplication of a 1.0 mile section centered
around the deficiency at no additional cost to the Department.
702-9 Submittals.
702-9.1 Submittal Instructions: Prepare a certification of quantities, using the
Departments current approved form, for each project in the Contract. Submit the certification of
quantities and daily worksheets to the Engineer. The Department will not pay for any disputed
items until the Engineer approves the certification of quantities.
702-9.2 Contractors Certification of Quantities: Request payment by submitting a
certification of quantities no later than Twelve Oclock noon Monday after the estimate cut-off
date or as directed by the Engineer, based on the amount of work done or completed. Ensure the
certification of quantities consists of the following:
(a) Contract Number, FPID Number, Certification Number, Certification Date and
the period that the certification represents.
(b) The basis for arriving at the amount of the progress certification, less
payments previously made and less any amount previously retained or withheld. The basis will
include a detailed breakdown provided on the certification of items of payment.
702-10 Method of Measurement.
The quantities to be paid for under this Section will be as follows:
(a) The length, in net miles, of 6 inch solid traffic stripes, authorized and
acceptably applied.
840
(b) The total traversed distance in gross miles of 10-30 skip line. The actual
applied line is 25% of the traverse distance for a 1:3 ratio. This equates to 1,320 feet of traffic
stripes per mile of single line.
702-11 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including, all cleaning and preparing of surfaces, furnishing of all materials, application, curing
and protection of all items, protection of traffic, furnishing of all tools, machines and equipment,
and all incidental necessary to complete the work. Final payment will be withheld until all
deficiencies are corrected.
Payment will be made under:
Item No. 702- 1
Wet Weather Pavement Markings
841
SECTION 705
OBJECT MARKERS AND DELINEATORS
705-1 Description.
Furnish and install object markers to mark obstructions within or adjacent to the roadway
of the types and at the locations called for in the Design Standards or on the Plans.
Furnish and install delineators along the side of the roadway to indicate the alignment of
the roadway as indicated in the Design Standards or in the Plans.
705-2 Materials.
705-2.1 General: Meet the following requirements:
Object Markers and Delineators .......................... Section 993
Retroreflective and Nonreflective
Sign Sheeting ....................................................... Section 994
705-2.2 Product Acceptance on the Project: Ensure that delineators, delineator posts,
and markers used to delineate guardrail and barrier wall are listed on the Qualified Products List.
Provide to the Engineer a manufacturers certification conforming to the
requirements of Section 6, which confirms that each product meets the requirements of this
Section.
705-3 Installation Requirements.
Install delineators, object markers, and reflector units for guardrail and barrier wall and in
accordance with the MUTCD, Design Standards and Plans.
705-4 Method of Measurement.
The quantity to be paid for will be the number of delineators or object markers furnished,
installed and accepted.
705-5 Basis of Payment.
Prices and payments will be full compensation for work specified in this Section,
including the cost of labor, materials, and incidental items required to complete the work.
Payment will be made under:
Item No. 705- 10
Object Marker - each.
Item No. 705- 11
Delineator - each.
842
SECTION 706
RAISED RETRO-REFLECTIVE PAVEMENT
MARKERS AND BITUMINOUS ADHESIVE
706-1 Description.
Place raised retroreflective pavement markers (RPMs) and adhesive, which upon
installation produces a positive guidance system to supplement other reflective pavement
markings.
706-2 Materials.
Use only Class B markers unless otherwise shown in the Plans.
Meet the requirements of Section 970.
706-2.1 Product Acceptance on the Project. Use only reflective pavement markers and
bituminous adhesive that are listed on the Departments Qualified Products List (QPL).
Provide to the Engineer a manufacturers certification conforming to the
requirements of Section 6, which confirms that each product meets the requirements of this
Section.
706-3 Equipment.
Use equipment having either thermostatically controlled double boiler type units utilizing
heat transfer oil or thermostatically controlled electric heating pots to install hot applied
bituminous adhesive. Do not use direct flame melting units with flexible adhesives; however,
this type of unit may be used with standard adhesive in accordance with manufacturers
recommendations. Use a melter/applicator unit suited for both melting and pumping the adhesive
through heated applicator hoses.
Heat the adhesive to between 375F and 425F and apply directly to the bonding surface
from the melter/applicator by either pumping or pouring. Maintain the application temperature
between 375F and 425F. The adhesive may be reheated. However, do not exceed the
manufacturers recommendations for pot life at application temperatures.
706-4 Application.
Apply RPMs to the bonding surface using bituminous adhesives only. The Engineer will
conduct field testing in accordance with FM 5-566. Correct RPMs not applied in accordance
with these requirements at no cost to the Department.
Prior to application of adhesive, clean the portion of the bonding surface of any material
which would adversely affect the adhesive.
Apply the adhesive to the bonding surface (not the marker) so that 100% of the bonding
area of the marker will be covered, in accordance with adhesive manufacturers
recommendations. Apply sufficient adhesive to ensure, that when the marker is pressed
downward into the adhesive, adhesive will be forced out around the entire perimeter of the
marker.
Immediately remove excess adhesive from the bonding surface and exposed surfaces of
the RPMs. Soft rags moistened with mineral spirits meeting Federal Specifications TT-T-291 or
kerosene may be used to remove adhesive from exposed faces of the RPMs. Do not use any other
solvent. If any adhesive, pavement marking materials or other foreign matter adheres to the
reflective face of the marker, replace the marker at no cost to the Department.
843
Install RPMs with the reflective face of the RPM perpendicular to a line parallel to the
roadway centerline.
Ensure that all final RPMs are in place prior to opening the road to traffic.
If more than 2% of the RPMs fail in adhesion or alignment within the first 45 days under
traffic, replace all failed markers at no expense to the Department. If more than 5% of the
markers fail in adhesion and or alignment during the initial 45 day period, the Engineer will
extend the replacement period an additional 45 days from the date that all replacement markers
have been installed. If, at the end of the additional 45 day period, more than 2% of all markers
(initial installation and 45 day replacements combined) fail in adhesion or alignment, replace all
failed markers at no expense to the Department.
706-5 Contractors Responsibility for Notification.
Notify the Engineer prior to the placement of RPMs. At the time of notification, indicate
the manufacturer and the LOT numbers of RPMs and bituminous adhesive that are intended for
use. Verify that the approved LOT numbers appear on the material packages. Furnish a test
report to the Engineer certifying that the materials meet all requirements specified.
706-6 Method of Measurement.
The quantities to be paid for will be the number of RPMs, furnished and installed,
completed and accepted.
706-7 Basis of Payment.
706-7.1 General: Price and payment will be full compensation for all work specified in
this Section.
706-7.2 Lump Sum Payment: Price and payment for retroreflective pavement markers
will not be measured or paid for separately, when the item for painted pavement markings (Final
Surface) is included in the proposal. Price and payment will be made in accordance with
710-11.2.
844
SECTION 709
TRAFFIC STRIPES AND MARKINGS TWO REACTIVE COMPONENTS
709-1 Description.
Apply two reactive component traffic stripes and markings in accordance with the
Contract Documents.
709-2 Materials.
709-2.1 Two Reactive Components: Use only two reactive component materials listed
on the Qualified Products List (QPL) as an approved system and meet the requirements of 971-1
and 971-8. The Engineer will take random samples of the materials in accordance with the
Departments Sampling, Testing and Reporting Guide schedule.
709-2.2 Reflective elements: Use only reflective elements recommended by the
manufacturer that meet the requirements of 971-1.7 and are part of the system listed on the QPL.
709-3 Equipment.
Use equipment capable of applying the two reactive component material to the pavement.
Use equipment which can produce varying width traffic stripes and which meets the following
requirements:
(a) capable of traveling at a uniform rate of speed, both uphill and downhill, to
produce a uniform application of the two reactive component material and capable of following
straight lines and making normal curves in true arcs.
(b) capable of applying reflective elements to the surface of the completed stripe
by an automatic reflective element dispenser attached to the striping machine such that the
reflective elements are dispensed closely behind the installed line. Use a reflective element
dispenser equipped with an automatic cut-off control that is synchronized with the cut-off of the
material and applies the reflective elements in a manner such that the reflective elements appear
uniform on the entire traffic stripes and markings surface with, 50 to 60% embedment.
(c) capable of providing the manufacturers recommended mixing ratio between
the components in a thorough and consistent manner.
709-4 Application.
709-4.1 General: Remove existing pavement markings, such that scars or traces of
removed markings will not conflict with new stripes and markings by a method approved by the
Engineer.
Before applying traffic stripes and markings, remove any material by a method
approved by the Engineer that would adversely affect the bond of the traffic stripes.
Offset longitudinal lines at least 2 inches from construction joints of portland
cement concrete pavement.
Apply traffic stripes or markings only to dry surfaces, and when the ambient air
and surface temperature is at least 40F and rising. Do not apply pavement markings when winds
are sufficient to cause spray dust.
Apply striping to the same tolerances in dimensions and in alignment specified in
710-5. When applying traffic stripes and marking over existing markings, ensure that not more
than 2 inches on either end and not more than 1 inch on either side of the existing line is visible.
845
Apply the two reactive component product to the pavement in accordance with
the manufacturers instructions or as directed by the Engineer.
Conduct field tests in accordance with FM 5-541. Take test readings
representative of the striping performance. Remove and replace traffic stripes and markings not
meeting the requirements of this Section at no additional cost to the Department.
Apply all final pavement markings prior to opening the road to traffic.
709-4.2 Thickness: Apply traffic stripes and markings to attain a minimum wet film
thickness in accordance with the manufacturers recommendations as identified on the QPL
system.
Measure, record and certify on a Department approved form and submit to the
Engineer, the thickness of white and yellow pavement markings in accordance with FM 5-541.
709-4.3 Retroreflectivity: Apply white and yellow traffic stripes and markings that will
attain an initial retroreflectivity of not less than 450 mcd/lxm2 and not less than 350 mcd/lxm2,
respectively for all longitudinal and transverse lines.
Measure, record and certify on the Department approved form and submit to the
Engineer, the retroreflectivity of white and yellow pavement markings in accordance with
Florida Method FM 5-541.
709-4.4 Color: Use materials that meet the requirements of 971-1.
709-4.5 Reflective elements: Apply reflective elements to all white and yellow traffic
stripes or markings, at the rates determined by the manufacturers recommendations as identified
on the QPL system.
709-5 Contractors Responsibility for Notification.
Notify the Engineer prior to the placement of the materials. Furnish the Engineer with the
manufacturers name and batch numbers of the materials and reflective elements to be used.
Ensure that the approved batch numbers appear on the materials and reflective elements
packages.
709-6 Protection of Newly Applied Traffic Stripes and Markings.
Do not allow traffic onto or permit vehicles to cross newly applied pavement markings
until they are sufficiently dry. Remove and replace any portion of the pavement markings
damaged by passing traffic or from any other cause, at no additional cost to the Department.
709-7 Observation Period.
Longitudinal pavement markings are subject to a 180 day observation period under
normal traffic. The observation period shall begin with the satisfactory completion and
acceptance of the work.
The longitudinal pavement markings shall show no signs of failure due to blistering,
excessive cracking, chipping, discoloration, poor adhesion to the pavement, loss of reflectivity or
vehicular damage. The retroreflectivity shall meet the initial requirements of 709-4.3. The
Department reserves the right to check the color and retroreflectivity any time prior to the end of
the observation period.
Replace, at no additional expense to the Department, any longitudinal pavement
markings that do not perform satisfactorily under traffic during the 180 day observation period.
846
709-8 Corrections for Deficiencies.
Deficiencies will be corrected by removal and reapplication of a 1.0 mile section centered
around the deficiency at no additional cost to the Department.
709-9 Submittals.
709-9.1 Submittal Instructions: Prepare a certification of quantities, using the
Departments current approved form, for each project in the Contract. Submit the certification of
quantities and daily worksheets to the Engineer. The Department will not pay for any disputed
items until the Engineer approves the certification of quantities.
709-9.2 Contractors Certification of Quantities: Request payment by submitting a
certification of quantities no later than Twelve O clock noon Monday after the estimate cut-off
date or as directed by the Engineer, based on the amount of work done or completed. Ensure the
certification of quantities consists of the following:
(a) Contract Number, FPID Number, Certification Number, Certification Date and
the period that the certification represents.
(b) The basis for arriving at the amount of the progress certification, less
payments previously made and less any amount previously retained or withheld. The basis will
include a detailed breakdown provided on the certification of items of payment.
709-10 Method of Measurement.
The quantities to be paid for under this Section will be as follows:
(a) The length, in net miles, of 6 inch solid traffic stripe, authorized and
acceptably applied.
(b) The total traversed distance in gross miles of 10-30 or 3-9 skip line. The actual
applied line is 25% of the traverse, distance for 1:3 ratio. This equates to 1,320 feet of marking
per mile of single line.
(c) The net length, in feet, of all other types of lines and stripes, authorized and
acceptably applied.
(d) The area, in square feet, of remove existing pavement markings, acceptably
removed.
709-11 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including, all cleaning and preparing of surfaces, furnishing of all materials, application, curing
and protection of all items, protection of traffic, furnishing of all tools, machines and equipment,
and all incidentals necessary to complete the work. Final payment will be withheld until all
deficiencies are corrected.
Payment will be made under:
Item No. 709
Two Reactive Components
Traffic Stripes, Solid - per net mile.
Traffic Stripes, Solid - per foot.
Traffic Stripes, Skip - per gross mile.
Traffic Stripe - Two Reactive Components, Remove - per
square foot.
847
SECTION 710
PAINTED PAVEMENT MARKINGS
710-1 Description.
Apply Painted Traffic Stripes and Markings, in accordance with the Contract Documents.
710-2 Materials.
Use only materials listed on the Departments Qualified Products List (QPL) meeting the
following requirements:
Raised Retroreflective Pavement Markers and Bituminous
Adhesive .............................................................Section 970
Standard Waterborne Fast Dry Traffic Paint
..................................................................... 971-1 and 971-3
Fast Dry Solvent Paint ................................ 971-1 and 971-4
Glass Spheres .............................................. 971-1 and 971-2
The Engineer will take random samples of all material in accordance with the
Departments Sampling, Testing and Reporting Guide schedule.
710-3 Equipment.
Use equipment that will produce continuous uniform dimensions of pavement markings
of varying widths and meet the following requirements:
(a) Capable of traveling at a uniform, predetermined rate of speed, both uphill and
downhill, in order to produce a uniform application of paint and capable of following straight
lines and making normal curves in a true arc.
(b) Capable of applying glass spheres to the surface of the completed stripe by an
automatic sphere dispenser attached to the striping machine such that the glass spheres are
dispensed closely behind the installed line. Use a glass spheres dispenser equipped with an
automatic cut-off control that is synchronized with the cut-off of the traffic paint and applies the
glass spheres in a manner such that the spheres appear uniform on the entire pavement markings
surface with, 50 to 60% embedment.
(c) Capable of spraying the paint to the required thickness and width without
thinning of the paint. Equip the paint tank with nozzles equipped with cut-off valves, which will
apply broken or skip lines automatically.
710-4 Application:
710-4.1 General: Remove existing pavement markings, such that scars or traces of
removed markings will not conflict with new pavement markings, by a method approved by the
Engineer. Payment for marking removal will be in accordance with 102-5.8.
Before applying traffic stripes and markings, remove any material by a method
approved by the Engineer that would adversely affect the bond of the traffic stripes.
Apply traffic stripes and markings only to dry surfaces, and when the ambient air
and surface temperature is at least 40F and rising. Do not apply traffic stripes and markings
when winds are sufficient to cause spray dust.
Apply traffic stripes and markings, having well defined edges, over existing
pavement markings such that not more than 2 inches on either end and not more than 1 inch on
either side is visible.
848
Mix the paint thoroughly prior to pouring into the painting machine. Apply paint
to the pavement by spray or other means approved by the Engineer.
Conduct field testing in accordance with FM 5-541. Remove and replace traffic
stripes and markings not meeting the requirements of this Section at no additional cost to the
Department.
Apply all pavement markings prior to opening the road to traffic.
710-4.1.1 Final Surface: Painted pavement markings (final surface) will include
two applications of standard painted pavement markings and one application of retroreflective
pavement markers applied to the final surface. Wait at least 14 days after the first application to
apply the second application of painted pavement markings (final surface). Second application
must be applied prior to final acceptance of the project.
Apply all retroreflective pavement markers per the requirements of
Section 706.
710-4.2 Thickness: Apply paint to attain a minimum wet film thickness in accordance
with the manufacturers recommendations.
710-4.3 Retroreflectivity: Apply white and yellow standard pavement markings that will
attain an initial retroreflectance of not less than 300 mcd/lxm2 and not less than 250 mcd/lxm2,
respectively. Measure, record and certify on a Department approved form and submit to the
Engineer, the retroreflectivity of white and yellow pavement markings in accordance with FM 5541.
The Department reserves the right to test the markings within 3 days of receipt of
the Contractors certification. Failure to afford the Department opportunity to test the markings
will result in non-payment. The test readings should be representative of the Contractors striping
performance. If the retroreflectivity values measure below values shown above, reapply the
striping at no additional cost to the Department.
For standard pavement markings, ensure that the minimum retroreflectance of
white and yellow pavement markings are not less than 150 mcd/lx m2. If the retroreflectivity
values fall below the 150 mcd/lx m2 value within six months of initial application, the striping
will be reapplied at the Contractors expense.
710-4.4 Color: Use paint material that meets the requirements of 971-1.
710-4.5 Glass Spheres: Apply glass spheres on all pavement markings immediately and
uniformly following the paint application. The rate of application shall be based on the
manufacturers recommendation.
710-5 Tolerances in Dimensions and in Alignment.
Establish tack points at appropriate intervals for use in aligning stripes, and set a
stringline from such points to achieve accuracy.
710-5.1 Dimensions:
710-5.1.1 Longitudinal Lines: Apply painted skip line segments with no more
than plus or minus 12 inches variance, so that over-tolerance and under-tolerance lengths
between skip line and the gap will approximately balance. Apply longitudinal lines at least
2 inches from construction joints of portland cement concrete pavement.
710-5.1.2 Transverse Markings, Gore Markings, Arrows, and Messages:
Apply paint in multiple passes when the marking cannot be completed in one pass, with an
overall line width allowable tolerance of plus or minus 1 inch.
849
710-5.1.3 Contrast Lines: Use black paint to provide contrast on concrete or
light asphalt pavement, when specified by the Engineer. Apply black paint in 10 foot segments
following each longitudinal skip line.
710-5.2 Alignment: Apply painted stripes that will not deviate more than 1 inch from the
stringline on tangents and curves one degree or less. Apply painted stripes that will not deviate
more than 2 inches from the stringline on curves greater than one degree. Apply painted edge
stripes uniformly, not less than 2 inches or more than 4 inches from the edge of pavement,
without noticeable breaks or deviations in alignment or width.
Remove and replace at no additional cost to the Department, traffic stripes that
deviate more than the above stated requirements.
710-5.3 Correction Rates: Make corrections of variations in width at a maximum rate of
10 feet for each 0.5 inches of correction. Make corrections of variations in alignment at a
maximum rate of 25 feet for each 1 inch of correction, to return to the stringline.
710-6 Contractors Responsibility for Notification.
Notify the Engineer prior to the placement of the materials. Furnish the Engineer with the
manufacturers name and batch numbers of the materials and glass spheres to be used. Ensure
that the approved batch numbers appear on the materials and glass spheres packages.
710-7 Protection of Newly Painted Pavement Markings.
Do not allow traffic onto or permit vehicles to cross newly applied pavement markings
until they are sufficiently dry. Remove and replace any portion of the pavement markings
damaged by passing traffic or from any other cause, at no additional cost to the Department.
710-8 Corrections for Deficiencies to Applied Painted Pavement Markings.
Reapply a 1.0 mile section centered around any deficiency, at no additional cost to the
Department.
710-9 Submittals.
710-9.1 Submittal Instructions: Prepare a certification of quantities, using the
Departments current approved form, for each project in the Contract. Submit the certification of
quantities and daily worksheets to the Engineer. The Department will not pay for any disputed
items until the Engineer approves the certification of quantities.
710-9.2 Contractors Certification of Quantities: Request payment by submitting a
certification of quantities no later than Twelve Oclock noon Monday after the estimate cut-off
date or as directed by the Engineer, based on the amount of work done or completed. Ensure the
certification of quantities consists of the following:
(a) Contract Number, FPID Number, Certification Number, Certification Date and
the period that the certification represents.
(b) The basis for arriving at the amount of the progress certification, less
payments previously made and less any amount previously retained or withheld. The basis will
include a detailed breakdown provided on the certification of items of payment.
710-10 Method of Measurement.
The quantities to be paid for under this Section will be as follows:
(a) The length, in net miles, of 6 inch solid traffic stripe, authorized and
acceptably applied.
850
(b) The total traversed distance in gross miles of 10-30 or 3-9 skip line. The actual
applied line is 25% of the traverse distance for a 1:3 ratio. This equates to 1,320 feet of marking
per mile of single line.
(c) The net length, in feet, of each of all other types of lines and stripes,
authorized and acceptably applied.
(d) The number of pavement messages, symbols and directional arrows,
authorized and acceptably applied.
(e) Lump Sum, as specified in 710-4.1.1 when the item for painted pavement
markings (final surface) is included in the proposal.
The net length, in feet of dotted and skip stripes other than 10-30 and 3-9 will be
measured as the distance from the beginning of the first painted stripe to the end of the last
painted stripe with proper deductions made for unpainted intervals as determined by plan
dimensions or stations, subject to 9-1.3. Unpainted intervals will not be included in pay quantity.
The gross-mile measurement of 10-30 and 3-9 skip traffic stripes will be taken as the
distance from the beginning of the first painted stripe to the end of the last painted stripe, and
will include the unpainted intervals. It will not include any lengths of unpainted intervals which,
by design or by other intent of the Department, are greater than 30 feet. Final measurement will
be determined by plan dimensions or stations, subject to 9-1.3.1.
710-11 Basis of Payment.
710-11.1 General: Prices and payments will be full compensation for all work specified
in this Section, including, all cleaning and preparing of surfaces, furnishing of all materials,
application, curing and protection of all items, protection of traffic, furnishing of all tools,
machines and equipment, and all incidentals necessary to complete the work. Final payment will
be withheld until all deficiencies are corrected.
710-11.2 Lump Sum Payment: When the item for painted pavement markings (final
surface) is included in the proposal, prices and payments will be full compensation for two
applications of all painted pavement markings applied to the final surface, and one application of
retroreflective pavement markers applied to the final surface in accordance with Section 706.
Payment will be made under:
Item No. 710
Painted Pavement Markings.
Traffic Stripes, Solid - per net mile.
Traffic Stripes, Solid - per foot.
Traffic Stripes, Skip - per gross mile.
Traffic Stripes, Skip - per foot.
Dotted/Guideline - per foot.
Messages -each.
Arrows - each.
Yield Markings - per foot.
Item No. 710-90
Painted Pavement Markings (Final Surface) - lump sum.
851
SECTION 711
THERMOPLASTIC TRAFFIC STRIPES AND MARKINGS
711-1 Description.
Apply new thermoplastic traffic stripes and markings, or refurbish existing thermoplastic
traffic stripes and markings, in accordance with the Contract Documents.
711-2 Materials.
711-2.1 Thermoplastic: Use only thermoplastic materials listed on the QPL. The
Engineer will take random samples of all material in accordance with the Departments
Sampling, Testing and Reporting Guide schedule.
711-2.1.1 Initial or Recapped Stripes and Markings: Use materials meeting the
requirements of 971-1 and 971-5.
711-2.1.2 Refurbishing Existing Stripes and Markings: Use materials meeting
the requirements of 971-1 and 971-5.
711-2.1.3 Preformed Stripes and Markings: Use Materials meeting the
requirements of 971-1 and 971-6.
711-2.2 Glass Spheres: Use only glass spheres listed on the QPL, meeting the
requirements of 971-1 and 971-2. The Engineer will take random samples of all glass spheres in
accordance with ASTM D1214 and the Departments Sampling, Testing and Reporting Guide
schedule.
711-2.3 Sand: Use materials meeting the requirements of 971-5.4.
711-3 Equipment.
Use equipment capable of providing continuous uniform heating of striping materials to
temperatures exceeding 390F, mixing and agitation of the material reservoir to provide a
homogeneous mixture without segregation. Use equipment that will maintain the striping
material in a plastic state, in all mixing and conveying parts, including the line dispensing device
until applied. Use equipment which can produce varying width traffic stripes and which meets
the following requirements:
(a) capable of traveling at a uniform, predetermined rate of speed, both uphill and
downhill, in order to produce a uniform application of striping material and capable of following
straight lines and making normal curves in a true arc.
(b) is capable of applying glass spheres to the surface of the completed stripe by a
double drop application for initial traffic striping and marking and a single drop application for
recapping and refurbishing. The bead dispenser for the first bead drop shall be attached to the
striping machine in such a manner that the beads are dispensed closely behind with the
thermoplastic material. The second bead dispenser bead shall be attached to the striping machine
in such a manner that the beads are dispensed immediately after the first bead drop application.
Glass spheres dispensers shall be equipped with an automatic cut-off control that is synchronized
with the cut-off of the thermoplastic material and applies the glass spheres in a manner such that
the spheres appear uniform on the entire traffic stripes and markings surface with, 50 to 60%
embedment.
(c) equipped with a special kettle for uniformly heating and melting the striping
material. The kettle must be equipped with an automatic temperature control device and material
852
thermometer for positive temperature control and to prevent overheating or scorching of the
thermoplastic material.
(d) meet the requirements of the National Fire Protection Association, state, and
local authorities.
711-4 Application.
711-4.1 General: Remove existing pavement markings such that scars or traces of
removed markings will not conflict with new stripes and markings by a method approved by the
Engineer. Cost for removing conflicting pavement markings during maintenance of traffic
operations to be included in Maintenance of Traffic, Lump Sum.
Before applying traffic stripes and markings, remove any material by a method
approved by the Engineer that would adversely affect the bond of the traffic stripes. Before
applying traffic stripes to any portland cement concrete surface, apply a primer, sealer or surface
preparation adhesive of the type recommended by the manufacturer. Offset longitudinal lines at
least 2 inches from any longitudinal joints of portland cement concrete pavement.
Apply traffic stripes or markings only to dry surfaces, and when the ambient air
and surface temperature is at least 50F and rising for asphalt surfaces and 60F and rising for
concrete surfaces.
Apply striping to the same tolerances in dimensions and in alignment specified in
710-5. When applying traffic stripes and markings over existing markings, ensure that no more
than 2 inches on either end and not more than 1 inch on either side of the existing line is visible.
Apply thermoplastic material to the pavement either by spray, extrusion or other
means approved by the Engineer.
Conduct field tests in accordance with FM 5-541.Take test readings representative
of the striping performance. Remove and replace traffic stripes and markings not meeting the
requirements of this Section at no additional cost to the Department.
Apply all final pavement markings prior to opening the road to traffic.
711-4.1.1 Preformed Thermoplastic: Apply markings only to dry surfaces and
when ambient air temperature is at least 32F. Prior to installation, follow the manufacturers
recommendations for pre-heating.
711-4.2 Thickness:
711-4.2.1 Initial or Recapped Stripes and Markings: Apply or recap traffic
stripes or markings such that all lane lines, center lines, transverse markings and traffic stripes
and markings within traffic wearing areas, will have a thickness of 0.10 to 0.15 inch when
measured above the pavement surface.
Also, all gore, island, and diagonal stripe markings, bike lane symbols and
messages, wherever located, will have a thickness of 0.09 to 0.12 inch when measured above the
pavement surface.
Measure, record and certify on Department approved form and submit to
the Engineer, the thickness of white and yellow pavement markings in accordance with FM 5541.
711-4.2.2 Refurbishing Existing Traffic Stripes and Markings: Apply a
minimum of 0.06 inch of thermoplastic material. Ensure that the combination of the existing
stripe and the overlay after application of glass spheres does not exceed the maximum thickness
of 0.150 inch for all lines.
711-4.3 Retroreflectivity: Apply white and yellow traffic stripes and markings that will
attain an initial retroreflectivity of not less than 450 mcd/lxm2 and not less than 350 mcd/lxm2,
853
respectively for all longitudinal lines. All transverse lines, messages and arrows will attain an
initial retroreflectivity of not less than 300 mcd/lxm2 and 250 mcd/lxm2 for white and yellow
respectively. All pedestrian crosswalks, bike lane symbols or messages in a proposed bike lane
shall attain an initial retroreflectivity of not less than 275 mcd/lxm2.
Measure, record and certify on Department approved form and submit to the
Engineer, the retroreflectivity of white and yellow pavement markings in accordance with FM 5541.
711-4.4 Glass Spheres:
711-4.4.1 Longitudinal Lines: For initial traffic striping and marking, apply the
first drop of Type 4 or larger glass spheres immediately followed by the second drop of Type 1
glass spheres. For refurbishing, apply a single drop of Type 3 glass spheres. Apply reflective
glass spheres to all markings at the rates determined by the manufacturers recommendations.
711-4.4.2 Transverse Stripes and Markings: Apply a single drop of Type 1
glass spheres. Apply reflective glass spheres to all markings at the rates determined by the
manufacturers recommendations.
Apply a mixture consisting of 50% glass spheres and 50% sharp silica
sand to all thermoplastic pedestrian crosswalk lines and bike lane symbols at the rates
determined by the manufacturers recommendations.
711-4.4.3 Preformed Markings: These markings are factory supplied with glass
spheres and skid resistant material. No additional glass spheres or skid resistant material should
be applied during installation.
711-5 Contractors Responsibility for Notification.
Notify the Engineer prior to the placement of the thermoplastic materials. Furnish the
Engineer with the manufacturers name and batch numbers of the thermoplastic materials and
glass spheres to be used. Ensure that the approved batch numbers appear on the thermoplastic
materials and glass spheres packages.
711-6 Protection of Newly Applied Traffic Stripes and Markings.
Do not allow traffic onto or permit vehicles to cross newly applied pavement markings
until they are sufficiently dry. Remove and replace any portion of the pavement markings
damaged by passing traffic or from any other cause, at no additional cost to the Department
711-7 Observation Period.
Longitudinal pavement markings are subject to a 180 day observation period under
normal traffic. The observation period shall begin with the satisfactory completion and
acceptance of the work.
The longitudinal pavement markings shall show no signs of failure due to blistering,
excessive cracking, chipping, discoloration, poor adhesion to the pavement, loss of reflectivity or
vehicular damage. The retroreflectivity shall meet the initial requirements of 711-4.3. The
Department reserves the right to check the color and retroreflectivity any time prior to the end of
the observation period.
Replace, at no additional expense to the Department, any longitudinal pavement
markings that do not perform satisfactorily under traffic during the 180 day observation period.
854
711-8 Corrections for Deficiencies.
Recapping applies to conditions where additional striping material is applied to new or
refurbished traffic stripes or markings to correct a deficiency. Recap a 1.0 mile section centered
around the deficiency with additional striping material or by complete removal and reapplication
at no additional cost to the Department.
If recapping will result in a thickness exceeding the maximum allowed, the traffic stripes
or markings will be removed and reapplied.
711-9 Submittals.
711-9.1 Submittal Instructions: Prepare a certification of quantities, using the
Departments current approved form, for each project in the Contract. Submit the certification of
quantities and daily worksheets to the Engineer. The Department will not pay for any disputed
items until the Engineer approves the certification of quantities.
711-9.2 Contractors Certification of Quantities: Request payment by submitting a
certification of quantities no later than Twelve O clock noon Monday after the estimate cut-off
date or as directed by the Engineer, based on the amount of work done or completed. Ensure the
certification of quantities consists of the following:
(a) Contract Number, FPID Number, Certification Number, Certification Date and
the period that the certification represents.
(b) The basis for arriving at the amount of the progress certification, less
payments previously made and less any amount previously retained or withheld. The basis will
include a detailed breakdown provided on the certification of items of payment.
711-10 Method of Measurement.
The quantities to be paid for under this Section will be as follows:
(a) The length, in net miles, of 6 inch solid traffic stripe, authorized and
acceptably applied.
(b) The total traversed distance in gross miles of 10-30 or 3-9 skip line. The actual
applied line is 25% of the traverse distance, for a 1:3 ratio. This equates to 1,320 feet of marking
per mile of single line.
(c) The net length, in feet, of all other types of lines and stripes, authorized and
acceptably applied.
(d) The area, in square feet, of removal of existing pavement markings,
acceptably removed.
(e) The number of pavement messages, symbols and directional arrows,
authorized and acceptably applied.
711-11 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including, all cleaning and preparing of surfaces, furnishing of all materials, application, curing
and protection of all items, protection of traffic, furnishing of all tools, machines and equipment,
and all incidentals necessary to complete the work. Final payment will be withheld until all
deficiencies are corrected.
Payment will be made under:
Item No. 711Thermoplastic
Traffic Stripes, Solid - per net mile.
Traffic Stripes, Solid - per foot.
855
Traffic Stripes, Skip - per gross mile.
Dotted/Guideline - per foot.
Messages - each.
Arrows - each.
Yield Markings - per foot.
Thermoplastic, Remove - per square foot.
856
SECTION 713
PERMANENT TAPE STRIPES AND MARKINGS
713-1 Description.
Apply permanent tape traffic stripes and markings, in accordance with the Contract
documents. Stripes and markings are divided into two classes, Standard and High Performance,
and are differentiated by their retroreflectivity and durability. High performance tapes are
required for all longitudinal markings. Standard tapes are limited to transverse lines, arrows and
messages.
713-2 Materials.
Use only permanent tape traffic stripes and markings materials listed on the Qualified
Products List (QPL), meeting the requirements of 971-1 and 971-7. The Engineer will take
random samples of the materials in accordance with the Departments Sampling, Testing and
Reporting Guide schedule.
713-3 Equipment.
Use equipment that is mobile and maneuverable to the extent that straight lines can be
followed and normal curves can be made in a true arc.
Ensure the mechanical applicator is equipped with film cut-off device and a measuring
device that automatically and accumulatively measures the length of each line placed with an
accuracy tolerance of plus or minus 2 percent. Tape may be placed by hand on short sections,
500 feet or less if the tolerances in dimensions and in alignment specified in 710-5 are met.
713-4 Application.
713-4.1 General: Remove existing traffic stripes and markings, such that scars or traces
of removed markings will not conflict with new stripes and markings by a method approved by
the Engineer.
Before applying traffic stripes and markings, remove any material by a method
approved by the Engineer that would adversely affect the bond of the traffic stripes.
Apply a primer, sealer or surface preparation adhesive of the type recommended
by the manufacturer. Ensure the tape stripes and markings adhere to the pavement surface.
Offset longitudinal lines at least 2 inches from construction joints on portland
cement concrete pavement.
Apply traffic stripes or markings only to dry surfaces, and when the ambient air
and surface temperature is at least 55F and rising.
Apply striping to the same tolerances in dimensions and in alignment specified in
710-5. When applying traffic stripes and marking over existing markings, ensure that no more
than 2 inches on either end and not more than 1 inch on either side of the existing line is visible.
Apply traffic stripes and markings to the pavement by means approved by the
Engineer. The stripes and markings shall be installed immediately following the paving
operation. Conduct field testing in accordance with FM 5-541.Take test readings representative
of the striping performance. Remove and replace pavement stripes and markings not meeting the
requirements of this Section at no additional cost to the Department.
Apply all final pavement markings prior to opening the road to traffic.
713-4.2 Thickness: Apply traffic stripes or markings such that, the stripes or markings
will have a thickness as designated on the QPL for the particular product used.
857
Measure, record and certify on a Department approved form and submit to the
Engineer, the thickness of white and yellow pavement markings in accordance with FM 5-541.
713-4.3 Retroreflectivity:
713-4.3.1 General: Black portions of contrast tapes and black masking tapes must
have a reflectance of less than 5 mcd/lx m2. Measure, record and certify on Department approved
form and submit to the Engineer, the retroreflectivity of white and yellow pavement markings in
accordance with FM 5-541.
713-4.3.2 Standard Markings: Apply white and yellow traffic stripes and
markings that will attain an initial retroreflectivity of not less than 300 mcd/lxm2 for white
markings and not less than 250 mcd/lxm2 for yellow markings.
713-4.3.3 High Performance Markings: Apply white and yellow traffic stripes
and markings that will attain an initial retroreflectivity of not less than 450 mcd/lxm2 for white
markings and not less than 350 mcd/lxm2 for yellow markings.
713-4.4 Color: Use material meeting the requirements of 971-1.
713-5 Contractors Responsibility for Notification.
Notify the Engineer prior to the placement of pavement stripes and marking material.
Furnish the Engineer with the manufacturers name and batch numbers of the material to be
used. Ensure that the approved batch numbers appear on the material packages.
713-6 Protection of Newly Applied Stripes.
Do not allow traffic onto or permit vehicles to cross onto newly applied traffic stripes and
markings until they are sufficiently bonded. Remove and replace any portion of the traffic stripes
and markings damaged by passing traffic or from any other cause, at no additional cost to the
Department.
713-7 Observation Period.
Longitudinal pavement markings are subject to a 180 day observation period under
normal traffic. The observation period shall begin with the satisfactory completion and
acceptance of the work.
The longitudinal pavement markings shall show no signs of failure due to blistering,
excessive cracking, chipping, discoloration, poor adhesion to the pavement, loss of reflectivity or
vehicular damage. The retroreflectivity shall meet the initial requirements of 713-4.3. The
Department reserves the right to check the color and retroreflectivity any time prior to the end of
the observation period.
Replace, at no additional expense to the Department, any longitudinal pavement
markings that do not perform satisfactorily under traffic during the 180 day observation period.
713-8 Corrections for Deficiencies.
Remove and reapply a 1.0 mile section centered around any deficiency, as determined by
the Engineer, at no additional cost to the Department.
713-9 Submittals.
713-9.1 Submittal Instructions: Prepare a certification of quantities, using the
Departments current approved form, for each project in the Contract. Submit the certification of
quantities and daily worksheets to the Engineer. The Department will not pay for any disputed
items until the Engineer approves the certification of quantities.
858
713-9.2 Contractors Certification of Quantities: Request payment by submitting a
certification of quantities no later than Twelve O clock noon Monday after the estimate cut-off
date or as directed by the Engineer, based on the amount of work done or completed. Ensure the
certification of quantities consists of the following:
(a) Contract Number, FPID Number, Certification Number, Certification Date and
the period that the certification represents.
(b) The basis for arriving at the amount of the progress certification, less
payments previously made and less any amount previously retained or withheld. The basis will
include a detailed breakdown provided on the certification of items of payment.
713-10 Method of Measurement.
The quantities to be paid for under this Section will be as follows:
(a) The length, in net miles, of 6 inch solid traffic stripe, authorized and
acceptably applied.
(b) The total traversed distance in gross miles of 10-30 or 3-9 skip line. The actual
applied line is 25% of the traverse distance, for a 1:3 ratio. This equates to 1,320 feet of marking
per mile of single line.
(c) The net length, in feet, of all other types of lines and stripes, authorized and
acceptably applied.
(d) The area, in square feet, of remove existing markings acceptably removed.
(e) The number of pavement messages, symbols and directional arrows,
authorized and acceptably applied.
713-11 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including, all cleaning and preparing of surfaces, furnishing of all materials, application, curing
and protection of all items, protection of traffic, furnishing of all tools, machines and equipment,
and all incidentals necessary to complete the work. Final payment will be withheld until all
deficiencies are corrected.
Payment will be made under:
Item No. 713-101Permanent Tape (Standard).
Item No. 713-102Permanent Tape (High Performance).
859
SECTION 715
HIGHWAY LIGHTING SYSTEM
715-1 Description.
Install a highway lighting system in accordance with the details shown in the Plans. Use
pole assemblies as shown in the Design Standards when standard aluminum pole assemblies or
standard high mast light assemblies are required by the Contract Documents. Include in the
system the light poles, bases, luminaires, ballasts, cable, conduit, protective devices, and control
devices; all as specified or required for the complete facility.
Obtain conventional light pole and high mast light pole assemblies from a fabrication facility
that is listed on the Departments list of Metal Producers with an Accepted Quality Control Program,
meeting the requirements of 105-3.
Provide metal lighting poles, excluding high mast lighting, with internal vibration
damping devices in accordance with Design Standard 17515 in all installations on bridges, walls
and concrete median barriers.
715-2 Shop Drawings and Working Drawings.
Submit shop drawings and working drawings with descriptive specifications and
engineering data for the service main, control panel enclosure, control panel main disconnect,
lighting contactor, electrical panel, transformer, in-line fuse holders, surge protective devices,
non-standard light poles (including brackets), luminaires, ballast, photo-electric cell, conduit and
cable or any other item requested by the Engineer as specified in Section 5.
715-3 Materials and Equipment to be Installed.
715-3.1 General: Meet the materials and equipment requirements of Section 992.
Provide products of established, reputable manufacturers of electrical equipment, meeting NEC
requirements and the approval of the Engineer.
715-3.2 Criterion Designation of Materials and Equipment: Where a criterion
specification is designated for any material or equipment to be installed, by the name or catalog
number of a specific manufacturer, understand that such designation is intended only for the
purpose of establishing the style, quality, performance characteristics, etc., and is not intended to
limit the acceptability of competitive products. The Engineer will consider products of other
manufacturers which are approved as similar and equal as equally acceptable.
715-4 Furnishing of Electrical Service.
Start the system with a weatherhead on a riser on a service pole and extend through the
required metering equipment of the power company, and through the lighting system as shown.
The power company will provide service to the areas in the vicinities indicated. Consult
and cooperate with the power company in locating its distribution transformer and service pole
so that the lines will be as short and direct as possible. Bear any line-extension costs up to the
first 2,000 feet. Furnish or install only those parts of the metering equipment or connections that
are customary and required by the power company in the locality involved.
715-5 Excavation and Backfilling.
715-5.1 General: For excavation and backfilling, meet the requirements of Section 125,
except that when rock is encountered, carry the excavation 3 inches below the required level and
refill with sand or with selected earth material, 100% of which passes the 1 inch sieve.
860
715-5.2 Trenches for Cable: Construct trenches for cable or conduit no less than
6 inches in width and deep enough to provide a minimum cover in accordance with the Design
Standards.
715-5.3 Placing Backfill for Cable: For installation of the cable, place an initial layer of
6 inches thick, loose measurement, sand or selected earth material, 100% of which passes a
1 inch sieve. Place and compact the remaining material in accordance with 125-8.
715-6 Foundations for Light Poles.
715-6.1 Concrete Foundations: Provide foundations for light poles of the sizes and
shapes shown in the Plans. Construct precast or cast-in-place concrete foundations in accordance
with the Design Standards. Obtain precast foundations from a plant that is currently on the
Departments list of Producers with Accepted Quality Control Programs. Producers seeking
inclusion on the list shall meet the requirements of 105-3.
715-6.2 Setting Anchor Bolts: Set anchor bolts according to manufacturers templates
and adjust to a plumb line, check for elevation and location, and hold rigidly in position to
prevent displacement while pouring concrete.
715-6.3 Installation: Do not erect roadway light poles or high mast light poles until the
concrete strength in the cast-in-place foundation is at least 2,500 psi. Determine concrete
strength from tests on a minimum of two test cylinders sampled and tested in accordance with
ASTM C31 and ASTM C39 and verifying test results have been provided to the Engineer.
Fill the voids around precast concrete foundations under roadway light poles with
flowable fill meeting the requirements of Section 121 or clean sands placed using hydraulic
methods to a level 6 inches below grade.
715-7 Pulling Conductors.
Leave at least 3 feet of conductor where the cable enters and leaves conduit. Protect
conductors pulled into conduit or ducts against abrasion, kinking, and twisting. Locate pull boxes
so that the conductors are not subjected to excessive pulling stresses.
715-8 Splicing.
Make all conductor splices in the bases of the light poles, or in pull boxes designed for
the purpose. Do not make underground splices unless specifically authorized by the Engineer,
and then only as directed by him.
Unless otherwise shown in the Design Standards or authorized by the Engineer, splices
shall be made with split bolt connectors. The connector shall be sealed in silicone gel that easily
peels away leaving a clean connection. The gel will be contained in a closure that when snapped
around the split bolt will provide a waterproof connection without the use of tools or taping. This
closure will be UV resistant, impact resistant and abrasion resistant.
715-9 Conduit and Ducts.
715-9.1 General: Install conduit and ducts at the locations shown in the Plans, or as
required for a satisfactory installation.
715-9.2 Conduit in Structures: Use conduit of either rigid steel or PVC for embedding
in structural concrete. Install an expansion fitting at every structural expansion joint through
which the conduit passes. Provide exposed runs of conduit with adequate expansion joints as
shown in the Plans or approved by the Engineer. Obtain the Engineers approval of the design of
the expansion joints.
861
715-9.3 Pre-wired Direct-burial Duct: Where specified in the Plans or directed by the
Engineer, install a pre-wired, flexible polyethylene plastic pipe containing the conductors for the
lighting circuits. Provide conductors and polyethylene pipe as described in the Plans.
715-10 Erecting Light Poles.
715-10.1 General: Install the light poles at the locations and in accordance with the
details shown in the Plans. Unless otherwise specifically approved by the Engineer, fasten
bracket (truss) arms to the pole prior to erection. Do not field weld on any part of the pole
assembly. Plumb the poles after erection and use metal shims or leveling nuts if necessary to
obtain precise alignment. Use a thin cement grout where necessary to eliminate unevenness or
irregularities in the top of the base.
715-10.2 Adjusting Anchor Bolts and Installing Nuts on Anchor Bolts: Where poles
are to be placed on existing foundations or bases with anchor bolts in place, furnish poles with a
base which fits the anchor bolt spacing. Include the cost of any necessary extension of existing
anchor bolts in the price bid for the lighting system. For high mast light pole bases, install nuts
on anchor bolts in accordance with 649-5.
715-10.3 Installation of Luminaire: Install the luminaire on the truss arm in accordance
with the manufacturers instructions, and place it so that the light pattern is evenly distributed
along the roadway.
715-10.4 Electrical Connections: Make primary ballast connections in accordance with
manufacturers instructions. Install sufficient cable to allow all connections to be made outside
the light pole base. Connect the ground conductor to the ground stud provided.
715-10.5 Identification Plates: If required by the Contract Documents, stamp the
identification plate on the pole with an identifying number or legend. Number the poles
consecutively, beginning with number 1. Stamp each light pole number with 3/4 inch figures and
stamp each circuit number with 1/2 inch figures.
715-10.6 Screen Installation for High Mast Light Pole Bases: Install a screen in
accordance with 649-6.
715-11 Grounding.
Ground in accordance with the NEC, and local codes which exceed these Specifications.
Ground each metal light pole, not on a bridge structure, with an approved rod, 20 feet in
length and at least 5/8 inch in diameter.
For poles on bridge structures, bring the grounding conductors out to a pull box at each
end of the structure and connect them to driven ground rods, 20 feet in length and at least
5/8 inch in diameter.
The 20 feet length of rod may be either two rods 10 feet in length connected by a
threaded coupling and driven as a single rod or two rods 10 feet in length separated by at least
6 feet.
Make all bonds between ground wires and grounding electrode assemblies or arrays with
an exothermic bond with the following exception: do not exothermically bond grounding
electrode to grounding electrode connections.
The work specified in this Section will not be paid for directly, but will be considered as
incidental work.
Ground all high mast poles in accordance with the details for grounding in the Design
Standards, Index No. 17502.
862
715-12 Labeling.
Stencil labels on the cases of transformer and panel board with white oil paint, as
designated by the Engineer. Also, mark the correct circuit designations in accordance with the
wiring diagram on the terminal marking strips of each terminal block and on the card holder in
the panel board.
715-13 Markers.
Construct duct, cable, and splice markers as shown in the Plans, and place them over the
ends of underground ducts and at each change in direction of cable or conduit run. Place markers
flat on the ground with 1 inch projecting above finished grade.
715-14 Tests of Installation.
Upon completion of the work, test the installation to ensure that the installation is entirely
free of ground faults, short circuits, and open circuits and that it is in satisfactory working
condition. Furnish all labor, materials, and apparatus necessary for making the required tests.
Remove and replace any defective material or workmanship discovered as a result of these tests
at no expense to the Department, and make subsequent re-tests to the satisfaction of the
Engineer.
Make all arrangements with the power supplier for power. Pay all costs, excluding energy
charges, required for the test period.
Not less than 48 hours prior to the beginning of the test period, give the power supplier
the schedule for such test.
Test the installation under normal operating conditions during the seven day test period
specified in 715-15, rather than as a continuous burn test period.
If the work is not open to traffic at the end of the seven day test period, de-energize the
lighting system until the work is opened.
715-15 Acceptance of Highway Lighting.
The Engineer may make partial acceptance of the highway lighting based on satisfactory
performance of all highway lighting for seven consecutive days. The seven day evaluation period
may commence upon written authorization by the Engineer that highway lighting is considered
ready for acceptance evaluation. Contract Time will be charged during the entire highway
lighting evaluation period. Correct any defects in materials or workmanship which might appear
during the evaluation period at no expense to the Department. Transfer to the Department any
guarantees on equipment or materials furnished by the manufacturer and ensure that the
manufacturer includes with such guarantees the provision that they are subject to such transfer,
and proper validation of such fact. The Departments written acceptance of highway lighting and
the transfer to the Department of all manufacturer guarantees will be conditions precedent to
final acceptance of all work under the Contract in accordance with 5-11.
715-16 Method of Measurement.
The quantities to be paid for will be as follows, completed and accepted:
(a) Conduit: The Contract unit price per foot of conduit, furnished and installed,
will include furnishing all connecting hardware, trenching and backfill as indicated in the Plans
and the Design Standards, and the cost of restoring cut pavement, sidewalks, sod, and etc., to its
original condition. The length will be based on the horizontal path of the installed conduit as
863
measured in a straight line between the centers of pull boxes, cabinets, poles, etc. No allowance
will be made for sweeps or vertical distances above or below the ground or the bridge deck.
(b) Luminaire and Truss Arm: The Contract unit price will include the truss arm,
luminaire with lamp, and all necessary mounting hardware as indicated in the Plans and the
Design Standards.
(c) Load Center: The Contract unit price will include the service pole, insulators,
weatherheads, transformers, enclosures, panel boards, breakers, safety switches, H.O.A.
switches, lighting protectors, fuses, photo electric assembly, meter base, and all external and
internal conduit and conductors for the service as indicated in the Plans and the Design
Standards.
(d) Light Pole Foundation: The Contract unit price will include the foundation and
anchor bolts with lock nuts and washers as indicated in the Plans and the Design Standards.
(e) Luminaire: The Contract unit price will include the luminaire with lamp and
necessary mounting hardware as indicated in the Plans and the Design Standards.
(f) Pull Box: The Contract unit price will include the pull box and cover as
indicated in the Plans and the Design Standards.
(g) High Mast Parts: The Contract unit price will include the part specified with
all mounting hardware as indicated in the Contract Documents and the Design Standards.
(h) Frangible Base for Light Pole: The Contract unit price will include the
frangible base, attachments, bolts, and washers as indicated in the Plans and the Design
Standards.
(i) Photo Electric Control Assembly: The Contract unit price will include the
photo electric control, transformers, conduit, and conductors as indicated in the Plans and the
Design Standards.
(j) Pre-Fab Pilaster: The Contract unit price will include the pilaster and all
mounting hardware as indicated in the Plans.
(k) High Mast Lighting Pole Complete: The Contract unit price will include the
pole, luminaires with lamps, lowering system, breakers and anchor bolts with lock nuts and
washers, and foundation as indicated in the Plans and the Design Standards.
(l) Conductor: The length, in feet, as indicated in the Plans and the Design
Standards.
(m) Lighting Pole Complete: The Contract unit price will include the pole,
internal vibration damping device, truss arm, luminaire with lamp, anchor bolts with lock nuts
and washers, frangible base and foundation.
(n) Pole Cable Distribution System: The Contract Unit price will include the surge
protector, fuse holders with fuses, waterproof connectors and the waterproof wiring connection
to the luminaries.
715-17 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section,
including all materials, equipment and tests.
864
SECTION 780
INTELLIGENT TRANSPORTATION SYSTEMS GENERAL REQUIREMENTS
780-1 Description.
The provisions contained in this Section include general requirements for all intelligent
transportation system (ITS) devices and equipment used on Floridas limited-access and nonlimited-access corridors and in transportation management centers (TMCs).
780-2 Equipment and Materials.
Use only ITS equipment and components that meet the requirements of these
specifications, and which are listed on the Departments Approved Product List (APL). Use only
new equipment and materials, except as specified in the Contract Documents. Ensure that
firmware and software furnished and installed as part of an ITS project are the most current and
approved releases or versions. Firmware and software updates released during Contractor and
manufacturer warranty periods shall be made available at no cost to the Department.
Meet the following requirements:
General Requirements for the Installation and Evaluation
of Traffic Control Signals and Devices ............................ Section 603
Guaranties ......................................................................... Section 608
Acceptance Procedures for Traffic Control Signals
and Devices ....................................................................... Section 611
Traffic Control Signal and Device Installation
Grounding ......................................................................... Section 620
Electrical Power Service Assemblies................................ Section 639
ITS Motorist Information Systems ................................... Section 781
ITS Video Equipment ....................................................... Section 782
ITS Fiber Optic Cable and Interconnect ........................... Section 783
ITS Network Devices ........................................................ Section 784
ITS Infrastructure .............................................................. Section 785
ITS Vehicle Detection and Data Collection...................... Section 786
780-3 Installation Requirements.
Install ITS equipment as detailed in the Plans, following the manufacturers
recommendations, and with the review and approval of the Engineer.
Furnish all tools, equipment, materials, supplies, and manufactured hardware necessary
for a complete installation. Perform all operations and equipment integration necessary to ensure
that the finished ITS equipment functions as depicted in the Plans.
Materials and workmanship shall conform to the requirements of the NEC, the National
Electrical Safety Code (NESC), and applicable codes of governing jurisdictions.
780-4 Testing.
Perform the required tests for the ITS equipment installed. Notify the Engineer of ITS
installation testing at least 14 days in advance.
Provide the test procedures to the Engineer at least 14 days in advance for approval prior
to commencement of testing. Ensure that the test plan demonstrates each and every functional
requirement specified for the device or system under test.
865
Furnish all equipment, software, and supplies necessary for conducting the tests. Include
in the test documentation the last calibration date of all test equipment, along with the test
parameters as set on the equipment.
All test results shall be compared with their corresponding specifications. Failure to
conform to the specifications of any test shall be considered a defect and the equipment shall be
subject to rejection by the Engineer. Rejected equipment may be offered again for a retest,
provided that all deficiencies have been corrected and evidence thereof has been submitted to the
Engineer.
866
SECTION 781
INTELLIGENT TRANSPORTATION SYSTEMS
MOTORIST INFORMATION SYSTEMS
781-1 Description.
Provide Motorist Information Systems meeting the general requirements of 781-2, the
specific requirements for each system as defined in 781-3 through 781-6 of this specification,
and in accordance with the details specified in the Contract Documents.
781-2 Materials.
Ensure that all materials furnished, assembled, fabricated, or installed are new products
and approved by the Engineer.
781-3 Dynamic Message Signs.
781-3.1 Sign Types: Dynamic message signs (DMS) must meet the requirements of
NEMA TS4-2005. DMSs are classified by the type of sign display and the type of mechanical
construction. Provide monochrome, tri-color, or full-color signs as shown in the Contract
Documents. Use only equipment and components that meet the requirements of these minimum
specifications and are listed on the Departments Approved Product List (APL).
781-3.1.1 Front Access DMS: Ensure that front access signs meet the
requirements of NEMA TS4 2005, section 3.2.5.
781-3.1.2 Walk-in DMS: Ensure that walk-in signs meet the requirements of
NEMA TS4 2005, section 3.2.7.
781-3.1.3 Embedded DMS: Embedded DMSs are DMSs that are typically
mounted to ground traffic signs, overhead traffic signs, or overhead cantilever traffic signs.
781-3.2 Sign Housing Requirements for all DMS: Ensure that the external skin of the
sign housing is constructed of aluminum alloy 5052 H32 that is a minimum of 0.125 inch thick
for walk-in DMS and 0.090 inch thick for front and embedded DMS. Ensure the interior
structure is constructed of aluminum. Ensure that the sign housing design and appearance is
approved by the Engineer. Ensure that no internal frame connections or external skin attachments
rely upon adhesive bonding or rivets.
Ensure the sign enclosure meets the requirements of NEMA TS4 2005, Section
3.1.1. Ensure that all drain holes and other openings in the sign housing are screened to prevent
the entrance of insects and small animals.
Ensure that the sign housing complies with the fatigue resistance requirements of
the fifth edition (2001) American Association of State Highway and Transportation Officials
(AASHTO) Standard Specifications for Structural Supports for Highway Signs, Luminaires, and
Traffic Signals with current addendums. Design and construct the DMS unit for continuous
usage of at least 20 years and the sign structure for a 50-year design life. Ensure that equipment
and structures are designed to withstand loads, including a wind load of 150 miles per hour, as
defined in the FDOT Structures Manual without deformation or damage.
Ensure that the top of the housing includes multiple galvanized or stainless steel
lifting eyebolts or equivalent hoisting points. Ensure hoist points are positioned such that the sign
remains level when lifted. Ensure that the hoist points and sign frame allow the sign to be
shipped, handled, and installed without damage.
867
Ensure all assembly hardware, including nuts, bolts, screws, and locking washers
less than 5/8 inch in diameter, are Type 304 or 316 passivated stainless steel and meet the
requirements of ASTM F593 and ASTM F594. All assembly hardware greater than or equal to
5/8 inch in diameter must be galvanized and meet the requirements of ASTM A307.
Ensure all exterior, excluding the sign face, and all interior housing surfaces are a
natural aluminum mill finish. Ensure signs are fabricated, welded, and inspected in accordance
with the requirements of the current American National Standard Institute/American Welding
Society (ANSI/AWS) Structural Welding Code-Aluminum.
Ensure the sign housing meets the requirements of NEMA TS4 2005, Section
3.2.8 for convenience outlets.
781-3.2.1 Sign Housing for Walk-in DMS: Ensure that exterior seams and
joints, except the finish coated face pieces, are continuously welded using an inert gas welding
method. Limit the number of seams on the top of the housing to a maximum of three. Stitch weld
the exterior housing panel material to the internal structural members to form a unitized
structure.
Ensure that exterior mounting assemblies are fabricated from aluminum
alloy 6061-T6 extrusions a minimum of 0.1875 inch thick. Include a minimum of three 6061-T6
structural aluminum Z members on the rear of the sign housing in accordance with the Design
Standards, Index No. 18300. Ensure these structural members run parallel to the top and bottom
of the sign housing and are each a single piece of material that spans the full length of the sign.
Ensure these structural members are attached to the internal framework of the sign.
Ensure hoist points are attached directly to structural frame members by
the sign manufacturer.
Ensure housing access is provided through an access door that meets the
requirements of NEMA TS4 2005, section 3.2.7.1. Ensure the access door includes a keyed
tumbler lock and a door handle with a hasp for a padlock. Ensure the door includes a closed-cell
neoprene gasket and stainless steel hinges.
Ensure the sign housing meets the requirements of NEMA TS4 2005,
section 3.2.7.3 for service lighting. If incandescent lamps are provided, ensure they are fully
enclosed in heavy-duty shatterproof, protective fixtures. Ensure that incandescent fixtures
include aluminum housing and base, a porcelain socket, and clear glass inner cover. Ensure that
all removable components are secured with set screws. If fluorescent lamps are provided, ensure
they are fitted with protective guards.
Ensure that the sign housing includes emergency lighting that
automatically illuminates the interior in the event of a power outage. Emergency lighting must be
capable of operation without power for a minimum of 90 minutes.
781-3.2.1.1 Walk-in DMS Work Area: Ensure the walk-in DMS has a
work area that meets the requirements of NEMA TS4 2005, section 3.2.7.2. Finish all edges of
the walkway to eliminate sharp edges or protrusions.
781-3.2.2 Sign Housing for Front Access and Embedded DMS: Ensure front
access and embedded signs meet the requirements of NEMA TS4 2005, section 3.2.4. Ensure
access does not require specialized tools or excessive force.
781-3.2.3 Housing Face requirements for all DMS: Ensure the sign face meets
the requirements of NEMA TS4 2005, section 3.1.3. Ensure that all sign face surfaces are
finished with a matte black coating system that meets or exceeds American Architectural
Manufacturers Association (AAMA) Specification No. 2605. Provide certification that the sign
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face parts are coated with the prescribed thickness. Except for embedded DMS, ensure the sign
face includes a contrast border that meets the requirements of NEMA TS4 2005, Section 3.1.6.
781-3.2.3.1 Housing Face for Walk-in DMS: No exposed fasteners shall
be allowed on the housing face. Ensure that display modules can be easily and rapidly removed
from within the sign without disturbing adjacent display modules.
781-3.2.3.2 Housing Face for Front Access and Embedded DMS: Any
exposed fasteners on the housing face shall be the same color and finish as the housing face.
Only captive fasteners shall be used on the housing face.
781-3.2.3.3 External Fascia Panels: If the sign includes external fascia
panels, ensure that they are constructed using aluminum. Finish each fascia panel with a matte
black coating system that meets or exceeds AAMA Specification No. 2605.
781-3.2.3.4 Lens Panel Assembly: If sign includes lens panel assemblies,
ensure they are modular in design, removable, and interchangeable without misalignment of the
lens panel and the light-emitting diode (LED) pixels. The lens panel assembly must consist of an
environmental shielding layer coating to protect and seal the LEDs and internal electronics. The
coating shall be a minimum 90% ultraviolet (UV) opaque. Lens panels must have a matte black
coating that meets or exceeds AAMA Specification No. 2605. Lens panels must include a mask
constructed of 0.080 inch minimum thickness aluminum. Ensure that the mask is perforated to
provide an aperture for each pixel on the display module. Ensure that the apertures do not block
the LED output at the required viewing angle.
781-3.2.4 Sign Housing Ventilation System: The ventilation systems for walkin, front-access, and embedded DMS must meet the requirements of NEMA TS4 2005, Section
3.1.2.
Ensure that air drawn into the sign is filtered upon entry. Ensure the
ventilation system is automatically tested once each day and that it may be tested on command
from remote and local control access locations. Ensure the sign includes a sensor or a sensor
assembly to monitor airflow volume to predict the need for a filter change. Ensure the ventilation
system fans possess a 100,000-hour, L10 life rating.
781-3.2.4.1 Ventilation System for Walk-in DMS: Ensure the sign
includes a fail-safe ventilation subsystem that includes a snap disk thermostat that is independent
of the sign controller. Preset the thermostat at 130F. If the sign housings interior reaches
130F, the thermostat must override the normal ventilation system, bypassing the sign controller
and turning on all fans. The fans must remain on until the internal sign housing temperature falls
to 115F.
781-3.2.5 Sign Housing Temperature Sensor: Ensure that the sign controller
continuously measures and monitors the temperature sensors. Ensure that the sign blanks when a
critical temperature is exceeded and that the sign will report this event when polled. Ensure that
remote and local computers can read all temperature measurements from the sign controller.
781-3.2.6 Sign Housing Humidity Sensor: Humidity sensors must detect from 0
to 100% relative humidity in 1% or smaller increments. Sensors must operate and survive in 0 to
100% relative humidity, and have an accuracy that is better than plus or minus 5% relative
humidity. A humidistat is not acceptable.
781-3.2.7 Sign Housing Photosensors: Ensure the sign meets the requirements of
NEMA TS4 2005, Section 8.8. Ensure that the sensors provide accurate ambient light condition
information to the sign controller for automatic light intensity adjustment. Ensure that the
automatic adjustment of the LED driving waveform duty cycle occurs in small enough
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increments that the signs brightness changes smoothly, with no perceivable brightness change
between adjacent levels. Ensure that stray headlights shining on the photoelectric sensor at night
do not cause LED brightness changes.
Ensure that the brightness and color of each pixel is uniform over the
signs entire face within a 30-degree viewing angle in all lighting conditions.
781-3.3: Display Modules: Provide display modules manufactured by one source and
fully interchangeable throughout the manufacturers sign systems. Ensure that removal or
replacement of a complete display module or LED board can be accomplished without the use of
special tools.
Ensure display modules contain solid-state electronics needed to control pixel
data and read pixel status.
Ensure that the sign has a full matrix display area as defined in the glossary of
NEMA TS4 2005.
781-3.3.1 LED and Pixel Specifications: Ensure that LED lamps have a
minimum viewing angle of 30 degrees.
Ensure that all pixels in all signs in a project, including operational
support supplies, have equal color and on-axis intensity. Ensure that the sign display meets the
luminance requirements of NEMA TS4 2005, section 5.4, for light emitting signs connected at
full power. Ensure that amber displays produce an overall luminous intensity of at least
9200 candelas per square meter when operating at 100% intensity. Provide the LED brightness
and color bins that are used in each pixel to the Engineer for approval. Ensure that the LED
manufacturer demonstrates testing and binning according to the International Commission on
Illumination (CIE) 127 (1997) standard.
Ensure that all LEDs operate within the LED manufacturers
recommendations for typical forward voltage, peak pulsed forward current, and other ratings.
Component ratings shall not be exceeded under any operating condition.
Provide a pixel test as a form of status feedback to the transportation
management center (TMC) from the local sign controller. Ensure that the operational status of
each pixel in the sign can be automatically tested once a day. Ensure that the pixel status test
determines the functional status of the pixel as defined by the pixel Failure Status object in
National Transportation Communications for ITS Protocol (NTCIP) 1203v0239 and does not
affect the displayed message for more than half a second.
Ensure that LEDs are individually mounted directly on a printed circuit
board (PCB).
781-3.3.2 Optical, Electrical, and Mechanical Specifications for Display
Modules: Ensure the display modules are rectangular and have an identical vertical and
horizontal pitch between adjacent pixels. Ensure that the separation between the last column of
one display module and the first column of the next module is equal to the horizontal distance
between the columns of a single display module. Full-color signs must have a pitch equal to or
less than 35mm.
Ensure that the LED circuit board is a NEMA FR4-rated, single
0.062 inch, black PCB. Ensure that no PCB has more than two PCB jumper wires present. Finish
all PCBs with a solder mask and a component-identifying silk screen.
Provide the LED motherboards with a complete conformal coating of
silicone resin with a minimum thickness of 0.01 inch, except for the pixels on the front of the
PCB. All other PCBs must be provided with a complete conformal coating of silicone resin with
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a minimum thickness of 0.01 inch. Meet the material requirements of MIL-I-46058C Military
Standard, United States Department of Defense (USDOD).
Ensure that any devices used to secure LEDs do not block air flow to the
LED leads or block the LED light output at the required viewing angle. Ensure that all
components on the LED side of PCBs are black.
Ensure that there are a minimum of two power supplies that are wired in a
parallel configuration for redundancy. Ensure that if one or 25% of the supplies in a group,
whichever is greater, completely fails, the sign shall still be supplied with enough power to run
40% of all pixels at a 100% duty cycle with an ambient operating temperature of 165F.
Ensure that the sign controller continuously measures and monitors all
LED module power supply voltages and provides the voltage readings to the TMC or a laptop
computer on command.
Ensure that LEDs are protected from external environmental conditions,
including moisture, snow, ice, wind, dust, dirt, and UV rays. Do not use epoxy to encapsulate the
LEDs.
781-3.3.3 Display Area for Walk-in DMS: Ensure that the display area is
capable of displaying three lines of 15 characters using an 18 inch font that meets the height to
width ratio and character spacing in the Manual on Uniform Traffic Control Devices for Streets
and Highways 2009 Edition (MUTCD), section 2L.04, paragraphs 05, 06, and 08.
781-3.4 Characters, Fonts, and Color: Ensure that the signs are capable of displaying
American Standard Code for Information Interchange (ASCII) characters 32 through 126,
including all uppercase and lowercase letters and digits 0 through 9, at any location in the
message line. Submit a list of the character fonts to the Engineer for approval.
All signs must be loaded (as a factory default) with a font in accordance with or
that resembles the standard font set described in NEMA TS4 2005, section 5.6. For signs with a
pixel pitch of 35mm or less, ensure the sign is loaded (as a factory default) with a font set that
resembles the Federal Highway Administration (FHWA) Series E2000 standard font.
Ensure DMS fonts have character dimensions that meet the MUTCD, Section
2L.04, paragraph 08.
Ensure that full-color signs can display the colors prescribed in the MUTCD,
Section 1A.12.
781-3.5 Main Power Supply and Energy Distribution Specifications:
Provide a nominal single-phase power line voltage of 120/240 VAC. Ensure the
DMS meets the requirements of NEMA TS4 2005, Section 10.2.
Locate all 120 VAC wiring in conduit, pull boxes, raceways, or control cabinets as
required by the National Electrical Code (NEC). Ensure that no 120 VAC wiring is exposed inside
or outside of the sign housing. Do not use the sign housing as a wiring raceway or control
cabinet.
Provide Type XHHW power cables sized as required by the NEC for acceptable
voltage drops while supplying alternating current to the sign.
Provide surge protective devices (SPD) installed or incorporated in the sign
system by the manufacturer to guard against lightning, transient voltage surges, and induced
current. Ensure that SPDs meet or exceed the requirements of Section 785-2. Ensure SPDs
protect all electric power and data communication connections.
781-3.6 Uninterruptible Power Supply (UPS): If a UPS is required in the Contract
Documents for walk-in DMS, ensure the UPS is installed within the sign housing or as shown in
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the Plans. If a UPS is required in the Contract Documents for front access and embedded signs,
ensure the UPS is installed within the control cabinet or as shown in the Plans. The UPS system
must be capable of displaying the current message on a sign when a power outage occurs. Signs
with UPS must be able to operate on battery power and display text messages for a minimum of
two hours. Ensure the system uses sealed absorbed glass mat (AGM) batteries.
781-3.7 Operational Support Supplies: Furnish the operational support supplies listed
in the table below. Promptly replace any of the supplies used to perform a repair during the
warranty period in accordance with 611-5.
For every group of 10 or fewer DMS provided or required, provide one set of
supplies as follows:
1 each
10 each
1 each
1 each
1 each
1 each
2 each
1 each
1 each
10 each
2 each
1 each
Sign controller and I/O board(s)
LED display modules
Display power supply
Uninterruptible power supply
Cable for connecting interface circuits to daughter boards
Display module cables
Surge suppression sets
Fan assembly
Time relay for fan control
Each type of small fuse ( 10 amp)
Each type of large fuse (> 10 amp)
Each type of sensor
781-3.8 Components: All components must meet the requirements of NEMA TS4 2005,
section 8.
781-3.8.1 Mechanical Components: Ensure that all fasteners, including bolts,
nuts, and washers less than 5/8 inch in diameter, are passivated stainless steel, Type 316 or
Type 304 and meet the requirements of ASTM F593 and ASTM F594 for corrosion resistance.
Ensure that all bolts and nuts 5/8 inch and over in diameter are galvanized and meet the
requirements of ASTM A307. Do not use self-tapping screws. Ensure that all parts are fabricated
from corrosion resistant materials, such as plastic, stainless steel, aluminum, or brass. Ensure that
construction materials are resistant to fungus growth and moisture deterioration. Ensure that all
dissimilar metals are separated with an inert, dielectric material.
781-3.8.2 Sign Controller: Ensure that the sign controller monitors the sign in
accordance with NEMA TS4 2005, Section 9. Ensure the sign monitors the status of any
photocells, LED power supplies, humidity, and airflow sensors. Ensure sign controllers use fiber
optic cables for data connections between the sign housing and ground-level cabinet.
Ensure that the sign controller meets the requirements of
NEMA TS4 2005, sections 8.9, 8.10. Ensure that the sign controller is capable of displaying a
self-updating time and date message on the sign. Ensure that sign controllers within ground
cabinets are rack-mountable, designed for a standard EIA-310 19 inch rack, and include a keypad
and display.
781-3.8.3 Display System Hardware: Ensure the sign utilizes a system data
interface circuit for communications between the sign controller and display modules. Except for
embedded DMS, ensure that the following components reside inside the sign housing: sign
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controller (master or slave), display system interface circuits, display modules, power supplies,
local and remote control switches, LED indicators, Electronic Industries Alliance (EIA)-232 null
modem cables (minimum of 4 feet long for connecting laptop computer to sign controller), and
surge protective devices.
781-3.8.4 Control Cabinet: Provide a control cabinet that meets the requirements
of 785-4. Ensure that the minimum height of the cabinet is 46 inches.
Provide a ground control cabinet that includes the following assemblies
and components: power indicator, surge suppression on both sides of all electronics,
communication interface devices, connection for a laptop computer for local control and
programming, a 4 foot long cable to connect laptop computers, a workspace for a laptop
computer, and duplex outlets.
Provide for all telephone, data, control, power, and confirmation
connections between the sign and ground control box, and for any required wiring harnesses and
connectors.
781-3.8.5 Sign Controller Communication Interfaces: Ensure the sign
controller has communication interfaces in accordance with NEMA TS4 2005, Section 8.7.1.
Ensure that EIA-232 serial interfaces support the following:
Data Bits
Parity
Number Stop Bits
7 or 8 bits
Even, Odd, or None
1 or 2 bit
Ensure the sign controller has a 10/100 Base TX 8P8C port or a 100 Base
FX port Ethernet interface.
For dial-up operations, acquire and bear the charges of installing and
connecting the dial-up telephone line. Provide modems to be retained by the Department at each
location. Provide a user-selectable data transmission rate of up to 19.2 kbps for dial-up
operations. Ensure that switching between dial-up, Ethernet, and multidrop operation does not
require sign controller software or hardware modifications.
Ensure that the TMC or a laptop computer can be used to remotely reset
the sign controller.
781-3.9 Message and Status Monitoring: Ensure the DMS provides two modes of
operation: (1) remote operation, where the TMC commands and controls the sign and determines
the appropriate message or test pattern; and (2) local operation, where the sign controller or a
laptop computer commands and controls the sign and determines the appropriate message or test
pattern.
Ensure that the sign can perform the following functions:
1. Control Selection - Ensure that local or remote sign control can be
selected. Ensure that there is a visual indicator on the controller that identifies whether the sign
is under local or remote control.
2. Message Selection - Ensure that the sign controller can select a blank
message or any one of the messages stored in the sign controllers nonvolatile memory when the
control mode is set to local.
3. Message Implementation - Ensure that the sign controller can activate
the selected message.
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Ensure that the sign can be programmed to display a user-defined message,
including a blank page, in the event of power loss.
Ensure that message additions, deletions, and sign controller changes may be
made from either the remote TMC or a local laptop computer. Ensure that each font may be
customized, and modifications to a font may be downloaded to the sign controller from the TMC
or a laptop computer at any time without any software or hardware modifications.
Ensure that there is no perceivable flicker or ghosting of the pixels during sign
erasure and writing periods.
781-3.10 TMC Communication Specification for all DMS: Ensure that the sign
controller is addressable by the TMC through the Ethernet communications network using
software that complies with the NTCIP 1101 base standard (formerly the NEMA TS 3.2 -1996
standard), including all amendments as published at the time of contract letting, the NTCIP
Simple Transportation Management Framework, and conforms to Compliance Level 1. Ensure
that the software implements all mandatory objects in the supplemental requirement SR-781-3-1,
FDOT Dynamic Message Sign NTCIP Requirements, as published on the FDOT State Traffic
Engineering and Operations Office web site at the time of contract letting. Ensure that the sign
complies with the NTCIP 1102v01.15, 2101 v01.19, 2103v02.07, 2201v01.15, 2202 v01.05, and
2301v02.19 standards. Ensure that the sign complies with NTCIP 1103v02.17, Section 3.
Ensure that the controllers internal time clock can be configured to synchronize
to a time server using the network time protocol (NTP). NTP synchronization frequency must be
user-configurable and permit polling intervals from once per minute to once per week in oneminute increments. The controller must allow the user to define the NTP server by internet
protocol (IP) address.
Provide communications line circuits that are point-to-point or multipoint, and
that provide full duplex asynchronous data transmissions at the rate shown in the contract
documents or directed by the Engineer.
Assign each sign controller a unique address.
781-3.11 Sign Control Software: Ensure that the sign is provided with computer
software from its manufacturer that allows an operator to program, operate, exercise, diagnose,
and read current status of all sign features and functions using a laptop computer. Ensure that
sign control software provides a graphical representation that visibly depicts the sign face and the
current ON/OFF state of all pixels as well as allows messages to be created and displayed on the
sign. Ensure that the laptop computer and sign can communicate when connected directly by an
EIA-232 cable and via Ethernet. Ensure that the software will allow communication between
multiple users and multiple signs across the same communication network.
781-3.12 Sign Support Structure: Meet the requirements of 700-2.4.
781-3.13 Installation Requirements: Provide walk-in DMS for locations over interstate
travel lanes. Do not install the sign prior to the availability of electric power. Verify that any
ventilation system incorporated within the sign is operational within 72 hours after sign
installation.
Ensure that the location of the lifting eyebolts, left in place or removed, is sealed
to prevent water entry after installation.
Load the initial message libraries on both the sign control software and the sign
controller. The Engineer will furnish the messages to be placed in these libraries.
781-3.14 Documentation: Provide documentation for electronic equipment in
accordance with 603-8.
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781-3.15 Licensing: Ensure that the manufacturer grants the Department a license that
allows the Department to use and internally distribute any and all sign communications
protocols, operating systems, drivers, and documentation.
781-3.16 Technical Assistance: Ensure that a manufacturers representative is available
to assist the Contractors technical personnel during pre-installation testing and installation.
Do not provide initial power to the sign(s) without the permission of the
manufacturers representative.
781-3.17 Environmental Requirements: The DMS must meet the requirements of
NEMA TS4 2005, section 2.
781-3.18 Pre-installation Field Testing: Conduct pre-installation tests on all units at a
Contractor-provided facility within the appropriate District. Perform the tests on each unit
supplied to verify that no damage was done to any sign during the shipment and delivery
process. Notify the Engineer a minimum of 10 calendar days before the start of any tests.
Conduct all tests according to the approved test procedures detailed in this section. Each DMS
must pass the individual tests detailed below prior to installation.
781-3.18.1 Material Inspection: Examine each DMS carefully to verify that the
materials, design, construction, markings, and workmanship comply with all applicable
standards, specifications, and requirements.
781-3.18.2 Operational Test: Operate each DMS long enough to permit
equipment temperature stabilization, and to check and record an adequate number of
performance characteristics to ensure compliance with applicable standards, specifications, and
requirements.
781-3.18.3 Pre-installation Test Failure Consequence: If any unit fails, the unit
shall be corrected or another unit substituted in its place and the test repeated.
If a unit has been modified as a result of a failure, a report shall be
prepared and delivered to the Engineer. The report shall describe the nature of the failure and the
corrective action taken.
If a failure pattern develops, the Engineer may direct that design and
construction modifications be made to all units without additional cost to the Department or an
extension of the contract period.
781-3.19 Installed Site Tests: Conduct an approved, stand-alone equipment installation
test at the field site. Test all stand-alone (i.e., non-network) functions of the field equipment
using equipment installed as detailed in the Plans and as approved by the Engineer.
Complete approved data forms and turn them over to the Engineer for review and
as a basis for rejection or acceptance. Provide a minimum notice of 30 calendar days prior to all
tests to permit the Engineer or his representative to observe each test.
If any unit fails to pass its stand-alone test, correct the unit or substitute another
unit in its place, then repeat the test.
If a unit has been modified as a result of a stand-alone test failure, prepare a report
describing the nature of the failure and the corrective action taken and deliver it to the Engineer
prior to re-testing the unit. If a failure pattern develops, the Engineer may direct that design and
construction modifications be made to all units without additional cost to the Department or an
extension of the contract period.
781-3.20 System Testing: Conduct approved DMS system tests on the field equipment
with the master equipment including, at a minimum, all remote control functions. Display the
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return status codes from the sign controller for a minimum of 72 hours. Complete approved data
forms and turn them over to the Engineer for review, and as a basis for rejection or acceptance.
Demonstrate the signs ability to display the proper predefined message or remain
blank when power is restored following an AC power interruption.
If the system test fails because of any subsystem component, repair that
component or substitute another in its place, then repeat the test. If a component has been
modified as a result of a system test failure, prepare a report and deliver it to the Engineer prior
to retesting.
781-3.21 Operational Testing: After the system testing is successfully completed,
conduct one continuous 72 hour, full-operating test prior to conducting the 60 day acceptance
test. The Engineer will approve the type of tests to be conducted. Include in the tests all control,
monitoring, and communications functions of the field equipment by the master equipment.
781-3.22 Acceptance Testing: Conduct a 60 day acceptance test after the successful
completion of the approved 72 hour operational test. During the 60 day test period, limit
downtime due to mechanical, electrical, or other malfunctions to a maximum total of five
calendar days. If the equipment fails to operate for a total of five or more calendar days, testing
will be restarted. The Engineer may select to pause and extend the 60 day test period by the
number of days lost by failure and repair time in lieu of restarting the full 60 day test. The
Engineer will furnish the Contractor with a letter of approval and completion stating the first and
last day of the 60 day test period.
781-4 Highway Advisory Radio.
781-4.1 Description: Furnish and install a highway advisory radio (HAR) system having
all equipment necessary to record verbal messages from onsite or remote locations, and to
continually broadcast live, prerecorded, or synthesized messages.
781-4.2 Materials:
781-4.2.1 General: Provide a HAR system that includes static signage with
flashing beacons to notify motorists of active HAR broadcasts. Ensure that all HAR transmitter
components are modular and fit in a rack-mounted chassis. Use HAR subsystems and
components that are programmable remotely or onsite.
Ensure that the HAR system includes software, hardware and any other
component required to fully configure, operate and monitor the HAR field equipment locally and
remotely using a personal computer. Use only equipment and components that meet the
requirements of these minimum specifications, and are listed on the Departments Approved
Product List (APL).
781-4.2.2 Transmitter: Ensure that the transmitter complies with the
requirements of Code of Federal Regulations (CFR) Title 47, Section 90.242, Travelers
Information Stations, and 47 CFR Section 2.901 et seqq. (Part 2, Subpart J), of the Federal
Communications Commission (FCC) Rules and Regulations.
Use a transmitter with a power efficiency of 80% or greater. Ensure that
the transmitter is adjustable from 0 to 10 watts. Ensure that the transmitter frequency is set at the
factory. Ensure that the transmitter parameters can be monitored locally and remotely.
Ensure that the radio frequency (RF) output impedance is 50 ohms and
unbalanced.
Ensure that the audio input impedance is 600 ohms and balanced. Ensure
that the transmitter module has audio distortion of less than 1.5% for a audio frequency response
of 200 Hz to 3.5 kHz.
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Provide a transmitter module with indicators or displays for power status,
RF power output, and audio modulation level.
781-4.2.3 Digital Recorder and Playback Unit: Ensure that the digital recorder
and playback unit can locally and remotely record, store, transmit, and receive digital messages
or audio files. Ensure that the digital recorder and playback unit allows operator control by dual
tone multi-frequency (DTMF) tones over standard public switched telephone networks (PSTNs)
and digital cellular telephone, and digital commands via serial modem. Ensure that the digital
recorder and playback unit is FCC certified under Part 68 for dial-up operations.
Ensure that the digital recorder and playback unit can schedule broadcasts,
which shall be programmable by the day of the week, month, date, and time. Ensure that the
digital recorder and playback unit uses solid state electronics. Do not use floppy disks or
magnetic tapes. Use a digital recorder and playback unit with the ability to record and store a
minimum of 250 distinct, variable-length messages, and provide a minimum of 14 minutes of
recorded message time.
Ensure that the digital recorder and playback unit has access to, and
command and control of, the remote flashing beacon controller.
Ensure that the digital recorder and playback unit is password protected
and has an input source indicator. Ensure that the digital recorder and playback unit can
simultaneously record and playback messages. Ensure that the digital recorder and playback unit
can retain messages indefinitely, in the event of a power loss, and not require a battery. Ensure
that the digital recorder and playback unit has built-in voice prompts.
781-4.2.4 Transmitter Synchronizer: Ensure that multiple HAR transmitters
broadcasting the same message are synchronized. Ensure that the synchronization eliminates
interference and audio distortion within possible overlapping areas.
Provide a global positioning system (GPS) receiver for audio
synchronization and frequency synchronization. Provide a minimum of eight channels in the
transmitter synchronizer module. Ensure that the accuracy of the module is within 45
nanoseconds at 10 MHz reference.
781-4.2.5 Antenna Assembly: Provide an antenna assembly with hardware and
cables to mount the antenna as shown in the Plans. Use either a vertical monopole, which
propagates omnidirectional radio waves in a circular pattern, or a directional array that
propagates radio waves in a noncircular shape, according to the Plans.
Use an antenna that can be tuned to the transmission frequency either
mechanically or electronically. Tune the antenna to the same frequency as the transmitter.
781-4.2.6 Ground Plane: Install system grounding components in accordance
with 785-1 or as shown in the Plans. Use a minimum of American Wire Gauge (AWG) #20 wire
for any radial ground planes. Install these wires extending outward from the base of the antenna,
at a minimum of 6 inches below ground, forming a circular pattern with a radius of 30 to 100
feet.
781-4.2.7 Surge Protective Devices: Install surge protective devices between the
transmitter and the antenna. Ensure surge protective devices meet the requirements of Section
785-2.
781-4.2.8 HAR Sign and Flashing Beacons: Provide roadside signs with
flashing beacons that are activated when the associated HAR system is transmitting. Ensure that
the HAR sign conforms to the Departments Design Standards for special sign details pertaining
to highway advisory radio.
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Provide 12 inch beacons that comply with Section 650, along with
controller, communications, power and material needed to provide a fully functioning flashing
beacon system. Ensure that the flashing beacons use a NEMA-rated flasher circuit. Ensure that
the flashing beacons can be operated locally and remotely.
781-4.2.9 Power System: Provide a solar or AC power system as shown in the
Plans. Provide a power distribution system, for both solar and AC powered sites, that includes
automatic battery charging circuitry. Ensure that battery chargers prevent overcharging and
provide a means of battery disconnection and isolation.
Provide external AC power supply module with backup batteries as shown
in the Plans. Ensure that AC powered systems utilize 120 volts of alternating current (VAC)
nominal input voltage. Ensure that the HAR operates from 89-135VAC with a frequency of 60
plus or minus 3 Hz. Provide batteries that can continuously operate the HAR system at full
power for a minimum period of three days without an external power source. Ensure that loss of
AC power to the system does not interrupt HAR transmissions.
Provide a solar power supply module, as shown in the Plans, with
photovoltaic array and battery storage system to operate the HAR system continuously at full
power for a minimum period of three days without sunlight. Verify that the systems solar panels
are compliant with the International Electrotechnical Commission (IEC) requirements detailed in
the IEC 61215 standard. Verify that the DC output power specifications are a nominal 13.6 volts
of direct current (VDC) at 5 amps, with a maximum of 15 VDC and a maximum of 10 amps.
Provide 12 volt batteries that are rated at a minimum of 180 Ah, are deep
cycle, and maintenance-free.
Provide an accessible attachment point that allows connection of a
portable generator for emergency power.
781-4.2.10 Control Cabinet: Provide a control cabinet for housing the
transmitter, digital recorder and playback unit, transmitter synchronizer, power, surge
suppressors, and flashing beacon controller, as shown in the Plans. Ensure that cabinets meet
NEMA 3R requirements for aluminum enclosures and conform to Section 676. Use a cabinet
that is constructed of aluminum alloy 5052-H32 measuring 0.125 inch thick.
781-4.2.11 Performance Requirements: Furnish a HAR system that is
compatible with the current version of the Departments SunGuide Software System.
Ensure that the system has a text-to-speech capability for converting typed
words to audio files. Ensure that the system logs the status of all devices. Ensure that the
operator is able to record, edit, and delete messages, and to select desired messages for
broadcast. Ensure that the system maintains event schedules, diagnostic information, and logs of
messages that have been downloaded and played, along with the date and time that a message
was activated for each HAR. Ensure that the HAR system provides system failure remote alarms
and indicates system status in the user interface.
781-4.2.12 Environmental Specifications: Ensure that the HAR system installed
at the field site is able to withstand temperatures between minus 29 and 165F as per the NEMA
TS 2 standard at 95% noncondensing humidity. Ensure that the HAR system meets the
requirements specified in the Plans Preparation Manual for wind loading.
781-4.3 Installation Requirements: Install all HAR equipment according to the
manufacturers recommendations or as directed by the Engineer.
Obtain all required licenses to operate the HAR as per FCC requirements using
the services of the HAR manufacturer. Perform all necessary on-site testing to select the clearest
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and most appropriate operating frequency for all HAR transmitters at the proposed locations.
Submit the results of the frequency search, testing, and the recommended frequency selection to
the Engineer for approval prior to application for FCC licenses.
Provide all utility coordination, power design and power service installations to
obtain power for the HAR and flashing beacon sites.
Ensure that any public network connections (PSTN, cellular, or other
connections) used for system interconnect are approved by the Engineer.
781-4.4 Testing: Subject the equipment covered by these specifications to design
approval tests (DATs) and field acceptance tests (FATs). Develop and submit a test plan for
DATs and FATs to the Engineer for consideration and approval.
The Engineer may accept certification by an independent testing laboratory in lieu
of the DATs to satisfy the requirement that certain features and functions have been witnessed
and documented as performing satisfactorily. Arrange and conduct the tests and satisfy all
inspection requirements prior to submission for the Engineers inspection and acceptance.
The Engineer reserves the right to witness all DATs and FATs. Complete the tests
within five calendar days.
Ensure that the test plans demonstrate each and every feature available in the
device or system under test and includes the tests discussed below.
781-4.4.1 Stand-Alone Tests: Perform the following stand-alone tests on the
HAR, after all equipment has been installed and initial adjustment is complete at the field site.
781-4.4.1.1 Ground Plane Resistivity: Conduct ground plane resistivity
measurements as required in 785-1.
781-4.4.1.2 Transmitter: Perform field measurements to verify
compliance with 47 CFR Part 90.242. Document the location and results of field measurements
and submit them to the Engineer.
781-4.4.1.3 Digital Recorder and Playback Unit: Demonstrate the
correct operation of each function of the digital recorder and playback unit at the field site using
the display screen. Verify the test message is received on a vehicle radio set to the approved
transmitter frequency and located within the coverage area of the HAR transmission.
781-4.4.1.4 Battery System: Verify that the charged batteries can run the
HAR system for the number of days as advertised by the manufacturer.
781-4.4.2 System Tests: Conduct approved HAR system tests on at least one
HAR system, including the operations center, one sign and flashing beacon, and one transmitter.
Perform, at a minimum, all remote control functions. Complete approved data forms and turn
them over to the Engineer for review, and as a basis for rejection or acceptance.
If the system test fails because of any subsystem component, correct that
component or substitute another in its place, then repeat the test. If a component has been
modified as a result of a system test failure, prepare a report and deliver it to the Engineer prior
to retesting.
781-4.4.2.1 Digital Recorder and Playback Unit: Test the remote
loading of the messages on digital recorder and playback unit and verify the quality of voice
broadcasted. Load 14 minutes of messages and demonstrate different sequences of playback.
Test the message loading from a remote location using cellular telephone, standard analog
telephone line and digital commands via serial modem.
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781-4.4.2.2 Transmitter Synchronization: If multiple HARs are
deployed, test that a clear signal is obtained in the signal influence region that is free of
interference caused by synchronization faults.
781-5 Road Weather Information System.
781-5.1 Description: Furnish and install a road weather information system (RWIS) as
shown in the Plans.
781-5.2 Materials: Provide an RWIS consisting of environmental sensor stations (ESS)
installed at specified locations. Provide an ESS as shown in the Plans that includes
environmental sensors mounted on an approved structure (typically a concrete pole), other
sensors mounted in the roadway, and a remote processing unit (RPU) at the base of the structure.
Ensure that the RPU can collect, store, and process sensor data to describe current weather
conditions.
Provide any ancillary equipment or incidental items required, including mounting
hardware, power supplies, grounding, surge protection devices, and communication equipment,
at each ESS location to make a complete and fully operational RWIS. Ensure that the system
provides real-time, accurate, reliable data on all system parameters to the degree of precision
defined in this specification.
Ensure all assembly hardware, including nuts, bolts, external screws and locking
washers less than 5/8 inch in diameter, are Type 304 or 316 passivated stainless steel and meet
the requirements of ASTM F593 and ASTM F594. All assembly hardware greater than or equal
to 5/8 inch in diameter must be galvanized and meet the requirements of ASTM A325.
781-5.2.1 Sensors: Provide an RWIS that can collect and store data from various
sensors including, but not limited to:
1. Roadway sensors located in or under the pavement.
2. Atmospheric sensors.
Ensure that all RWIS sensors and other field equipment are
made of UV, heat, and corrosion resistant materials
Provide ultrasonic anemometers and other sensors that are
electronic devices which do not rely on moving parts to create electrical signals for processing.
781-5.2.2 Sensor Performance: Each environmental sensor and its associated
transducers shall record the following attributes to the listed degree of accuracy:
Roadway Data
Surface Temperature
Precipitation
Temperature
Relative Humidity at 70
F
Barometric Pressure
0.36 F between -40 and 176 F
Dry, wet at >32 F; wet at <32 F; frozen, frost and
Type:
dew
Percent of Ice:
From 0 to 100%
Depth/Amount:
From 0 to 0.5 inch
Atmospheric Data
1 F between -40 and 176 F; resolution of 0.1 degree
5% between 10 and 100%
Accurate to 0.02 inch of mercury (in. Hg) between 27.2 and 31.9 in.
Hg; resolution of 0.005 inches Hg
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Type:
Light rain, rain and ice
Intensity:
20% between 0.02 to 200 inches per hour
Precipitation
Visibility:
10% from 0.005 to 1 mile
Direction:
3 degrees between 0 and 360 degrees
Wind
Speed:
3% between 0 and 120 mph
Ensure that pavement sensors function as specified above when installed
at a maximum of 2,000 feet from the RPU.
781-5.2.3 ESS: Install an ESS having the sensors necessary to collect, store, and
transmit the following data:
1. Roadway data, including:
A) Temperature
B) Surface data that includes ice and precipitation depth/amount.
2. Atmospheric data, including:
A) Temperature
B) Relative humidity
C) Barometric pressure
D) Precipitation data that includes type and intensity
E) Visibility as affected by fog, smoke, or a combination thereof
F) Wind data, including direction and average speed
781-5.2.4 Communications: Use an RPU capable of transmitting all collected
data to the transportation management center (TMC) using the National Transportation
Communications for ITS Protocol (NTCIP). Ensure that the RWIS field station supports EIA
232/485 serial communication, TCP/IP, and UDP/IP.
Ensure that all communications, including those between sensors and the
RPU, are nonproprietary and compatible with the Departments SunGuide Software System.
781-5.2.5 Remote Processing Unit:
The RPU shall store a minimum of 24 data records. Each data record will
include sensor readings of a user-defined time interval of up to 5 minutes.
Ensure that the RPU operates using a nominal input voltage at the cabinet
of 110 to 120 VAC, and also be capable of operating on 12 VDC of solar battery power. The RPU
shall issue an alarm to the TMC if the AC power supply is low or if there has been a complete
power loss. Ensure that the system sends a message when the unit returns to normal conditions.
781-5.2.6 RPU Enclosure: Use a cabinet listed on the APL to house and protect
the RPU and all field electronics associated with the RWIS.
781-5.2.7 RWIS Software: Ensure that the RWIS software enables the system
operator to derive environmental measurements, such as the dew point, wind chill, and heat
index, from sensor data received. Ensure that the RWIS software can be used to report
minimums, maximums, averages, cumulative values, and standard deviations for all data over a
prescribed time period.
Ensure that the RWIS software provides English-to-metric unit
conversions, when applicable, and lets the operator choose which unit of measure to report if
more than one unit is common for a particular measurement.
When the software supplied with the RWIS is installed on a laptop
computer or a remote workstation, ensure that the operator is able to access, either remotely
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through the workstation or at the site with the laptop computer, all user-defined parameters and
stored data within the RPU, including the ability to view, download, and delete stored data.
781-5.2.8 Electrical Specifications: Provide RWIS equipment and components
installed at the ESS that operate at 110 to 120 VAC from a commercial utility company or,
alternatively, 12 VDC from a solar-powered or battery-powered system. In cases where the ESS
are mounted on the Departments MAS towers, ensure that the devices can utilize the 48 VDC
power supply available at the site.
Ensure that solar- and battery-powered units operate continuously for
14 days without requiring battery recharging. Provide an appropriate means of conversion for
any device that requires a different power source.
Equip each ESS installation with provisions for emergency backup power
in the event of primary power loss. Ensure that backup power is capable of continuing the ESS
operations for a minimum of 12 hours.
781-5.2.9 Foundation and Tower Specifications: Provide a supporting tower or
pole as shown in the Plans. Ensure the tower or pole provides a mounting platform for
atmospheric sensors free of influences from topography, buildings, and vehicles. Ensure that the
tower also supports any lightning protection devices (e.g., grounding rods) for the site. Provide a
support structure that is self-supporting without guy wires, using a 50-year design life, and in
accordance with the current Structures Manual.
If the field site is solar powered, ensure that the structure provides the
mounting platform for the solar array and the control cabinet that houses the battery bank and
charger.
Place a concrete work pad measuring 4 feet wide by 3 feet long by
4 inches deep in front of the RPU control cabinet if the cabinet is ground mounted. Construct the
pad using concrete meeting the requirements of Section 347.
781-5.3 Applicable Standards: Ensure that the RWIS complies with all applicable
standards from the National Weather Service.
Ensure that the RWIS complies with the latest revisions of all applicable NTCIP
standards, including NTCIP-1201 and NTCIP-1204. Ensure that all RWIS field equipment
complies with the environmental requirements of section A615 of the MSTCSD.
781-5.4 Installation Requirements: Ensure that all equipment and materials furnished,
assembled, fabricated, or installed are commercial off-the-shelf products.
Unless detailed otherwise in the Plans, mount all atmospheric sensors except
anemometers at cabinet-top height, approximately 10 feet above grade. Mount anemometers at
the top of the tower or as shown in the Plans. Locate pavement sensors as shown in the Plans.
Install all wiring so that it is either internal to a pole or in conduit.
Install all buried lead-in cable to pavement sensors in conduit.
Mount all roadway sensors flush with the roadway surface.
781-5.5 Testing: Utilize a testing procedure that includes a remote field sensor and RPU
test, a remote-to-central communication test, and a systems operational test. Conduct the
following tests and submit the results to the Engineer:
1. Perform and document laboratory tests verifying proper sensor calibration.
2. Calibrate instrument alignment with true north.
3. Furnish sensor calibration protocols and adjustment procedures.
4. Verify and ensure that sensors are reporting proper field data.
5. Detail regular site maintenance procedures and calibration training.
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6. Provide block diagrams, schematics, catalogs, and line drawings.
7. Program source codes in both printed and digital form.
8. Verify proper orientation of wiring and cabling.
9. Ensure that above-ground conduit is straight, neat, and properly secured.
10. Verify that the grounding system is installed per the requirements of 785-2.
Subject the RWIS to a 30-day observation period, during which time the
Contractor shall perform any and all maintenance, recalibration, and data verification required by
the Engineer.
Certify anemometers by wind tunnel tests. Submit test results to the Engineer for
review and approval. Upon request, furnish independent laboratory testing documentation
certifying adherence to the stated wind force criteria using a minimum effective projected area
(EPA), the actual EPA, or an EPA greater than that of the device to be attached.
Perform local field operational testing at each RWIS field site according to the
test plans detailed in this section. After the environmental sensor and RPUs, and other RWIS
hardware, power supplies, and connecting cables have been installed, perform the following:
1. Verify that physical construction has been completed as specified in the Plans.
2. Inspect the quality and tightness of ground and surge protector connections.
3. Check power supply voltages and outputs.
4. Connect devices to the power sources.
5. Verify installation of specified cables and connections between the
environmental sensor and RPUs, and the control cabinet.
6. Test local operation of all environmental sensor and RPU components.
Deliver a summary test report and a copy of all test results to the Engineer for
approval. Include documentation of any discrepancies found during testing, along with
environmental sensor and RPU serial numbers. Include assembly installation locations and
successful test completion dates.
781-6 Warranty.
Ensure that the manufacturer will furnish replacements for any part or equipment found
to be defective during the warranty period at no cost to the Department or the maintaining
agency within 10 calendar days of notification.
Ensure that the DMS and HAR systems and equipment have a manufacturers warranty
covering defects for a minimum of five years from the date of final acceptance by the Engineer
in accordance with 5-11 and Section 608.
Ensure that the RWIS equipment and components have a manufacturers warranty
covering defects for a minimum of three years from the date of final acceptance by the Engineer
in accordance with 5-11 and Section 608.
781-7 Method of Measurement.
Measurement for payment will be in accordance with the following work tasks.
781-7.1 Furnish and Install: For DMS, the quantity to be paid for will be each sign
furnished, installed, complete in accordance with the details shown in the Plans, warranted, made
fully operational, and tested in accordance with the specifications in this section.
For DMS Support Structure, the quantity to be paid for will be each structure
furnished, installed, complete in accordance with the details shown in the Plans; including posts
and supports, catwalks, handrails, footings, excavation, site grounding, painting, and incidentals
necessary to complete the work.
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The Contract unit price for each HAR system, furnished and installed, will
include furnishing, placement, and testing of all materials and equipment, and for all tools, labor,
equipment, hardware, operational software package(s) and firmware(s), supplies, support,
personnel training, shop drawings, documentation, and incidentals necessary to complete the
work.
The Contract unit price for an RWIS at each field location, furnished and
installed, will include furnishing, placement, and testing of all materials and equipment, and for
all tools, labor, equipment, hardware, operational software package(s) and firmware(s), supplies,
support, personnel training, shop drawings, warranty documentation, and incidentals necessary to
complete the work.
781-7.2 Furnish: The Contract unit price per each DMS, HAR or RWIS system,
furnished, will include all equipment specified in the Contract Documents, plus all shipping and
handling costs involved in delivery as specified in the Contract Documents.
781-7.3 Install: The Contract unit price per each DMS, HAR or RWIS system, installed,
will include placement, and testing of all materials and equipment, and for all tools, labor,
equipment, hardware, operational software package(s) and firmware(s), supplies, support,
personnel training, shop drawings, documentation, and incidentals necessary to complete the
work. The Engineer will supply the equipment specified in the Contract Documents.
781-8 Basis of Payment.
Price and payment will be full compensation for furnishing all materials and completing
all work as specified in this section or shown in the Plans.
Payment will be made under:
Item No. 781-2
Item No. 781-3
Item No. 781-4
Item No. 781-5
Highway Advisory Radio System - each.
Road Weather Information System - each.
Dynamic Message Sign - each.
Dynamic Message Sign Support Structure - each.
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SECTION 782
INTELLIGENT TRANSPORTATION SYSTEMS
VIDEO EQUIPMENT
782-1 CCTV Camera.
782-1.1 Description. Furnish and install a closed-circuit television (CCTV) camera at the
location(s) shown in the Plans. Ensure that the installed equipment provides unobstructed video
images of the roadway, traffic, and other current conditions around a roadside CCTV field site;
that it responds to camera control signals from the operator; and that the video images can be
transmitted to remote locations for observation.
782-1.2 Materials:
782-1.2.1 Camera: Furnish a CCTV camera that is compatible with the current
version of the Departments SunGuide software system, and any other camera operating
software indicated in the Plans or in the contract documents. Use either a dome-type or external
positioned-type CCTV camera assembly. Ensure that the appropriate type is used at the locations
shown in the Plans. Use only equipment and components that meet the requirements of these
minimum specifications, and are listed on the Departments Approved Product List (APL).
For analog cameras, ensure that the camera produces National Television
System Committee (NTSC) composite video output of 1 volt peak-to-peak (Vp-p) at 75 ohms
(). In addition, ensure analog and internet protocol (IP) cameras provide the following features
and capabilities:
1. Day (color)/night (monochrome) switchover and iris control,
with user-selectable manual and automatic control capabilities.
2. Minimum resolution of 470 horizontal and 350 vertical TV
lines.
3. Ability to produce clear, detailed, and usable video images of
the areas, objects, and other subjects visible from a roadside CCTV field site. Ensure that video
produced by the camera is true, accurate, distortion free, and free from transfer smear,
oversaturation, and any other image defect that negatively impacts image quality under all
lighting and weather conditions in both color and monochrome modes.
4. User-selectable automatic gain control (AGC) that is peakaverage adjustable to 30 decibels (dB).
5. A minimum signal-to-noise ratio of 50 dB.
6. Automatic color balance that references the white areas of the
scene through the lens.
7. An automatic electronic shutter that is user selectable from
1/60 to 1/10,000 of a second.
8. A digital signal processor that provides a minimum 10x digital
zoom.
9. Programmable azimuth and compass display with ability to
display pan and tilt position with a 1 degree resolution.
Furnish a CCTV camera that provides titling and masking features,
including, but not limited to, programmable camera title, programmable preset titles for each
preset position, and programmable privacy zones. Ensure that programmable titles are a
minimum of 18 characters per line.
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782-1.2.2 Lens: Ensure that the CCTV camera has a minimum 22x motorized
optical zoom lens with automatic iris. Ensure that the lens is capable of automatic and manual
focus and iris control. Ensure that the lens depth of field provides a clear image of roadside areas
under all lighting conditions and that the lens has a maximum aperture of at least f/1.6.
782-1.2.3 Pan/Tilt Mechanism for Dome-Type Cameras: Ensure that dometype CCTV cameras include an integrated pan/tilt mechanism capable of providing 360 degree
continuous pan with a minimum 90 degree tilt range (i.e., 0 degrees to minus 90 degrees);
provide variable speed control; have a preset position return accuracy of plus or minus
0.36 degree, or less than 0.10% or better; support a minimum of 64 presets; support a minimum
of one tour with a minimum of 32 presets; and support a minimum of eight programmable
blackout zones.
Ensure that the positioner within the dome-type CCTV camera has a
minimum automatic pan speed of 240 degrees per second to a preset camera position; that
maximum manual pan and tilt speeds are programmable; that the maximum manual pan speed
range is adjustable from 1 degree to a minimum of 80 degrees per second; and that maximum
manual tilt speed range is adjustable from 1 degree to a minimum of 40 degrees per second.
782-1.2.4 Pan/Tilt Mechanism for External Positioner-Type Cameras: Ensure
that external positioner-type CCTV cameras include a pan/tilt mechanism capable of providing
360 degree continuous pan with a minimum 115 degree tilt range (i.e., minus 90 to plus
25 degrees); provide variable speed control; have a preset position return accuracy of plus or
minus 0.36 degree, or less than 0.10% or better; and support a minimum of 32 presets.
782-1.2.5 Communication: Ensure that the CCTV camera supports the National
Transportation Communications for ITS Protocol (NTCIP) 1205 v1.08. Ensure that the camera is
capable of communication with other devices using Telecommunications Industry
Association/Electronic Industries Alliance (TIA/EIA)-232 or TIA-422 at a rate of 9600 bps,
transmission control protocol (TCP)/IP, or user datagram protocol (UDP)/IP. Ensure that the
CCTV camera supports the communication links shown in the Plans.
782-1.2.6 Electrical Specifications: Ensure that the CCTV camera system
operates using a nominal input voltage at the cabinet of 120 volts alternating current (VAC).
Ensure that the camera power supply will operate with an input voltage ranging from 89 VAC to
135 VAC.
Ensure that the CCTV camera and positioner operate at 24 VAC or
10 volts to 28 volts of direct current (VDC). If the camera or any camera-related ancillary device
requires operating voltages other than these, provide an appropriate voltage converter. Ensure
power consumption does not exceed 125 watts.
782-1.2.7 Mechanical Specifications: Provide camera housings and hardware
that are light in color or as noted in the Plans.
Ensure that the camera housing has a sunshield to reduce the solar heating
of the camera. Ensure that the total weight of dome type CCTV cameras (including the housing,
sunshield, and all internal components) is less than 17.0 pounds. Ensure that the lower dome of
the camera housing is distortion free clear plastic.
Ensure that pressurized dome-type housings are capable of pressurization
at 5 pounds per square inch (psi) using dry nitrogen, that they have a low-pressure alarm feature,
and carry a NEMA 4X/IP-67 rating.
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If a non-pressurized dome-type housing enclosure is used, ensure that the
unit is vented with a thermostat-controlled heater and blower. Ensure that the non-pressurized
enclosure has a NEMA 4/IP-66 rating.
Ensure that the total weight of external positioner-type CCTV cameras
(including housing, sunshield, all internal components, and external pan and tilt mechanism) is
less than 35 pounds.
782-1.2.8 Environmental Specifications: Ensure that the CCTV camera
performs all required functions during and after being subjected to an ambient operating
temperature range of minus 30F to 165 F, as defined in the environmental requirements section
of the NEMA TS 2 Standard. Verify that the CCTV camera manufacturer certifies its device has
successfully completed environmental testing as defined in the environmental requirements
section of the NEMA TS 2 Standard.
Ensure that the housing protects the camera and other internal components
from rain, dust, corrosive elements, and typical conditions found at a roadside environment.
Ensure that the CCTV camera, mounting hardware, and any other camera-related material that is
exposed to the environment can withstand 150 mph wind speeds and meet the requirements of
the Departments Structures Manual, Volume 9.
782-1.2.9 Additional Requirements for IP Cameras: The following sub-articles
provide additional requirements for IP-enabled cameras.
782-1.2.9.1 Video Encoding: The camera must utilize the Moving Picture
Experts Groups MPEG-2 video compression technology in accordance with the International
Organization for Standardization (ISO) and International Electrotechnical Commission (IEC)
requirements detailed in the ISO/IEC 13818 standard or the Moving Picture Experts Groups
MPEG4 part 10 (H.264) video compression technology in accordance with the ISO and IEC
requirements detailed in the ISO/IEC 14496-10:2009 Standard.
Ensure that the camera is capable of unicast and multicast operation, and
that it supports the Session Announcement Protocol (SAP) as recommended by the Internet
Engineering Task Force (IETF) RFC 2974, and Differentiated Services/Quality of Service
(DiffServ/QoS) software components. Ensure that the camera provides 99.999% error-free
operation. If the camera supports MPEG-2 encoding, ensure the encoded video can be
transmitted utilizing programmable bit rates from 1 Mbps to 8 Mbps. If the camera supports
H.264 encoding, ensure the encoded video can be transmitted utilizing programmable bit rates
from 64 kbps to 8 Mbps. Ensure the camera supports, at a minimum, fixed bit rate mode.
782-1.2.9.2 Encoded Video Interoperability: Ensure the cameras
encoded video is interoperable with hardware and software decoders from other manufacturers.
Ensure the cameras encoded video can be decoded by a minimum of two other manufacturers
software decoders and a minimum of two hardware decoders.
782-1.2.9.3 Encoded Video Specifications: Ensure that the cameras
encoded video supports resolutions that include, but are not limited to, those defined in
Table 1.1. Ensure that the camera is capable of delivering color and monochrome video at
30 frames per second (fps) regardless of resolution.
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Table 1.1 Resolution Requirements
Format
Resolutions
MPEG-2
352 x 240, 352 x 480, 720 x 480
H.264
176 x 120, 352 x 240, 720 x 480
Note: The resolutions attained depend on the data transmission rate.
782-1.2.9.4 Network Interface: Ensure that the cameras local area
network (LAN) connection supports the requirements detailed in the IEEE 802.3 Standard for
10/100 Ethernet connections. The camera shall have a minimum of one Ethernet port, which
shall be a 10/100 Base-TX connection. Ensure that the connector complies with applicable EIA
and TIA requirements.
Ensure that all unshielded twisted pair/shielded twisted pair network
cables are compliant with the TIA-568 Standard. Ensure that the network communication
conforms to TCP, UDP, Version 4 of the IP, real-time streaming protocol (RTSP), and Version 2
of the internet group multicast protocol (IGMP), at a minimum. Ensure the camera can be
controlled via NTCIP using either TCP/IP or UDP/IP.
782-1.2.9.5 Configuration Management: The camera shall support local
and remote configuration and management. Configuration and management functions shall
include access to all user-programmable features, including but not limited to, network
configuration, video settings, device monitoring, and security functions. Ensure that the camera
supports configuration and management via serial login, telnet login, or a web-based interface.
782-1.3 Installation Requirements: Install the CCTV camera on a pole in accordance
with Design Standards, Index Nos. 18100 through 18111 and as shown in the Plans.
Furnish and install the power supplies, local control equipment, and any other
camera-related field electronic equipment and transient voltage surge suppressors within a poleor base-mounted lockable cabinet. Ensure that the cabinet protects these electrical and electronic
devices from rain, dust, dirt, and other harmful elements of nature.
Furnish and install all power, video, and data cables necessary to provide
connection points for camera video and pan/tilt/zoom (PTZ) control signals within the cabinet.
Furnish and install any and all ancillary equipment required to provide a complete and fully
operational CCTV camera. Verify that all wiring meets National Electric Code (NEC)
requirements where applicable.
Ensure that data and video cables from the pole or support structure to the camera
are routed inside the mounting hardware and protected from exposure to the outside
environment.
Coat the exterior of the dome-type enclosures lower half with a clear, rain
repellant product prior to final acceptance.
782-1.4 Testing:
782-1.4.1 General: Subject the equipment covered by these specifications to a
field acceptance test (FAT). Develop and submit a test plan to the Engineer for review and
approval. Ensure that the test plan demonstrates each and every functional requirement specified
for the device or system under test. The Engineer reserves the right to witness all tests.
782-1.4.2 Field Test Requirements: Perform local field operational tests at
CCTV field sites according to the following:
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1. Verify that physical construction has been completed as specified in the
Plans.
2. Verify the quality and tightness of ground and surge protector
connections.
3. Verify proper voltages for all power supplies and related power circuits.
4. Verify all connections, including correct installation of communication
and power cables.
5. Verify that the video signal from the camera is present and of consistent
quality at all connection points between the camera, the cabinet, and any video devices therein.
6. Exercise PTZ and focus in all directions and execute a minimum of
three other unique programming commands to ensure that the communication link between the
cabinet and the camera is functioning properly.
782-2 Video Display Equipment.
782-2.1 Description. Furnish and install video display equipment as shown in the Plans.
782-2.2 Materials:
782-2.2.1 General: Use video display equipment that can display analog, digital,
and other images associated with the operation of the transportation management center (TMC).
These types of images include, but are not limited to:
1. CCTV video images, including feeds from other TMCs.
2. Video vehicle detection (VVD) system images.
3. System infrastructure mapping images.
4. Graphical user interfaces from computers running typical TMC
applications.
5. Weather mapping images.
6. Television broadcasts.
7. Digital video discs (DVDs), videocassette recordings, or other video
storage media.
Provide equipment, mounting hardware, cabling, and other video display
components that are compatible with each other. Ensure that all equipment and materials
furnished and installed are reviewed and approved by the Engineer.
Use display devices of the types shown in the Plans.
782-2.2.2 Video Display Control System: Furnish a video display control system
listed on the APL. Ensure that the video display control system enables the operator to control
and manage the display of video and computer-generated graphics on the display equipment
connected to the system as well as provide selection and switching of multiple sources for
display, including video streams available on the TMC Ethernet network. Ensure that the display
control system allows an operator to control all displays from the same workstation that is used
for the SunGuide operator interface. Ensure that the video display control system is capable of
decoding and displaying all video streams produced by encoders listed on the APL.
Use a video display control system capable of simultaneously displaying a
minimum of 32 video windows, each containing streaming video at a minimum resolution of
720 pixels x 480 pixels and frame rate of 30 (fps). Ensure that the system allows any display
window to be sized from 1/32 of the total display area up to the total display area, and any size in
between.
Ensure that the video display control system hardware is designed to be
rack mounted and secured in an EIA 19 inch equipment rack. Ensure that any system
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incorporating personal computer (PC) hardware utilizes current microprocessor technology and
commercial, off-the-shelf components, including random access memory (RAM), hard disk
drives, and network interface cards sufficient to provide the functional requirements of the
system.
782-2.2.2.1 Display Control Software: Provide display control software
that enables multiple operators to control all features and functions of the video display control
system. These features and functions include, but are not limited to, selection of video sources
for display; adjusting the size, location, and layout of video and other graphic information the
system displays; and system configuration and setup. Ensure that the control software is able to
operate a video wall composed of multiple display components as though it were a single, highresolution display.
Use display control software that is compatible with the
Departments SunGuide software system.
Ensure that the display control software includes a non-proprietary
software development kit (SDK) including, but not limited to, an application programming
interface (API) that describes interfaces and protocols which can be used to integrate system
features and functions with third-party applications.
782-2.2.2.2 Inputs and Outputs: Use a video display control system that
supports and displays a variety of video and data inputs simultaneously, including composite and
component National Television System Committee (NTSC) video, digital visual interface (DVI),
video graphics array (VGA), super video graphics array (SVGA), and super extended graphics
array (SXGA) computer graphics. Ensure that all inputs and outputs can be controlled by an
operator in order to display any or all of this information on any number of display devices
within the system. Ensure all inputs and outputs can be sized with and without constrained
proportions across multiple screens and moved at will around any display area and combination
of displays.
Ensure that the video display control system is expandable and
scalable to support any combination of inputs and outputs. Provide the video display control
system with a minimum configuration of 8 composite video inputs, 4 component (red, green, and
blue [RGB]) video inputs, 8 SXGA inputs, and 8 DVI inputs as well as network connections,
decoders, and associated hardware and software required to display 32 inputs simultaneously at a
minimum resolution of 720 pixels x 480 pixels and a frame rate of 30 fps, or as shown in the
Plans. Provide the video display control system with a minimum configuration of 4 composite
video outputs, 2 component (RGB video outputs), 4 SXGA outputs, and 4 DVI outputs, or as
shown in the Plans. Ensure the video display control system can be expanded to accommodate at
least 128 discreet inputs and outputs.
Ensure that a single input can be routed to multiple displays
simultaneously and that multiple inputs can be routed to a single display simultaneously for
viewing in separate windows. Ensure that all inputs and outputs are synchronized by the video
display control system and that switching between inputs or outputs does not cause displayed
images to unlock, roll, or otherwise exhibit visible distortion.
782-2.2.2.2.1 Analog Video: Ensure that the video display control
system is able to accept S-video, composite, and component video sources, and can digitize these
signals for manipulation and display on any display device attached to the system. Ensure that all
analog video inputs utilize BNC connectors.
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Ensure that analog video sources can be displayed within
their own windows, and can be resized up to or beyond their native resolution to conform to the
wall display size.
782-2.2.2.2.2 Digital Video: Ensure that the video display control
system is able to accept digital video sources, and can manipulate and display these signals on
any display attached to the system. Ensure that all digital video outputs utilize DVI connectors.
Ensure that each MPEG video stream can be displayed
within its own window, which shall be freely movable and sizable up to or beyond its native
resolution to conform to the wall display size.
782-2.2.2.2.3 RGB Video: Include an analog input that enables the
TMC operator to project an exact copy of his or her workstation desktop display on the video
wall display. Ensure that analog RGB inputs allow native images up to 1,280 pixels
by 1,024 pixels at 60 Hz to be displayed on the video wall.
Ensure that RGB inputs are sizable up to or beyond their
native resolution to conform to the wall display size.
782-2.2.2.2.4 Streaming Media: Ensure that the video display
control system can display a minimum of 32 compressed video streams simultaneously in
MPEG-2 over TCP/UDP/RTP over IP and supports multicasting as defined in Version 2 of the
Internet Gateway Message Protocol (IGMP). Ensure that the video display control system can be
upgraded to also accept MPEG-4 and H.264. Ensure that the MPEG video input interface is, at
minimum, a 10/100 megabit per second network port per every 15 streams.
782-2.2.2.2.5 Primary Display Output: Use a video display
control system that can process the various signal input types to be viewed, such as the RGB
feeds from monitor outputs and streaming video feeds. Ensure that the unit provides direct digital
streaming video through cable feeds using a digital video decoder. Ensure that the video display
control system provides the layout definitions for each signal to be displayed and saves the
predefined layouts. Ensure that the video display control system also permits switching of the
predefined layouts and accepts external alarm triggers to change the layouts.
Include output capacity with sufficient memory and
processing speed to provide fast rendering of video and image displays. Ensure that the output
has, at a minimum, a dual DVI connector that allows a digital connection of 1,280 horizontal
pixels by 1,024 vertical pixels or greater resolution. Ensure that the color depth is a minimum of
24 bits per pixel. If the projection device requires an analog signal, then breakout cables may be
used to convert the DVI output connector to a HD15 analog RGB connector.
782-2.2.2.2.6 Secondary Display Output: Provide an integrated,
secondary display system that accepts multiple layouts and signal types, such as video, RGB, or
serial data interface (SDI), for use on a single integrated display at the operator workstation. Use
a secondary display system consisting of the video display control system and the display device.
782-2.2.3 Video Wall Display: Furnish and install a video wall display consisting
of tiled, rear projection video display cubes arranged in a wall, as shown in the Plans, together
with a video display control system.
Ensure that the video wall display is capable of producing, at a minimum,
a large-scale, high-resolution video image having accurate color rendition, sufficient image
brightness, and a high contrast ratio, as described in 782-2.3. Ensure that the display system
provides access to serviceable components for repair and replacement of electronics, lamps, and
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optical components without removing the device from service for a period longer than
30 minutes.
Integrate the individual projection units in a single, seamless display
capable of projecting a continuous image across the entire active display area provided, under the
complete control of the TMC operators from their individual shared workstations.
Source all major wall display components from a single provider or
manufacturer to ensure that the various devices are compatible with each other and able to
function together as an integrated display.
Ensure that the individual video images exhibit a uniformity of color
quality across the multiple displays. Ensure that colors are displayed evenly across the video
wall, and that the video wall maintains uniform brightness characteristics from one video display
unit to the next in the tiled display, with no degradation in color or brightness uniformity over
time. Ensure that the video wall display provides features that allow physical and electronic
alignment of the separate high-resolution display units that comprise the wall.
782-2.2.4 Video Wall Support Structure: Furnish and install an aluminum or
steel-frame structure capable of supporting the rear projection video display units as mounted
and stacked to form the matrix for the video wall display. Ensure that the support structure
consists of stackable projection modules delivering a one-to-one relationship between the
number of projectors and the number of screens. Ensure that this structure maintains a consistent
maximum horizontal and vertical spacing of 0.04 inches between adjacent display units in the
video wall matrix.
Fabricate the support structure specifically to ensure that a continuous,
accurate image is projected on the screens without any distortion or unused screen space. Ensure
that no observable distortions are present in the installed video wall display due to normal
building vibration. Ensure that each completed structure is enclosed such that there is no ambient
light effect on the screen from behind the display.
Ensure that the components of the individual video modules can be
serviced without disturbing the integrity of the entire video wall display.
782-2.2.5 Rear Projection Video Display: Use rear projection video displays
that are suitable for digital video wall applications in mission-critical TMCs where video wall
image quality, operational reliability, and serviceability objectives as stated in this specification
can be achieved.
Use rear projection video displays capable of displaying a minimum of a
single or quad-split, four-paned CCTV camera video image. Ensure that each video display can
be independently controlled from any of the central operator or shift supervisor workstations, and
that each video display can be integrated with additional video units to form a single video
display, or a virtual desktop where video windows can be positioned and resized by the operator.
Ensure that the rear projection video display facilitates lamp replacement
without the need to readjust the image being projected on the screen.
Ensure that the rear projection video displays intensity is sufficient to
ensure effective and comfortable viewing by TMC operations personnel under normal lighting
conditions, subject to approval by the Department. Ensure that the units display engine produces
a minimum light output of 550 ANSI lumens.
Ensure that the rear projection video units have the following minimum
features and characteristics:
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1. Screen brightness achieved by a combination of projection
techniques and screen materials, so that the video display has a minimum brightness
measurement of 130 candelas per square meter (cd/m2) across the outside viewing surface of the
projection screen.
2. Brightness uniformity that meets or exceeds 80 percent across
the display unit, as measured using a photometer.
3. A multi-lamp optical engine must be provided for rear
projection video units that do not use light-emitting diodes (LEDs) for illumination. Multi-lamp
optical engines must provide a failover feature whereby a second lamp can be automatically
activated when the first lamp fails. Ensure displays with multi-lamp optical engines provide
indication of lamp status.
4. Multi-lamp optical engines must include (1) a hot standby
mode in which failover to the second lamp takes no more than two seconds and (2) a cold
standby mode in which failover and the time for the display to return to full light output does
not exceed 30 seconds.
5. A display module that utilizes modular component architecture
to permit service or replacement of serviceable parts without removing the projection engine.
6. Each unit shall be completely enclosed and light tight, with
fixed panels for access to the lamp, power supply, and projection engine.
782-2.2.6 Flat Panel Display: Furnish and install a flat panel display unit to
reproduce video and computer graphics information. Ensure that the device displays, at a
minimum, a high-resolution, distortion-free image and maintains a consistent level of
illumination across the entire screen area. Ensure that it has the following minimum features and
characteristics:
1. Dimensions of 24 inches high by 41 inches wide by 4 inches deep, or as
shown in Plans.
2. Ability to be installed on the face of a standard wall or flush mounted
within the wall system.
782-2.2.7 Cabling: Furnish each video display component with all required
appurtenances, including all the necessary cables, with proper length and connectors for power
and communication, as defined by the manufacturer. Ensure that cabling conforms to applicable
EIA/TIA standards. Size the power cables to meet NEC requirements. Provide communication
cables from each video display component to the network communication devices that are
appropriate for and compatible with the technology employed (e.g., fiber optic, twisted pair, or
coaxial), and meet the minimum size and bandwidth specifications the manufacturer requires.
Provide all cabling of adequate length, along with the compatible
connectors and any ancillary equipment necessary to fully interconnect the video components
and display control systems needed to achieve the functions required. Label all cables at both
ends, as approved by the Engineer.
782-2.2.8 Electrical Specifications: Provide equipment that operates on
120 VAC at a frequency of 60 Hz. Furnish a transformer or other necessary means of power
conversion for any device that requires another voltage or frequency.
Conduct TMC field reviews to examine the electrical distribution panels
allocated for various equipment items and the electrical schedules for each. Make any changes,
additions, or corrections to the electrical panels, wiring, outlets, and connectors that may be
deemed necessary to adequately power all of the equipment proposed for a video display project
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at the intended location, subject to the approval of the Engineer. Make any changes to the
buildings electrical wiring in accordance with applicable codes and permits, and with the NEC.
Have any modifications to an existing buildings wiring or the video wall electrical wiring plans
signed and sealed by a Specialty Engineer, as defined in 1-3.
782-2.3 Performance Specifications: Use only display devices meeting the following
minimum requirements.
Rear Projection
Flat Panel Display
Video Display
Type
Direct View LCD
Plasma
DLP or LCD
Size
(dependent on TMC design, as shown in Plans)
1280 x 768
1600 x 1200 / 1280 x 768 pixels; 16.7
1024 x 768
Resolution
pixels; 16.7
million colors
pixels
million colors
Aspect Ratio
4:3
16:9
16:9
4:3
170 degrees
160 degrees
160 degrees
160 degrees
Viewing Angle
horizontally and
horizontally
horizontally
horizontally
vertically
and vertically and vertically and vertically
40 degrees
Half Gain Angle
horizontally
and vertically
Contrast Ratio
500:1
600:1
600:1
600:1
Screen Brightness *
250 cd/m2
450 cd/m2
400 cd/m2
130 cd/m2
8,000 hrs.
Lamp Life
(avg.)
Composite
Composite
video (NTSC, video (NTSC,
Composite
PAL) on RCA PAL) on RCA
video (NTSC,
connector; S- connector; SPAL) on BNC;
video (NTSC, video (NTSC,
S-video
PAL
PAL
Analog/digital via 15(NTSC, PAL)
compliant) on compliant) on
pin D-sub (HD-15)
on mini DIN 4Video Inputs
mini 4-pin
mini 4-pin
connector; DVI-D
pin connector;
connector;
connector;
connector.
RGB via 15analog/digital analog/digital
pin HD D-sub
via 15-pin D- via 15-pin Dconnectors;
sub (HD-15) sub (HD-15)
DVI-D
connector;
connector;
connectors.
DVI-I
DVI-I
connector.
connector.
Operating Temperature
32 to 95F.
32 to 95F. 20 32 to 95F. 20 32 to 95F. 20
and Humidity
20 to 80%.
to 80%.
to 80%.
to 80%.
120 VAC at 60 120 VAC at 60 120 VAC at 60
Power Requirements
120 VAC at 60 Hz
Hz
Hz
Hz
* Measured using a photometer.
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782-2.4 Installation Requirements: Do not proceed with any part of the procurement,
construction, or installation of the video display equipment until the Construction Plans and
materials are approved by the Engineer. Provide the Engineer with submittal documentation,
including the manufacturers product specification sheets and a detailed description of each
items function as well as a compliance matrix that confirms all equipment meets or exceeds the
requirements of these specifications.
Configure each video display unit to provide individual, independent control from
each operator workstation.
Create the video wall display by arranging individual video display units in a
framework or apparatus that creates the video wall configuration as shown in the Plans. Ensure
that the finished video wall provides a single, apparently seamless display area. Ensure that
adjacent individual display units are aligned physically and electronically so that image content
stretched across multiple monitors align within plus or minus 2 lines of horizontal and vertical
resolution.
Ensure that all rear projection video unit controls are accessible at all times when
the devices are permanently installed. Ensure that installation and positioning does not conceal or
limit access to any display unit controls at any time during active use.
Follow proper ventilation and cooling procedures for the equipment installed, as
determined by the equipment manufacturers. Provide electrical requirements and power
distribution units and power supplies for the video display components on an as-needed basis.
782-2.5 Testing:
782-2.5.1 General: Submit a detailed system acceptance test plan to the Engineer
for review and approval. Prepare a test plan that covers all areas of system function described in
this section, and that is developed according to the various equipment manufacturers
recommendations.
Check and test the satisfactory operation of all video display components
upon completion of the equipments installation. At minimum, include in the video display
system test the testing of each color video monitor type, each secondary display output at
workstations, each rear projection video display unit, and the video wall displays image
alignment and control functions.
782-2.5.2 Observation Period: Subject the video wall display to a 90 day
operational observation period, during which time the Contractor shall perform any and all
maintenance, recalibration, system checking, and display modifications required by the Engineer.
The Engineer has the option to require a restart of the observation period if a major system flaw
or failure occurs.
782-3 Warranty.
782-3.1 General: Ensure that CCTV cameras and video display equipment have a
manufacturers warranty covering defects for a minimum of three years from the date of final
acceptance by the Engineer in accordance with 5-11 and Section 608. Ensure that the warranty
requires the manufacturer to furnish replacements for any part or equipment found to be
defective during the warranty period at no cost to the Department or the maintaining agency
within 10 calendar days of notification.
Replace any operational support supplies used during this warranty period at no
additional cost to the Department. Warranty repairs of the video display control system and
related TMC display equipment must commence within 24 hours after notification by the
Department.
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782-3.2 Operational Support Supplies: Furnish a supply of replacements for all video
wall display parts that might reach the end of their useful life or require replacement within the
warranty period. Provide operational support supplies upon delivery and prior to acceptance of
the video wall display system.
Assemble the operational support supply kit according to the wall display and
associated subsystem manufacturer recommendations, but ensure that it contains at least one unit
of each system component that may require replacement during the warranty period, including
printed circuit boards and projection lamps. Submit the operational support supply kit for review
and approval of the Engineer.
782-4 Method of Measurement.
782-4.1 General: Measurement for payment will be in accordance with the following
tasks.
782-4.2 Furnish and Install: The Contract unit price for each CCTV camera or video
display device or system, furnished and installed, will include furnishing, placement, and testing
of all equipment and materials, and for all tools, labor, operational software packages and
firmwares, supplies, support, personnel training, shop drawings, documentation, and incidentals
necessary to complete the work.
The video display equipment shall be measured as each major system component
is furnished, installed, made fully operational, and tested in accordance with this Specification or
as directed by the Engineer.
782-4.3 Furnish: The Contract unit price per CCTV camera or video display device or
system, furnished, will include all equipment specified in the Contract Documents, plus all
shipping and handling costs involved in delivery as specified in the Contract Documents.
782-4.4 Install: The Contract unit price per CCTV camera or video display device or
system installed will include placement and testing of all materials and equipment, and for all
labor, equipment, hardware, and incidentals necessary to complete the work. The Engineer will
supply the equipment specified in the Contract Documents.
782-5 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 782-1CCTV Cameraeach.
Item No. 782-2Video Displayeach.
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SECTION 783
INTELLIGENT TRANSPORTATION SYSTEMS
FIBER OPTIC CABLE AND INTERCONNECT
783-1 Fiber Optic Cable System.
783-1.1 Description. Furnish and install a fiber optic cable system as shown in the Plans.
783-1.2 Materials:
783-1.2.1 Fiber Optic Cable: Provide all-dielectric, dry-filled, loose-tube,
dispersion- unshifted, single-mode fiber (SMF) with low water peak, gel free, and suitable for
underground (i.e., in conduit) and aerial outside plant installation. All fiber optic cable shall be
splice-compatible with the Departments existing dispersion-unshifted SMF and require no
electronic equipment for dispersion compensation between new and existing fiber. Ensure that
all components that comprise a single length of cable are continuous and of the same material.
Furnish only commercial off-the-shelf materials, equipment, and components.
783-1.2.1.1 Optical Fiber: Ensure that the optical fibers used in the cable
meet or exceed the Telecommunications Industry Association (TIA) and Electronic Industries
Alliance (EIA) TIA/EIA-492-CAAB specification, the U.S. Department of Agriculture Rural
Utilities Service (RUS) 7 CFR 1755.900, and International Telecommunication Union ITU-T
G.652.D requirements. Use only optical fibers meeting the additional requirements as follows:
Geometry
Cladding Diameter: 125m, 0.7 m
Core-to-Cladding Concentricity: 0.5 m
Cladding Noncircularity: 0.7%
Mode Field Diameter: 1,550 nm; 10.4 m, 0.5 m
Coating Diameter: 245 m, 5 m
Colored Fiber Nominal Diameter: 250 15 m
Optical
Cabled Fiber Attenuation: 1,310 nm, 0.4 dB/km; 1,550 nm, 0.3 dB/km
Point Discontinuity: 1,310 nm, 0.05 dB/km; 1,550 nm, 0.05 dB/km
Cable Cutoff Wavelength ( ccf ): 1,260 nm.
Total Dispersion: 1,625 nm 23.0 ps/(nmkm)
Macrobend Attenuation: Turns 100; Outer diameter (OD) of the mandrel 60 mm, 2 mm;
0.05 dB at 1,550 nm
Cabled Polarization Mode Dispersion: <0.5 ps km
Ensure that each optical fiber is glass and consists of a
germania-doped silica core surrounded by concentric silica cladding. Ensure that all fiber in the
buffer tube is usable fiber that complies with attenuation requirements. Ensure that fibers do not
adhere to each other. Ensure that the fiber is free of surface imperfections and inclusions. Ensure
that all fiber optic core glass is from the same manufacturer.
783-1.2.1.2 Buffer Tubes: Ensure that the fiber optic cable includes loose
buffer tubes that isolate internal optical fibers from outside forces and provide protection from
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physical damage as well as water ingress and migration. Ensure that buffer tubes provide
freedom of movement for internal optical fibers. Ensure buffer tubes allow for expansion and
contraction of the cable without damage to internal optical fiber. Ensure that fiber does not
adhere to the inside of the tube. Ensure that buffer tubes permit intentional scoring and breakout
without damage to the fiber. Ensure that each fiber optic cable buffer tube contains 12 fibers per
tube unless otherwise noted in the Plans.
783-1.2.1.3 Color Code: Ensure that the marking and color-coding of the
fibers and buffer tubes conforms to telecommunication industry requirements as detailed in the
TIA/EIA-598-B standard.
Ensure that colors are permanent and stable during temperature
cycling, and not subject to fading or smearing onto each other or into the water-blocking
material. Ensure that fibers are colored with UV curable inks that remain clearly distinguishable
as the intended color.
783-1.2.1.4 Strength Member: Ensure that the fiber optic cable contains
a dielectric central strength member and dielectric outside strength member to prevent buckling
of the cable and provide tensile strength. Ensure that the fiber optic cable can withstand a pulling
tension of 600 lbs. without damage to any components of the fiber optic cable.
783-1.2.1.5 Water Blocking Compound: Ensure that the fiber optic cable
contains a dry water-blocking material to prevent the ingress of water within the outer cable
jacket. Ensure that water-blocking materials are non-nutritive, dielectric, and homogeneous, and
free from dirt and foreign matter. Use dry water-blocking material for fiber optic cables used for
either aerial or underground installations. Apply dry water-blocking compound longitudinally
around the outside of the central buffer tubes. Construct all cables with water-blocking material
that complies with the requirements of the EIA/TIA-455-81B standard and is subjected to water
penetration tests as defined in the EIA/TIA-455-82B standard.
783-1.2.1.6 Ripcord: Ensure that the cable contains at least one ripcord
under the sheath. Ensure that the ripcord permits the removal of the sheath by hand or with
pliers.
783-1.2.1.7 Filler: Fillers or rods may be included in the cable core to
lend symmetry to the cable cross section if required.
783-1.2.1.8 Outer Jacket: Ensure that the fiber optic cable is jacketed
with medium density polyethylene (MDPE) that is free of blisters, cracks, holes, and other
deformities. Ensure that the nominal jacket thickness is a minimum of 0.03 inches. Apply the
jacketing material directly over the tensile strength members and water-blocking material.
Ensure that the MDPE contains carbon black to provide UV protection and does not promote the
growth of fungus.
Mark the jacket with the cable manufacturers name, fiber type,
fiber count, date of manufacture, the words FDOT FIBER OPTIC CABLE, and the sequential
cable lengths marked in feet. Ensure that the actual length of the cable is within 1% of the length
indicated by the marking. Provide legible marking with contrasting color to that of the cable
jacket.
783-1.2.1.9 Performance Requirements:
783-1.2.1.9.1 Operating Temperature: Ensure that the shipping
and the operating temperature range of fiber optic cable meets or exceeds minus 30 to 158 F.
Ensure that the installation temperature range of fiber optic cable meets or exceeds minus 22 to
140 F.
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783-1.2.1.9.2 Bend radius: Ensure that the fiber optic cable is
capable of withstanding a minimum unloaded bend radius of 10 times the cable diameter and a
minimum loaded bend radius of 20 times the cable diameter when loaded to pulling tension of
600 pounds. Test the cable as required in the EIA-455-33A standard. Ensure that bending the
fiber optic cable up to the minimum bend radius does not affect the optical characteristics of the
fiber.
783-1.2.1.9.3 Cable Strength: Ensure that the fiber optic cable is
capable of withstanding a pulling tension of 600 pounds during installation without increasing
the fiber attenuation more than 0.8 decibel per mile and without changing other optical fiber
characteristics after the tensile load is removed. Ensure that optical fiber is proof-tested by the
fiber manufacturer at a minimum of 100 kilo pounds per square inch. Ensure that the cable will
withstand 25 impact cycles and the change in attenuation does not exceed 0.2 decibel at
1,550 nanometers when tested according to the requirements as detailed in the TIA/EIA-455-25B
standard. Ensure that the fiber optic cable can withstand a minimum compression load of
125 pounds per square inch when applied uniformly over the length of the sample at the rate of
0.15 inches to 0.8 inches per minute and maintained for 10 minutes as defined in the TIA/EIA455-41A standard. Ensure that the change in attenuation will not exceed 0.15 decibel during
loading at 1,550 nanometers, and that no fiber displays a measurable change in attenuation after
load removal.
783-1.2.1.9.4 Water Penetration: Ensure that the fiber optic cable
is capable of withstanding the tests for water penetration defined in the TIA/EIA-455-82
standard. Ensure that a one-meter length of cable is able to withstand a one-meter static head of
water applied at one end for 24 hours without water leaking through the other open cable end.
783-1.2.2 Splicing Materials: Ensure that all splice enclosures, organizers, cable
end preparation tools, and procedures are compatible with the fiber optic cable, and are approved
by the Engineer.
783-1.2.2.1 Splice Enclosures: Contain all optical fiber splices within a
splice enclosure. Ensure that the enclosures provide storage for fiber splices, nonspliced fiber,
and buffer tubes. Ensure that the splice enclosure restores the mechanical and environmental
integrity of the fiber optic cable, encases the sheath opening in the cable, and organizes and
stores optical fiber. Ensure all hinges and latching devices are stainless steel. Ensure that the
enclosure is airtight and prevents water intrusion. Ensure that the splice enclosure can
accommodate pressurization and has the ability to be reentered without requiring specialized
tools or equipment. Ensure that the enclosure provides fiber and splice organizers including
splice trays and strain relief.
Ensure that splice enclosures allow re-entry and are hermetically
sealed to protect internal components from environmental hazards such as moisture, insects, and
UV light. Fiber optic splice enclosures shall also:
Comply with the Telcordia Technologies GR-711-CORE standard
and all applicable NEC requirements.
Provide space for future expansion equal to 100% of the initial
utilization.
Provide fiber optic cable penetration end caps to accommodate a
minimum installation of two trunk fiber optic cables and two fiber optic drop cables. Ensure that
the enclosure end caps are factory-drilled to the proper diameter to accept and seal the fiber optic
cable entries. Ensure that the cable entry locations can accommodate an assortment of cables
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with outside diameters ranging from 0.45 inches to 0.55 inches, plus 10%, without jeopardizing
the waterproof characteristics of the enclosure.
Provide fiber optic splice enclosures meeting the following
requirements:
Mechanical
Resist compression deformation to a maximum of 400 pounds.
Withstand an impact energy to a maximum of 40 foot-pounds at 0 F.
Axial Tension: 100 pounds for 30 minutes.
Cable Torsion: ten 90-degree rotations.
Cable Flexing: ten 90-degree bends.
Environmental
Hydrostatic Pressure Head: Up to 20 foot-pounds (-9 pounds per square inch).
Withstand 40 freeze/thaw temperature cycles.
Ultraviolet resistant during a maximum 30-day exposure in compliance with the requirements
detailed in the ASTM B117 standard.
Chemical
Withstand a 90-day exposure to solutions of 3% sulfuric acid, 0.2 normal of sodium hydroxide,
10% Igepal, kerosene, and be fungus resistant as required in the ASTM G21 standard.
783-1.2.2.2 Splice Trays: Ensure that the splice trays are securely
attached and accessible, and provide adequate storage for the fiber cable. Ensure the splice trays
provide access to individual fibers without disrupting other fibers in the tray. Ensure that the
splice trays hold the buffer tubes rigidly in place and provide protection for fusion splices.
Ensure that the raceway accommodates the minimum bend radius of the fiber. Ensure that splice
trays allow visible inspection of the fiber. Ensure that the splice tray includes a cover with a
locking mechanism to hold it in place.
783-1.2.3 Cable Terminations: Use Type ST, SC, LC, or FC connectors only, as
specified in the Plans or by the Engineer. Ensure that all ST-type fiber optic connectors, whether
factory pre-terminated or field-installed, are 0.1 inch physical contact with preradiused tips.
Ensure that ST and FC connectors include a ceramic ferrule and a metallic body, and provide a
strain relief mechanism when installed on a single fiber cable that contains strength elements.
Ensure that the ST-type connector provides a minimum 50 pound pullout strength. Ensure that
the optical fiber within the body of all connectors is mechanically isolated from cable tension,
bending, and twisting.
Ensure that all connectors are compliant with the TIA/EIA-568-A and
TIA/EIA-604 standards, as applicable, and are tested according to the Telcordia/Bellcore GR326-CORE standard. When tested according to the TIA and EIAs Fiber Optic Test Procedure
(FOTP)-171 (TIA/EIA-455-171), ensure that the connectors test to an average insertion loss of
less than or equal to 0.4 decibel and a maximum loss of less than or equal to 0.75 decibel. Test
the connectors as detailed in FOTP-107 (TIA/EIA-455-107) to reflectance values of less than or
equal to minus 50 decibels.
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Ensure that the ST-type connectors have an operating and storage
temperate range of minus 30 to 165F as per the NEMA TS 2 standard.
783-1.2.3.1 Pre-terminated Connector Assemblies (Pigtails): Ensure
that pre-terminated connector assemblies are used for fiber termination. Ensure that the preterminated cable assemblies consist of fiber optic cables with factory-installed ST-type
connectors on one end of the cable and an un-terminated optical fiber on the other. Ensure that
the pre-terminated connector assemblies are installed with fusion splices. Ensure that all buffer
tubes and fibers are protected once the attachment of pre-terminated connector assemblies is
complete.
783-1.2.3.2 Buffer Tube Fan-out Kits: Ensure that a buffer tube fan-out
kit is installed when fiber optic cables are terminated. Use a kit compatible with the fiber optic
cable being terminated and that is color-coded to match the optical fiber color scheme. Ensure
that the buffer tube fan-out kit supports 12 fiber strands. Ensure that output tubing and the fiber
strands contained therein are of sufficient length for routing and attachment of fiber optic cable
to connected electronics or as directed by the Engineer. Ensure that the kit and the connectors are
supplied by the same manufacturer.
783-1.2.4 Patch Panels: Ensure that the patch panel is compatible with the fiber
optic cable being terminated and color coded to match the optical fiber color scheme. Ensure that
the patch panel has a minimum of 12 ST type panel connectors. Ensure that the patch panel
dimensions do not exceed 14 inches x 6 inches x 4 inches for fiber counts of twelve or less.
Ensure the patch panel is suitable for mounting within an approved cabinet at the field device
location. Ensure patch panels are sized to accommodate specified coupler housings and maintain
sufficient bend radius for cables to maintain their specified optical performance. Ensure the patch
panel is sized to occupy the minimum space required to adequately accommodate fiber capacity.
783-1.2.4.1 Pre-terminated Patch Panels: Ensure that the pre-terminated
patch panel is a termination panel that includes a factory installed all-dielectric SMF cable stub.
Ensure that the panel includes factory installed and terminated ST-type panel connectors. Ensure
that the cable stub is of adequate length to splice the stub and provide a fiber connection between
the panel and the backbone fiber cable or as directed by the Engineer.
783-1.2.4.2 Field Assembled and Terminated Patch Panels: Ensure that
the field-assembled patch panel is a termination panel that includes a connector panel and the
hardware required to mount the patch panel within an approved cabinet at the field device
location and connect the panel to the backbone fiber cable.
783-1.2.4.2.1 Connector Panel: Ensure that the connector panel
provides 12 ST-type, bulkhead-mount coupling connectors. Ensure that each coupling connector
allows connection of a cable terminated on one side of the panel to a cable on the opposite side.
Ensure that each bulkhead-mount coupling connector
includes a locknut for mounting the connector in predrilled or punched holes in the connector
panel.
783-1.2.5 Handling:
783-1.2.5.1 Cable End-Sealing: Ensure that fiber optic cable ends are
capped or sealed to prevent the entry of moisture during shipping, handling, storage, and
installation. Equip one end of the fiber optic cable with flexible pulling eyes.
783-1.2.5.2 Protective Wrap: Ensure that the fiber optic cable is shipped
and stored with a protective wrap or other approved mechanical reel protection device over the
outer turns of the fiber optic cable on each reel. Ensure that the wrap is weather resistant and
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protects the cable reel from environmental hazards. Ensure that the cable reel remains wrapped
until cable is to be installed.
783-1.2.5.3 Packaging, Shipping and Receiving: Ensure that the
packaging and delivery of fiber optic cable reels comply with the following minimum
requirements:
1. Ensure cable is shipped on reels of marked continuous length.
2. Ensure each cable is shipped on a separate, strongly constructed
reel designed to prevent damage to the cable during shipment and installation.
3. Ensure each reel has a minimum of 6 feet on each end of the
cable available for testing.
4. Ensure that all fiber optic cable is continuous and free from
damage.
5. Ensure no point discontinuities greater than 0.1 decibel per reel.
6. Ensure that all cable delivered has been manufactured within
6 months of the delivery date.
7. Provide a copy of the transmission loss test results as required
by the EIA/TIA-455-61 standard, as well as results from factory tests performed prior to
shipping.
8. Ensure that the manufacturer provides the date of manufacture;
product and serial numbers; cable data, including the reel length; refraction index; the project
name and location; type of fiber and quantity of strands used; technical product data sheets; and
reel numbers.
783-1.3 Installation: Install all equipment according to the latest version of the
manufacturers installation procedures and the industry-accepted installation standards, codes,
and practices, or as directed by the Engineer. Ensure that all materials and installation practices
are in accordance with the applicable OSHA requirements as found in 29 Code of Federal
Regulations (CFR) Part 1926, Safety and Health Standards for Construction. In addition, perform
the following:
1. Ensure conduit and inner-duct is clean and free from damage prior to installing
fiber optic cable.
2. Document the sequential cable length markings at each splice box and pull box
wall that the cable passes through, and include the information with the as-built documentation.
Provide all incidental parts needed to complete the installation, but not specified
in the Plans, as necessary for a complete and properly operating system.
783-1.3.1 Fiber Optic Cable Installation: Develop a nomenclature plan for
identification of fiber optic cable. Submit the nomenclature plan to the Engineer for approval.
Use approved cable nomenclature to create cable tags for the identification of fiber optic cable.
Provide cable tag identification on all test results or fiber related documents provided to the
Engineer.
Install cable tags within 1 foot of each splice and/or termination point
indicating the cable type, fiber count, and each fiber optic cables origination and termination
points. Ensure that the cable tags are permanent labels suitable for outside plant applications and
are affixed to all fiber optic cables. Ensure that lettering is in permanent ink and displays the
phrase FDOT FIBER OPTIC CABLE.
783-1.3.1.1 Pulling: Install the fiber optic cable by hand or by using a
mechanical pulling machine. If a mechanical pulling machine is used, equip the machine with a
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monitored or recording tension meter. Ensure that at no time the manufacturers recommended
maximum pulling tension is exceeded. Ensure that the central strength member and aramid yarn
are attached directly to the pulling eye during cable pulling. Use pulling attachments, such as
basket grip or Chinese finger type, to ensure that the optical and mechanical characteristics
are not degraded during the fiber optic cable installation.
Ensure that excess cable is coiled in a figure eight and fed
manually when pulling through pull boxes and splice boxes by hand. If pulleys and sheaves will
be used to mechanically pull through pull boxes and splice boxes, provide a drawing of the
proposed layout showing that the cable will never be pulled through a radius less than the
manufacturers minimum bend radius. Use large diameter wheels, pulling sheaves, and cable
guides to maintain the appropriate bend radius. Provide tension monitoring at all times during the
pulling operation. Ensure that cable pulling lubricant used during installation is recommended by
the optical fiber cable manufacturer.
783-1.3.1.2 Blowing: Use either the high-airspeed blowing (HASB)
method or the piston method. When using the HASB method, ensure that the volume of air
passing through the conduit does not exceed 600 cubic feet per minute or the conduit
manufacturers recommended air volume, whichever is more restrictive. When using the piston
method, ensure that the volume of air passing through the conduit does not exceed 300 cubic feet
per minute or the conduit manufacturers recommended air volume, whichever is more
restrictive.
783-1.3.1.3 Slack Cable Storage: Provide and store fiber optic cable at
each pull box and splice box to allow for future splices, additions, or repairs to the fiber network.
Store the fiber optic cable without twisting or bending the cable below the minimum bend radius.
Store a total of 200 feet of fiber optic cable in splice boxes, with
100 feet of cable on each side of the cable splice point or as shown in the Plans.
Store 50 feet of spare fiber optic cable in pull boxes.
783-1.3.2 Splicing: Perform all optical fiber splicing using the fusion splicing
technique, and according to the latest version of the manufacturers cable installation procedures;
industry-accepted installation standards, codes, and practices; or as directed by the Engineer.
Ensure that all splices match fiber and buffer tube colors unless shown otherwise in the Plans.
Where a fiber cable is to be accessed for lateral or drop signal insertion, only open the buffer
tube containing the fiber to be accessed and only cut the actual fiber to be accessed. If a fiber end
is not intended for use, cut the fiber to a length equal to that of the fiber to be used and neatly lay
it into the splice tray. Treat any fibers exposed during splicing with a protective coating and
place in a protective sleeve or housing to protect the fiber from damage or contaminants.
783-1.3.2.1 Splice Plan: Provide a splice plan showing the location and
configuration of splices in the system for approval by the Engineer. Perform all splicing
according to the plan. Document each splice location and identify the source and destination of
each fiber in each splice tray. Document all fiber colors and buffer jacket colors used during
installation, and develop a sequential fiber numbering plan as required in the TIA/EIA-598-A
standard for color-coding in the documentation.
Neatly store all splice enclosures within a splice box. Attach the
splice enclosure to the splice box interior wall to prevent the enclosure from lying on the bottom
of the splice box.
783-1.3.2.2 Splice Equipment Specifications: Use a fusion splice
machine to splice all optical fiber. Ensure that the unit is portable, and capable of 120 VAC and
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internal battery-powered operation. Ensure that the unit is able to splice fibers with a
250 micrometer coating. The fusion splice machine shall have the following capabilities:
1. Splice loss measurement.
2. Splice protection sleeve heater.
3. Battery with charging unit and power cable.
4. Spare electrodes, fuses, and lamps.
5. Power meter/light source with carrying case.
Ensure that the power meter/light source is a calibrated pair that is
portable and battery operated. Ensure that the power meter/light source operates at selectable
wavelengths of 850/1,300/1,550 nanometers. Ensure that the power meter has a decibel milliwatt
measurement scale with a range of plus 3 to minus 45 decibel milliwatts for SMF operation and
an accuracy of 0.5 decibel or better.
Ensure that the splice machine is new from the factory, or serviced
and certified by the factory or its authorized representative within the previous 6 months from
the commencement of its use. Provide the Engineer with a letter from the manufacturer or his
authorized representative certifying compliance. Clean all splicing equipment and calibrate
according to the manufacturers recommendations prior to each splicing session at each location.
783-1.3.3 Cable Termination Installation: Ensure that cables, buffer tubes, or
strands are neatly routed, secured and terminated in a patch panel. Ensure all cable termination
points include documentation regarding the identification, route, and function of each fiber
installed at that location. Ensure that at least one copy of this information is placed alongside the
installed equipment (for instance, in a document pouch or drawer within a field cabinet).
783-1.3.4 Patch Panel Installation: Ensure that patch panels neatly installed and
secured in a weather proof enclosure. Ensure all patch panel connectors are clearly and
permanently labeled. Ensure all installed patch panels include documentation regarding the
identification, route, and function of each patch panel connector at that location. Ensure that at
least one copy of this information is placed alongside the installed equipment.
783-1.4 Testing and Certification:
783-1.4.1 Manufacturers Testing: Provide documentation of all factory tests
performed by the manufacturer for all fiber optic cable, splicing material, cable terminations, and
patch panels.
783-1.4.2 Installation Testing: Notify the Engineer of cable testing at least
14 calendar days in advance. Provide the testing procedures to the Engineer for approval prior to
commencement of testing. Perform all tests at 1,310/1,550 nanometer wavelengths, and include
the last calibration date of all test equipment with the test parameters set on the equipment in the
test documentation. Test all installed fibers (terminated and un-terminated) using methods
approved by the Engineer.
783-1.4.2.1 End to End Attenuation Testing: Perform testing on all
fibers to ensure that end to end attenuation does not exceed allowable loss (0.4 db/km for
1310nm wavelength, 0.3 db/km for 1550nm wavelength, plus 0.5 db for any connectors and
0.1 db for splices). Repair or replace cable sections exceeding allowable attenuation at no cost to
the Department.
783-1.4.2.2 OTDR Tracing: Test all fibers from both cable end points
with an optical time domain reflectometer (OTDR) at wavelengths of 1310 and 1550nm. Test the
fibers that are not terminated at the time of installation using a bare fiber adapter. Present the
results of the OTDR testing (i.e., traces for each fiber) and a loss table showing details for each
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splice or termination tested to the Engineer in an approved electronic format. Ensure all OTDR
testing complies with the EIA/TIA-455-61 standard.
783-1.4.2.3 Splice Loss Testing: Ensure that the splice loss for a SMF
fusion splice does not exceed a maximum bidirectional average of 0.1 decibel per splice. Repair
or replace splices that exceed allowable attenuation at no cost to the Department.
783-1.4.2.4 Connector Loss Testing: Ensure that the attenuation in the
connector at each termination panel and its associated splice does not exceed 0.5 decibel. Repair
or replace connectors exceeding allowable attenuation at no cost to the Department.
783-2 Conduit and Locate System.
783-2.1 General: Furnish and install conduit and a locate system for fiber optic cable.
Ensure that the conduit complies with the requirements of Section 630.
Place the locate system along any underground conduit installation. Ensure that
the locate system includes aboveground route markers, warning tape, tone wire, and electronics
that allow detection of buried conduit and other related underground facilities.
Furnish and install a system as shown in the Plans and as directed by the
Engineer. Ensure that the locate system provides:
1. An end-to-end electrical conductor, such as a locate wire, buried along
the conduit system for conductive facility locating.
2. Visual notification of the presence of conduit installed on Department
projects.
3. Public notification of potential hazards and contact information for
public or private inquiries regarding the conduit system.
4. A means of locating any conduit system pull box or splice box that is
buried.
5. Surge protection and dissipation of transient voltages that may be
induced into the route marker system.
783-2.2 Materials:
783-2.2.1 Route Markers: Mark the location of the conduit system with rigid
sign posts known as route markers. Use route markers of the type shown in the Plans and
approved by the Engineer. Route markers may be either a Standard Route Marker (SRM) type or
an Electronic Route Marker (ERM) type. The SRM is a rigid, tubular, driven post used for
location and notification purposes only. The ERM should be physically identical to the SRM, but
also include a termination board to provide aboveground access to locate wire buried alongside
conduit and cable runs.
Ensure that each SRM is labeled and identified as an FDOT fiber optic
cable marker as shown in the Plans and approved by the Engineer. Ensure that labels include the
Departments logo, contact information for the local FDOT District, and a telephone number to
call prior to any excavation in the area. Ensure that the identification information is permanently
imprinted on the top fitting, and will not peel, fade, or deteriorate with prolonged exposure to the
typical roadside environmental hazards. Ensure that all route markers used on the project are new
and consistent in appearance.
783-2.2.1.1 Standard Route Marker: Ensure that the SRM post is white
with a top fitting cover that is orange with white lettering and graphics. Ensure that the SRM is a
tubular configuration, and both the marker post and the top fitting are made from virgin
Type 111 high-density polyethylene (HDPE). Ensure that any fasteners used with the SRM are
constructed of stainless steel.
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Ensure that all SRMs have a minimum outside diameter of
3.5 inches with a minimum 0.125 inch wall thickness. Ensure that the top fitting cover is a
minimum of 1.5 feet long and has an outside diameter of 3.75 inches with a 0.125 inch wall
thickness. Ensure that each SRM provides a tensile strength of 4,200 pounds per square inch as
required in the ASTM D638 standard. Ensure that each SRM is manufactured for use in
temperatures range of minus 30 to 165F as per the NEMA TS 2 standard.
Ensure that each SRM can withstand 70 foot-pounds of impact
force at 32F as required in the ASTM D2444 standard before and after UV conditioning for
2,000 hours as required in the ASTM G53-88 standard. Ensure that the control sample of any
material employed maintains a minimum of 70% of its original tensile strength as required by the
ASTM D638 standard.
Ensure that an SRM installed at the minimum 2 foot depth
withstands at least one vehicle impact at 45 miles per hour by a car or truck weighing no less
than 3,500 pounds. After impact, ensure that the post returns to an upright position within
10 degrees of vertical alignment within 30 seconds from the time of impact. Ensure that all
SRMs withstand a 12-gauge shotgun blast without penetration by any pellets when fired from a
50 foot distance.
783-2.2.1.2 Electronic Route Marker: Ensure that the ERMs meet the
same material and performance requirements as the SRMs with the following exceptions. Equip
each ERM with a removable, top-fitting cover that is black with white lettering. Ensure that each
ERM contains a terminal board equipped with locate wire and ground connectors.
Ensure that the terminal board is made from corrosion-resistant
materials and includes terminal facilities labeled according to function. Ensure the terminal
board includes uniform spacing between connection points.
783-2.2.2 Warning Tape: Ensure that the buried cable warning tape is flexible,
elastic material 3 inches wide and 6 mil thick, intended for burial and use as an underground
utility warning notice. Ensure that the surface of the warning tape is coated and sealed to prevent
deterioration caused by harsh soil elements. Ensure that the tape material and ink colors do not
change when exposed to acids, alkalis, and other destructive chemical variances commonly
found in Florida soils. Ensure that the warning tape color is orange as required by the American
Public Works Association (APWA) Uniform Color Code, and has CAUTION: FDOT FIBER
OPTIC CABLE BURIED BELOW, or other wording approved by the Engineer, permanently
printed on its surface.
Include buried cable warning tape with all conduit.
783-2.2.3 Locate Wire: Ensure that the locate wire and locate wire splices
comply with Section 630.
783-2.2.3.1 Locate Wire Surge Protection: Furnish and install a locate
wire surge protection system as shown in the Plans or directed by the Engineer. Ensure that
locate wires are attached to a surge protection system dedicated to safely dissipating high
transient voltages or other foreign electrical surges induced into the designating system. Provide
this grounding through a stand-alone system that does not include electric power or ITS device
grounding. Ensure that the surge protection system allows signals generated by locate system
transmitters to pass through the protection system without going to ground. Ensure that the
protection system automatically resets and passes locate system transmitter signals after the unit
has grounded to dissipate over-voltages. Ensure that the locate wire surge protection is intended
for below- or above-grade applications. Ensure that the locate wire surge protection system is
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grounded to a driven rod within 10 feet of the system using a AWG #6 single conductor wire
with green insulation. Ensure that the locate wire surge protection is enclosed for protection from
environmental hazards and accessible for connection of portable locate system transmitters.
Ensure that the locate wire surge protection system meets the
following minimum standards for surge protection:
Surge Element
Rating
Life
Fail-Safe
Insulation
Resistance
Clamp Voltages
3-element maximum duty fail-safe gas tube.
40,000 A surge capacity (single-cycle, 8 by 20 microsecond
waveform).
Minimum 1,000 surges (1000 A to ground).
Integral fail-shorted device.
1,000 megohm minimum at 100 volts of direct current (VDC).
a. Impulse at 100 Volts per Microsecond: Typically 500 volts.
b. Direct Current: 300 to 500 volts.
783-2.2.4 Locate System Electronic Equipment: Provide locate system
electronic equipment that is designed specifically for locating buried pipes and cables. Ensure
that the locate system electronic equipment is able to detect the location and depth of the locate
wire buried alongside conduit and cable runs. Ensure that the locate system electronic equipment
is capable of locating faults in the sheath of a buried locate wire. Ensure that locate system
electronic equipment is provided with protective cases suitable for daily transport and storage of
transmitters and receivers. Ensure that the locate system electronic equipment includes a
transmitter, receiver, and electronic box markers as shown in the Plans and approved by the
Engineer.
783-2.2.4.1 Transmitter: Ensure that the transmitter is a portable unit
designed to create and apply an identifiable signal onto a locate wire so that it can be located and
traced with a receiver. Ensure the transmitter is capable of applying a trace signal using direct
connection and inductive methods. Ensure that the transmitter output circuitry is protected
against inadvertent connection to conductors carrying voltages up to 250V at 50/60Hz.
Deliver the transmitter to the Engineer upon completion of the
installation and acceptance of the work.
783-2.2.4.1.1 Electrical Specifications: Ensure that the system
operates using 120 VAC input power as well as self-contained, rechargeable battery power.
Ensure that the transmitter can operate from battery power for a minimum of 10 hours per
charge. Ensure that the transmitter is supplied with all chargers, cords, cables, and accessories
required for standard operation.
783-2.2.4.1.2 Mechanical Specifications: Ensure that the
transmitters physical dimensions allow portability and storage in a case no larger than
16 inches x 12 inches x 5 inches. Ensure that the transmitter weight does not exceed 10 pounds.
783-2.2.4.1.3 Environmental Specifications: Ensure that the
transmitter is constructed with impact-resistant materials, is weather resistant, and designed to
operate unattended in all weather and climates found in the outdoor roadside environment.
Ensure that operating temperature meets or exceeds minus 4 to 122 F.
783-2.2.4.1.4 Operation and Display: Ensure that the transmitter
includes programming buttons and visual indicators or displays for self-contained setup and
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operation. Ensure that all transmitter functions and operational parameters are programmable
using an onboard, man-machine interface. Ensure that the operational status, including battery
strength and current device settings, are displayed on the transmitter.
783-2.2.4.1.4.1 Transmitter Output: Ensure that the
transmitter is capable of generating radio frequency (RF) signals and audio tones. Ensure that RF
and audio output levels are user selectable.
783-2.2.4.1.4.2 Output Frequency Requirements: Ensure
that RF frequencies produced for locate operations are user-selectable. Ensure that the
transmitter produces consistent, stable, and defined frequencies normally associated with
locating and marking equipment. Ensure that the transmitter can transmit at least three different
user-selectable frequencies, with at least one frequency in each of three general ranges, defined
here as low (0-1 kHz), mid-range (1 kHz - 40kHz), and high (40 kHz - 85 kHz) bands.
783-2.2.4.2 Receiver: Ensure that the receiver is a portable hand-held unit
ergonomically designed and intended for the purpose of locating underground utilities, conduit,
cable, and pull and splice boxes. Ensure the receiver is capable of receiving all of the signals
generated by the transmitter as well as those associated with electronic box markers. Ensure that
the receiver can serve as a marker locator by energizing and detecting electronic box markers.
Ensure that the receiver can passively locate cables transmitting power and RF signals.
Deliver the receiver to the Engineer upon completion of the
installation and acceptance of the work.
783-2.2.4.2.1 Electrical Specifications: Ensure that the system
operates using self-contained, rechargeable battery power. Ensure that the receiver can operate
from battery power for a minimum of 10 hours per charge. Ensure that the receiver is supplied
with all chargers, cords, cables, and accessories required for standard operation.
783-2.2.4.2.2 Mechanical Specifications: Ensure that the
receivers physical dimensions allow portability and storage in a case no larger than
30 inches x 12 inches x 9 inches. Ensure that the receiver weight does not exceed 6 pounds.
783-2.2.4.2.3 Environmental Specifications: Ensure that the receiver is
constructed with impact-resistant materials, is weather resistant, and designed to operate in all
weather and climates found in the outdoor roadside environment. Ensure that operating
temperature meets or exceeds minus 4 to 122 F.
783-2.2.4.2.4 Operation and Display: Ensure that the receiver includes
programming buttons and a graphical display for self-contained setup and operation. Ensure that
all receiver functions and operational parameters are programmable using an on-board manmachine interface. Ensure that current operational status, including battery strength and current
device settings, and current signal strength from targets are displayed on the receiver. Ensure that
receiver sensitivity is adjustable. Ensure that the receiver includes an internal speaker and
headphone output that is able to provide audible tones that indicate received signal strength.
Ensure audible outputs include on/off and volume control.
Ensure that the receiver is capable of locating buried locate wire
and electronic box markers within plus or minus 5% of actual depth. Ensure that the receiver can
detect the center line of a target locate wire within 3 inches of its actual location.
783-2.2.4.3 Electronic Box Marker: Equip all pull boxes and splice boxes buried
below finish grade with an electronic box marker inside the pull box or splice box to mark the
location. Ensure that the electronic box marker is a device specifically manufactured to
electronically mark and locate underground facilities. Ensure that the electronic box marker
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includes circuitry and an antenna encased in a waterproof polyethylene shell. Ensure that the
outer shell is impervious to minerals, chemicals, and temperature extremes normally found in
underground plant environments. Ensure that the electronic box marker does not require any
batteries or active components to operate. Ensure that electronic box markers used to mark fiber
optic cable and general telecom applications are orange in color and operate at 101.4 kHz. When
excited by a marker locator, ensure that the electronic box markers passive circuits produce an
RF field to direct the marker locator to its position. Ensure that the electronic box marker has a
minimum operating range of 5 feet from the marker locator.
783-2.3 Installation Requirements:
783-2.3.1 Route Markers: Install route markers as shown in the Plans and as
directed by the Engineer. Ensure that route markers are plumb and level with the notification
information clearly visible when viewed from the side facing the roadway. Place route markers
at a 1 foot offset from the conduit system or as shown in the Plans. Ensure that markers are set
within the right-of-way.
Set the route markers concurrently with the conduit system installation and
prior to the fiber cable installation. Install route markers of the type as shown in the Plans and as
follows:
1. 1. So that a clear line of sight is maintained from one marker to
the next.
2. A maximum distance apart of 500 feet.
3. On both sides of the road at any crossing point where the
conduit system changes to the opposite side of the road.
4. At the center point of any conduit run between two pull or splice
boxes.
5. At gate locations when the conduit system is adjacent to a fence
line.
6. On both sides of a stream, river, or other water crossing.
7. On both sides of aboveground attachments, such as bridges and
walls.
Remove and replace all marker posts damaged during installation at no
additional cost. Ensure that the top of the marker post is a minimum of 5 feet and no more than
6 feet above the finish grade.
Ensure that route marker signs are labeled with a unique identification
number, as detailed in the Plans or as approved by the Engineer. Provide as-built documentation
at the completion of installation that includes identification number and location of all installed
route markers and correlates the marker to the fiber optic infrastructure that it signifies.
Ensure that installation of ERMs includes connection of the route marker
to the locate wire associated with the conduit run that the markers identify. Install locate wire
through the base of the marker and terminate the locate wires to connectors mounted on the
terminal board inside the marker. Install an underground magnesium anode at a minimum of
10 feet away from the marker and perpendicular to the conduit system. Terminate the anode lead
on the connector mounted on the terminal board inside the marker. Install the bond straps
between the anode connector and all locate wire connectors to provide cathodic protection for the
locate wire conductor.
783-2.3.2 Warning Tape: Install buried cable warning tape 1 foot below the
finish grade, directly over any installed conduit and cable run.
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783-2.3.3 Locate Wire: Ensure that the installation of locate wire and locate wire
splices are compatible with Section 630.
783-2.3.4 Locate Wire Grounding Units: Install locate wire grounding units
(WGUs) in pull boxes and splice boxes as shown in the Plans or directed by the Engineer. Mount
the device in a location high enough from the bottom of the box to allow access to terminal
facilities without disturbing cables present within the box. Terminate the locate wires and
connect the surge protection device to ground per the manufacturers instructions. Do not use
power utility grounds or any ITS device grounding system as the grounding point for WGUs.
783-2.3.5 Locate System Electronic Box Marker: Install an electronic box
marker inside all pull boxes and splice boxes buried below finish grade at the time of installation.
Place the electronic box marker on the floor or wall of the box. Ensure that the electronic box
marker is installed less than 5 feet below finish grade.
783-2.4 Testing and Certification. Inspect all conduit route marker system components
and approve prior to installation. Fully test the locate wire system after installation to ensure that
it functions and can be used to accurately locate the conduit system.
Ensure that the conduit route marker system is fully functional prior to installing
the fiber optic cable.
783-3 Pull Boxes and Splice Boxes for Fiber Optic Cable.
783-3.1 Description: Furnish and install pull boxes and splice boxes of the type, size,
and quantity as shown in the Plans. Ensure that pull boxes and splice boxes meet the
requirements of Section 635. Use only equipment and components that are listed on the
Departments Approved Product List (APL).
Use pull boxes and splice boxes that provide:
1. At-grade access to fiber optic cables housed within conduit systems
used for Department ITS communications.
2. At-grade access to aid in the installation of fiber optic cable.
3. Protection for installed fiber optic cable.
4. Adequate space for cable storage and splice enclosures.
Ensure that pull boxes and splice boxes containing fiber optic cable do not contain
power cables for ITS devices or other equipment.
783-3.2 Materials:
783-3.2.1 General Requirements: Ensure that all pull boxes and splice boxes are
compatible with the fiber optic cable and are approved by the Engineer.
783-3.2.2 Pull Box: Ensure that all pull boxes have an open bottom. Ensure that
the pull box is equipped with a nonskid cover secured by bolts and any other miscellaneous
hardware required for installation or as shown in the in the Plans.
Ensure that the minimum pull box size is approximately 2 feet wide by
3 feet long by 3 feet deep, or as required in the Plans. Ensure that the pull box is large enough to
house fiber optic cable without subjecting the cable to a bend radius less than 14 times the
diameter of the cable.
783-3.2.3 Splice Box: Use splice boxes at all fiber optic splice locations, as
shown in the Plans, and at other locations as approved by the Engineer. Ensure that all splice
boxes have an open bottom. Ensure that the splice box is equipped with a nonskid cover secured
by bolts; cable racks and hooks; pulling eyes; and any other miscellaneous hardware required for
installation or as shown in the in the Plans.
Ensure that the splice box size is approximately 2.5 feet wide by 5 feet
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long by 4 feet deep or as shown in the Plans. Ensure that the splice box is large enough to house
fiber optic cable without subjecting the cable to a bend radius less than 14 times the diameter of
the cable.
783-3.2.4 Marking: Ensure that all pull box and splice box covers include the
words FDOT FIBER OPTIC CABLE or text shown in Plans permanently cast into their top
surface. Ensure that markings are permanently affixed and clearly visible after installation.
783-3.3 Installation Requirements. Install all pull boxes and splice boxes according to
the manufacturers recommendations; as shown in the Plans; and in compliance with Section 635
and Design Standards, Index No. 17700. Complete the installation of pull boxes, splice boxes,
and conduit prior to cable installation. Provide all pull boxes and splice boxes a final finish grade
elevation as shown in the Plans. Excavate pull box and splice box installation sites to a depth of
1 foot below the bottom of the box, and replace with a 1 foot bed of pearock or crushed stone at
the excavation base prior to installing the box.
Ensure that the box cover is flush with the existing finish grade after installation.
Taper the finish grade contour to provide drainage from the splice box.
783-3.3.1 General Placement and Spacing: Place pull boxes and splice boxes as
detailed in the Plans, and at the following locations, unless directed otherwise by the Engineer:
1. At all major fiber optic cable and conduit junctions.
2. Approximately every 2,500 feet in rural areas with any continuous
section of straight conduit if no fiber optic cable splice is required.
3. At a maximum of 1,760 feet in metropolitan areas.
4. At each end of a tunnel, and on each side of a river or lake crossing.
5. On each side of an aboveground conduit installation, such as an
attachment to a bridge or wall.
6. At all 90 degree turns in the conduit system.
Ensure that all pull boxes and splice boxes are flush mounted at grade
level, and are located near the base of a service pole or near the communication equipment
cabinet serving the ITS field device to provide:
1. A transition point between the fiber optic conduits extending
from the fiber backbone and the conduit feeding the communication cabinet.
2. An assist point for the installation of fiber optic drop cable.
3. Storage of slack fiber optic drop cable.
Do not place the pull boxes in roadways, driveways, parking areas,
ditches, or public sidewalk curb ramps. Avoid placing pull boxes and splice boxes on steep
slopes where the cover cannot be leveled within a tolerance of 1 inch of drop to 1 foot of grade
or in low-lying locations with poor drainage.
783-3.3.2 Bonding and Grounding: Ensure that pull box and splice box
installation includes a bonding and grounding system including a driven rod that is a minimum
of 10 feet in length and 5/8 inches in diameter. Ensure that grounding rod is constructed of
copper clad steel and complies with the UL 467 standard. Ensure that bonding conductors are
bare solid AWG #6 copper wire as required in the ASTM B1 standard. Ensure that splice and
termination components meet or exceed the UL 467 requirements, and are clearly marked with
the manufacturer, catalog number, and conductor size. Ensure that grounding system complies
with the NEC.
783-3.3.3 Material Removal and Restoration Specifications: Provide all
material, equipment and labor for the removal of turf, earth, concrete/asphalt pavement or other
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site specific material to be removed for box installation. Ensure that original turf, earth,
concrete/asphalt pavement or other site specific material is restored to its original condition once
box installation is complete.
783-3.4 Testing and Certification:
783-3.4.1 Material Inspection: Inspect all pull boxes and splice boxes and
approve prior to installation, and again prior to installation of the fiber optic cable.
783-3.4.2 Compaction and Density Testing: Perform compaction tests for each
soil type encountered. Provide sufficient in-place density tests to confirm the adequacy and
uniformity of the compaction procedures as required by the governing authorities or right of way
owners, or as shown in the Plans.
783-4 Guaranty Provisions.
Ensure that the fiber optic cable, the splice enclosures, termination points, conduit, locate
system, pull boxes and splice boxes have a two year manufacturers warranty from the date of
final acceptance by the Engineer in accordance with 5-11 of all the work to be performed under
the Contract. If the manufacturers warranties for the components are for a longer period, those
longer period warranties will apply.
Ensure that the manufacturers warranties on the fiber optic cable, the splice enclosures,
termination points, conduit, locate system, pull boxes and splice boxes are fully transferable from
the Contractor to the Department. Ensure that these warranties require the manufacturer to
furnish replacements for any part or equipment found to be defective during the warranty period
at no cost to the Department within 10 calendar days of notification by the Department.
783-5 Method of Measurement.
783-5.1 Furnish and Install: Fiber optic cable shall be measured per foot of cable
furnished, installed, warranted, tested and deemed fully operational.
Splices and terminations as shown in the Plans shall be measured per each fiber
connection furnished and installed.
The conduit and locate system shall be measured for payment per foot of conduit,
buried cable warning tape and locate wire furnished, installed; designated with standard or
electronic route markers (SRM or ERM), grounded, and protected. The conduit and locate
system shall be warranted, made fully operational, and tested according to this specification.
The locate system electronic equipment (transmitters and receivers) shall be
measured as each is delivered to the Engineer upon completion of the installation and acceptance
of the work. Electronic box markers shall be measured as each is furnished, installed, and tested.
The locate system electronic equipment shall be warranted, made fully operational, and tested
according to this specification.
The fiber optic pull boxes and splice boxes shall be measured as each is furnished
and installed, with grounding and associated hardware as detailed in the Plans.
The Contract unit price, furnished and installed, will include furnishing,
placement, and testing of all materials and equipment, and for all tools, labor, equipment,
hardware, operational software packages and firmwares, supplies, support, personnel training,
shop drawings, documentation, and incidentals necessary to complete the work.
783-5.2 Furnish: The Contract unit price per foot of fiber optic cable, conduit, or locate
wire and route markers (SRM or ERM); each locate system transmitter, receiver, or electronic
box marker; and each pull box or splice box, furnished, will include all equipment specified in
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the Contract Documents, plus all shipping and handling costs involved in delivery as specified in
the Contract Documents.
783-5.3 Install: The Contract unit price per foot of fiber optic cable, conduit, or locate
wire and route markers (SRM or ERM); each electronic box marker; and each pull box or splice
box, installed, will include placement and testing of all materials and equipment, and for all
tools, labor, equipment, hardware, operational software packages and firmwares, supplies,
support, personnel training, shop drawings, documentation, and incidentals necessary to
complete the work. The Engineer will supply the equipment specified in the Contract
Documents.
783-6 Basis of Payment.
Prices and payments will be full compensation for all work described herein or shown in
the Plans.
Payment will be made under:
Item No. 783- 1ITS Fiber Optic Cable-per foot.
Item No. 783- 2ITS Fiber Optic Connection-each.
Item No. 783- 3ITS Fiber Optic Connection Hardware.
Item No. 783- 4ITS Conduit-per foot.
Item No. 783- 5ITS Pull Box for Fiber Optic - each.
Item No. 783- 6ITS Splice Box for Fiber Optic - each.
Item No. 783- 9ITS Locate System Electronic Equipment - each.
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SECTION 784
INTELLIGENT TRANSPORTATION SYSTEMS
NETWORK DEVICES
784-1 Managed Field Ethernet Switch.
784-1.1 Description. Furnish and install a hardened, device-level managed field Ethernet
switch (MFES) for intelligent transportation system (ITS) projects. Ensure that the MFES
provides wire-speed fast Ethernet connectivity at transmission rates of 100 megabits per second
from the remote ITS device installation location to the ITS network trunk interconnection point.
Use only equipment and components that meet the requirements of these minimum
specifications, and are listed on the Departments Approved Product List (APL).
784-1.2 Materials:
784-1.2.1 General: Ensure that the ITS network administrator will be able to
manage each MFES individually and as a group for switch configuration, performance
monitoring, and troubleshooting. Ensure that the MFES includes Layer 2+ capabilities,
including, QoS, IGMP, rate limiting, security filtering, and general management.
Ensure that the furnished MFES is fully compatible and interoperable with
the ITS trunk Ethernet network interface, and that the MFES supports half and full duplex
Ethernet communications.
Furnish an MFES that provides 99.999% error-free operation, and that
complies with the Electronic Industries Alliance (EIA) Ethernet data communication
requirements using single-mode fiber optic transmission medium and Category 5E copper
transmission medium. Provide a switched Ethernet connection for each remote ITS field device.
Ensure that the MFES has a minimum mean time between failures
(MTBF) of 10 years, or 87,600 hours, as calculated using the Bellcore/Telcordia SR-332
standard for reliability prediction.
784-1.2.2 Networking Standards: Ensure that the MFES complies with all
applicable IEEE networking standards for Ethernet communications, including but not limited to:
1. IEEE 802.1D Standard for Media Access Control (MAC) Bridges used
with the Rapid Spanning Tree Protocol (RSTP).
2. IEEE 802.1Q standard for port-based virtual local area networks
(VLANs).
3. IEEE 802.1P standard for Quality of Service (QoS).
4. IEEE 802.3 standard for local area network (LAN) and metropolitan
area network (MAN) access and physical layer specifications.
5. IEEE 802.3u supplement standard regarding 100 Base TX/100 Base
FX.
6. IEEE 802.3x standard regarding flow control with full duplex operation.
784-1.2.3 Optical Ports: Ensure that all fiber optic link ports operate at 1,310 or
1,550 nanometers in single mode. Ensure that the optical ports are Type ST, SC, LC, or FC only,
as specified in the plans or by the Engineer. Do not use mechanical transfer registered jack
(MTRJ) type connectors.
Provide an MFES having a minimum of two optical 100 Base FX ports
capable of transmitting data at 100 megabits per second. Ensure the MFES is configured with the
number and type of ports detailed in the Contract Documents. Provide optical ports designed for
use with a pair of fibers; one fiber will transmit (TX) data and one fiber will receive (RX) data.
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The optical ports shall have an optical power budget of at least 15 dB, or as detailed in the
Contract Documents.
784-1.2.4 Copper Ports: Provide an MFES that includes a minimum of four
copper ports. All copper ports shall be Type RJ-45 and shall auto-negotiate speed (i.e.,
10/100 Base) and duplex (i.e., full or half). All 10/100 Base TX ports shall meet the
specifications detailed in this section and shall be compliant with the IEEE 802.3 standard
pinouts.
All Category 5E unshielded twisted pair/shielded twisted pair network
cables shall be compliant with the EIA/TIA-568-B standard.
784-1.2.5 Management Capability: Ensure that the MFES supports all Layer 2
management features and certain Layer 3 features related to multicast data transmission and
routing. These features shall include, but not be limited to:
1. An MFES that is a port-based VLAN and supports VLAN tagging that
meets or exceeds specifications as published in the IEEE 802.1Q standard, and has a minimum
4-kilobit VLAN address table.
2. A forwarding/filtering rate that is a minimum of 14,880 packets per
second for 10 megabits per second and 148,800 packets per second for 100 megabits per second.
3. A minimum 4-kilobit MAC address table.
4. Support of, at a minimum, Version 2 of the Internet Group Management
Protocol (IGMP).
5. Support of remote and local setup and management via telnet and
secure Web-based GUI.
6. Support of the Simple Network Management Protocol (SNMP). Verify
that the MFES can be accessed using the resident EIA-232 management port, a
telecommunication network, or the Trivial File Transfer Protocol (TFTP).
7. Port security through controlling access by the users. Ensure that the
MFES has the capability to generate an alarm and shut down ports when an unauthorized user
accesses the network.
8. Support of remote monitoring (RMON) of the Ethernet agent and the
ability to be upgraded to switch monitoring (SMON), if necessary.
9. Support of TFTP and either Network Time Protocol (NTP) or the
Simple Network Time Protocol (SNTP). Ensure that the MFES supports port mirroring for
troubleshooting purposes when combined with a network analyzer.
784-1.2.6 Mechanical Specifications: Ensure that all wiring complies with NEC
requirements and standards. Furnish and identify all equipment and appurtenances by name,
model number, serial number, technical support and warranty telephone numbers, and any other
pertinent information required to facilitate equipment maintenance.
Ensure that every conductive contact surface or pin is gold-plated or made
of a noncorrosive, nonrusting, conductive metal.
Do not use self-tapping screws on the exterior of the assembly.
All parts shall be made of corrosion-resistant materials, such as plastic,
stainless steel, anodized aluminum, brass, or gold-plated metal.
784-1.2.7 Electrical Specifications: Ensure that the MFES operates and power is
supplied with 115 volts of alternating current (VAC). Ensure that the MFES operates over an
input voltage range from 89 VAC to135 VAC. If the device requires operating voltages other
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than 120 VAC, supply the required voltage converter. Ensure that the maximum power
consumption does not exceed 50 watts.
Ensure that the MFES has diagnostic light emitting diodes (LEDs),
including link, TX, RX, and power LEDs.
784-1.2.8 Environmental Specifications: Ensure that the MFES operates
properly during and after being subjected to the environmental testing procedures described in
NEMA TS 2, Sections 2.2.7, 2.2.8., and 2.2.9.
784-1.3 Installation Requirements: Mount the MFES inside a field site cabinet. Ensure
that the MFES is resistant to all electromagnetic interference (EMI). Ensure that the MFES is
mounted securely in 19 inches EIA racking and is fully accessible by field technicians.
Due to the nature of the equipment, complexity of the electronics, and harsh
environmental conditions at installation locations, use MFES units that can be serviced or
replaced immediately when defective or damaged units must be removed and replaced.
784-1.4 Testing:
784-1.4.1 General: Subject the MFES to field acceptance tests (FATs). Develop
and submit a test plan for FATs to the Engineer for consideration and approval. The Engineer
reserves the right to witness all FATs. Complete the tests within five calendar days.
784-1.4.2 Field Testing: Once the MFES has been installed, conduct local FATs
at the MFES field site according to the submitted test plan. Perform the following:
1. Verify that physical construction has been completed as detailed in the
plans.
2. Inspect the quality and tightness of ground and surge protector
connections.
3. Verify proper voltages for all power supplies and related power circuits.
4. Connect devices to the power sources.
5. Verify all connections, including correct installation of communication
and power cables.
6. Verify configuration of the MFES Internet Protocol (IP) addresses and
subnetwork mask.
7. Verify the network connection to the MFES through ping and telnet
sessions from a remote personal computer (PC).
8. Perform testing on multicast routing functionality.
784-2 Device Server.
784-2.1 Description. Furnish and install a device server as shown in the plans. Provide a
device server that includes a central processing unit (CPU), realtime operating system (RTOS),
Transmission Control Protocol/Internet Protocol (TCP/IP) stack, and Ethernet and serial data
ports to allow connection of serial devices with EIA-232, EIA-422, and EIA-485 connections to
an Ethernet network. Ensure that the device server (also referred to as a terminal server)
encapsulates serial data in network packets and transports them across IP networks. Use only
equipment and components that meet the requirements of these minimum specifications, and are
listed on the Departments Approved Product List (APL).
784-2.2 Materials:
784-2.2.1 General: Ensure that the device server provides a TCP/IP interface to
one or more field devices using EIA-232/422/485 standard connections. Ensure that the device
server supports TCP/IP, User Datagram Protocol (UDP)/IP, Dynamic Host Configuration
Protocol (DHCP), Address Resolution Protocol (ARP), Internet Control Message Protocol
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(ICMP), Simple Network Management Protocol (SNMP), Hypertext Transfer Protocol (HTTP),
and telnet.
Ensure that the device server provides 99.999% error-free operation and
EIA-compatible Ethernet data communication by way of a Category 5E copper or fiber optic
transmission medium, as shown in the plans.
Ensure that the device server is resistant to all electromagnetic
interference.
Use a device server having an encryption feature that provides data
security and prevents interception or sniffing of transmitted information by unauthorized
parties. Data security shall comply with Version 2 of the Secure Shell Protocol (SSHv2), or the
NIST requirements as defined in the Federal Information Processing Standard (FIPS)
Publication (PUB)-197 for the Advanced Encryption Standard (AES).
Ensure that the device server has a minimum mean time between failures
(MTBF) of 10 years, or 87,600 hours.
784-2.2.2 Serial Interface: Ensure that the device server provides a minimum of
one serial data interface and connector as specified in the plans that conforms to EIA232/422/485 standards. Ensure that the serial interface supports 2-wire and 4-wire EIA-485
connections. Ensure that the serial port(s) support data rates up to 230 kbps; error detection
procedures utilizing parity bits (i.e., none, even, and odd); and stop bits (1 or 2).
Ensure that the device server provides flow control (request to send
[RTS]/clear to send [CTS] and transmit on/transmit off [XON/XOFF]), as well as allow control
of the data terminal ready (DTR), data carrier detect (DCD), data set ready (DSR), CTS, and
RTS signals. Ensure that the device server supports RTS toggle for half-duplex emulation.
784-2.2.3 Network Interface: Ensure that the device server includes a minimum
of one Ethernet port, which must provide a 10/100 Base TX or a 10/100 Base FX connection as
specified in the plans. Verify that all Category 5E, unshielded twisted pair/shielded twisted pair
network cables and connectors comply with the EIA and Telecommunications Industry
Association (TIA) requirements as detailed in the EIA/TIA-568-B standard. Verify that all
copper-based network interface ports utilize registered jack (RJ)-45 connectors. Verify that the
optical ports are Type ST, SC, LC, or FC only, as specified in the plans or by the Engineer.
Mechanical transfer registered jack (MTRJ) type connectors are not allowed.
784-2.2.4 Configuration and Management: Provide a device server that
supports local and remote configuration and management, which must include access to all userprogrammable features, including but not limited to addressing, port configuration, device
monitoring, diagnostic utilities, and security functions. Ensure that the device server supports
configuration and management via serial login, SNMP, telnet login, and browser-based interface.
784-2.2.5 Mechanical Specifications: Ensure that all parts are made of
corrosion-resistant materials, such as plastic, stainless steel, anodized aluminum, brass, or goldplated metal.
Ensure that the dimensions of the device server accommodate the units
installation in a control cabinet as specified in the plans.
784-2.2.6 Electrical Specifications: Verify that all wiring meets applicable NEC
requirements and that the device server operates using a nominal input voltage of 120 volts
alternating current (VAC). The input voltage range shall be 89 to 135 VAC. If the device requires
nominal input voltage of less than 120 VAC, furnish the appropriate voltage converter. Verify that
the maximum power consumption does not exceed 12 watts.
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Ensure that the device server includes diagnostic status indicators in the
form of light emitting diodes (LEDs) that provide link, transmit (TX), receive (RX), and power
status information.
784-2.2.7 Environmental Specifications: Verify that the device server meets all
specifications and is capable of performing all of its functions during and after being subjected to
an ambient operating temperature range of -31 degrees () to 165 Fahrenheit (F), as required in
the NEMA TS 2 standard, with a noncondensing relative humidity of 0% to 95%.
Install the device server in an enclosure that provides protection from
moisture and airborne contaminants, blowing rain, wind, blowing dust, temperature, humidity,
roadside pollutants, vandalism, pests, and theft of equipment.
Verify that the device server meets the vibration and shock resistance
specifications as provided in Section 2.1.9 and 2.1.10, respectively, of the NEMA TS 2 standard.
784-2.3 Installation Requirements: Install all equipment and software according to the
manufacturers recommendations or as directed by the Engineer. Mount the device server
securely in a location in the equipment cabinet that allows the unit to be fully accessible by field
technicians.
Due to the nature of the equipment, complexity of the electronics, and harsh
environmental conditions at installation locations, use device servers that can be replaced
immediately when defective or damaged units must be removed and replaced.
784-2.4 Testing:
784-2.4.1 General: Subject the Device Server to field acceptance tests (FATs).
Develop and submit a test plan for FATs to the Engineer for consideration and approval. The
Engineer reserves the right to witness all FATs. Complete the tests within five calendar days.
784-2.4.2 Field Testing: Perform local field operational tests at device server
field sites according to the test procedures stated herein.
1. Verify that physical construction has been completed as specified in the
plans.
2. Verify the quality and tightness of ground and surge protector
connections.
3. Verify proper voltages for all power supplies and related power circuits.
4. Connect devices to the power sources.
5. Verify all connections, including correct installation of communication
and power cables.
6. Verify the network connection to the device server through ping and
telnet session from a remote personal computer (PC).
7. Verify serial data transmission through the device server.
784-3 Digital Video Encoder and Decoder.
784-3.1 Description: Furnish and install digital video encoder (DVE) and digital video
decoder (DVD) hardware and software to create a video-over-IP network system, as shown in
the plans, and as directed by the Engineer. Use only equipment and components that meet the
requirements of these minimum specifications, and are listed on the Departments Approved
Product List (APL).
784-3.2 Materials:
784-3.2.1 General: Use DVEs and DVDs that are specialized network-based
hardware devices and software which allow video and data signals to be transmitted across IP
networks. Ensure that the video and data packets produced by the DVE and placed onto the
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network allow reconstruction of digital video signals by hardware-based and software-based
DVDs that are also attached to the network.
Ensure that the complete video and data transmission system, defined as
the combination of DVE and DVD hardware together with the existing or planned network
infrastructure, simultaneously transports video and data from multiple remote field locations to
multiple monitoring locations for roadway surveillance and traffic management.
784-3.2.2 Software: Provide a software decoding and control package that allows
the viewing of any video source connected to the network through a DVE, and which allows the
pan-tilt-zoom (PTZ) control of any PTZ camera on the network, the discovery of DVE and DVD
devices on the network, and the control and adjustment of programmable parameters in the DVE
and DVD equipment, including the network addresses of these devices, at no additional cost.
Provide all setup, control programs, and diagnostic software related to the
DVE or DVD. Provide all equipment licenses, where required for any software or hardware in
the system.
784-3.2.3 MPEG-2 Format: Furnish DVE and DVD components that utilize the
Moving Picture Experts Groups MPEG-2 video compression technology in accordance with the
International Organization for Standardization (ISO) and International Electrotechnical
Commission (IEC) requirements detailed in the ISO/IEC 13818 standard. Ensure that the DVE
and DVD are capable of unicast and multicast operation. Ensure DVEs support the Session
Announcement Protocol (SAP) as recommended by the Internet Engineering Task Force (IETF)
RFC 2974. Ensure that the DVE provides 99.999% error-free operation. Ensure MPEG-2 DVE
and DVD equipment supports programmable bit rates. Ensure that MPEG-2 equipment supports
fixed bit rate mode.
784-3.2.4 H.264 Format: Furnish DVE and DVD components that utilize video
compression technology in accordance with the International Organization for
Standardization (ISO) and International Electrotechnical Commission (IEC) requirements
detailed in the ISO/IEC 14496-10:2009 standard. Ensure that the DVE and DVD are capable of
unicast and multicast operation. Ensure that DVEs support the Session Announcement
Protocol (SAP) as recommended by the Internet Engineering Task Force (IETF) RFC 2974, and
Real Time Streaming Protocol (RTSP). Ensure that the DVE provides 99.999% error-free
operation. Ensure H.264 DVE and DVD equipment supports programmable bit rates. Ensure that
H.264 equipment supports fixed bit rate mode.
784-3.2.5 Digital Video Encoder: Provide a DVE that is a hardware-based
network device able to accept a minimum of one analog National Television System Committee
(NTSC) video input and digitize it for transport across IP networks. Use a DVE that provides a
minimum of one serial data interface for transmission of command and control data to other
devices (typically camera PTZ commands), as well as console and configuration functions.
Provide compatible decoder software along with the DVE at no additional cost, as shown in the
plans, or as directed by the Engineer.
784-3.2.6 Digital Video Decoder: Provide a DVD that is either a hardware-based
network device or a software application that resides on a workstation personal computer (PC).
784-3.2.6.1 Hardware-based Decoder: Provide a hardware-based
decoder that has a minimum of one analog NTSC video output and decodes digital video and
data streams present on an IP network into analog formats for interconnection with other devices.
Use a DVD that has a minimum of one serial data interface for transmission of command and
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control data to other devices, as well as console and configuration functions. Use a DVD that
includes an Ethernet interface for connection to IP networks.
784-3.2.6.2 Software-based Decoder: Ensure that any software-based
decoder applications do not interfere with SunGuide software operating when installed and
used together on a shared hardware platform. Ensure that the software application provides PC
desktop display of IP network video streams. Ensure that the software-based decoder offers an
open Application Programming Interface (API) and software development kit available to the
Department at no cost for integration with third party software and systems.
784-3.2.7 Interoperability: Provide DVE and DVD devices and software that are
interoperable and interchangeable with DVE and DVD devices and software from other
manufacturers. Ensure that the DVE is compatible and fully interoperable with software and
hardware DVDs from the DVE manufacturer, as well as a minimum of two software and
hardware DVDs from other manufacturers. Ensure that the DVD is compatible and fully
interoperable with DVEs from the DVD manufacturer, as well as a minimum of two other DVEs
from other manufacturers. Ensure DVE and DVD can be controlled using SunGuide or
support stream selection and switching using ONVIF commands.
784-3.2.8 Video Specifications: Ensure that composite video inputs and outputs
utilize BNC connectors. Ensure video inputs and outputs support 1 volt peak-to-peak (Vp-p)
NTSC composite video. Ensure that the DVE and DVD operate with both color and
monochrome video, and that DVEs allow the user to select and adjust video resolution. Ensure
that the DVE and DVD support resolutions that include, but are not limited to, those defined in
Table 3.1. Ensure that the DVE and DVD are capable of delivering color and monochrome video
at 30 fps regardless of resolution.
Table 3.1 Resolution Requirements
Format
Resolutions
MPEG-2
352 x 240, 352 x 480, 720 x 480
H.264
176 x 120, 352 x 240, 720 x 480
Note: The resolutions attained depend on the data transmission rate.
784-3.2.9 Serial Interface: Ensure that hardware-based DVEs and DVDs provide
a minimum of one serial data interface that supports EIA/TIA-232 and TIA-422. Ensure that the
serial port(s) support data rates up to 115 kbps; error detection procedures utilizing parity bits
(i.e., none, even, and odd); and stop bits (1 or 2).
Ensure that hardware-based DVEs and DVDs provide a TCP/IP interface
to their serial port using a network socket connection with configurable IP address and port
number. Serial interface ports may utilize RJ-45 connectors, D-sub connectors, or screw
terminals.
784-3.2.10 Network Interface: Ensure that the DVE/DVD local area network
(LAN) connection supports the requirements detailed in the IEEE 802.3 standard for
10/100 Ethernet connections. Provide a DVE/DVD having a minimum of one Ethernet port,
which shall be a 10/100 Base TX connection or a 100 Base FX ST, SC, LC or FC interface.
Ensure that the connector complies with applicable EIA and TIA requirements. Provide copperbased network interface ports that utilize RJ-45 connectors. Ensure that fiber ports are single
920
mode with a minimum link budget of 30 dB or the type and power detailed in the Contract
Documents.
Ensure that all Category 5E, unshielded twisted pair/shielded twisted pair
network cables are compliant with the EIA/TIA-568-B standard. Ensure that the network
communication conforms to User Datagram Protocol (UDP), Version 4 of the Internet
Protocol (IP) and Version 2 of the Internet Group Multicast Protocol (IGMP).
784-3.2.11 Front Panel Status Indicators: Provide DVEs and DVDs that have
light-emitting diode (LED) displays, liquid crystal displays (LCDs), or similar illuminated
displays to indicate status for power, data activity, link status, and video transmission.
784-3.2.12 Configuration and Management: Provide DVEs and DVDs that
support local and remote configuration and management. Configuration and management
functions shall include access to all user-programmable features, including but not limited to
addressing, serial port configuration, video settings, device monitoring, and security functions.
Ensure that the DVE and DVD support configuration and management via serial login, telnet
login, web browser, or Simple Network Management Protocol (SNMP).
784-3.2.13 Electrical Specifications: Ensure that all wiring meets NEC
requirements and standards. Provide equipment that operates on a nominal voltage of 120 volts
alternating current (VAC). The equipment shall operate within a voltage range of 89 VAC to
135 VAC. The operating frequency range for power shall be 60 hertz plus or minus 3 Hz. If the
device requires operating voltages of less than 120 VAC, supply the appropriate voltage
converter.
784-3.2.14 Environmental Specifications: Except as may be stated otherwise in
the plans, provide DVEs and hardware DVDs that meet all specifications during and after being
subjected to an ambient operating temperature range of -30 degrees () to 165 Fahrenheit (F) as
defined in the environmental requirements section of the NEMA TS 2 standard, with a maximum
non-condensing relative humidity of 95%.
Ensure that cabinets housing system components comply with the
environmental requirements detailed in the NEMA TS 2 standard. House the DVE in a field
cabinet with protection from moisture and airborne contaminants, blowing rain, wind, blowing
sand, blowing dust, humidity, roadside pollutants, vandalism, and theft. Ensure that the DVE is
resistant to vibration and shock, and conforms to Sections 2.1.9 and 2.1.10, respectively, of the
NEMA TS 2 standard.
Ensure that a hardware DVD installed in a climate-controlled
environment, such as a TMC computer room, meets all specifications during and after being
subjected to an ambient operating temperature range of 32 degrees () to 113 Fahrenheit (F).
784-3.3 Installation Requirements: Ensure that the DVE is shelf- and/or rackmountable, and designed for use in roadside control cabinets without climate control. Ensure that
the dimensions of the DVE allow installation in a control cabinet as specified in the plans.
Ensure that front panel status indicators remain unobstructed and visible. All parts shall be made
of corrosion-resistant materials, such as plastic, stainless steel, anodized or painted aluminum,
brass, or gold-plated metal.
Because a DVD may be hardware or software-based, these mechanical
specifications apply only to hardware-based DVDs. Field-hardened DVDs shall be shelf- and
rack-mountable, and designed for use in roadside control cabinets without climate control. The
dimensions of the DVD shall allow installation in a control cabinet as specified in the plans.
Non-hardened DVDs shall be shelf- and rack-mountable, and designed for use in
921
a climate-controlled TMC. The rack-mounted DVD shall be designed to fit in a standard EIA
19 inch rack and shall not require shielding from other electronic devices, such as power supplies
and other communication equipment. The dimensions of the DVD shall allow installation as
specified in the plans.
Due to the nature of the equipment, complexity of the electronics, and harsh
environmental conditions at installation locations, use DVEs and DVDs that can be replaced
immediately when defective or damaged units must be removed and replaced.
784-3.4 Testing:
784-3.4.1 General: Subject the DVEs and DVDs to field acceptance tests (FATs).
Develop and submit a test plan for FATs to the Engineer for consideration and approval. The
Engineer reserves the right to witness all FATs. Complete the tests within five calendar days.
784-3.4.2 Field Testing: Perform local field operational tests at the device field
site and end-to-end video streaming tests as required by the Engineer in order to demonstrate
compliance with Department specifications. Testing will include, but not be limited to, the
following:
1. Verify that physical construction has been completed as detailed in the
plans.
2. Inspect the quality and tightness of ground and surge protector
connections.
3. Verify proper voltages for all power supplies and related power circuits.
4. Connect devices to the power sources.
5. Verify all connections, including correct installation of communication
and power cables.
6. Verify video image is present and free from oversaturation and any
other image defect in both color and monochrome mode.
7. Verify network connection to the DVE and DVD through ping and
telnet session from a remote PC.
8. Verify serial data transmission through the DVE and DVD serial ports.
9. Verify support of unicast, multicast, and SAP.
784-4 Warranty.
784-4.1 General: Ensure that the manufacturer will furnish replacements for any part or
equipment found to be defective during the warranty period at no cost to the Department or the
maintaining agency within 10 calendar days of notification.
784-4.2 MFES: Ensure that the MFES has a manufacturers warranty covering defects
for five years from the date of final acceptance by the Engineer in accordance with 5-11 and
Section 608.
784-4.3 Device Server: Ensure that the device server has a manufacturers warranty
covering defects for five years from the date of final acceptance by the Engineer in accordance
with 5-11 and Section 608.
784-4.4 Digital Video Encoder and Decoder: Ensure that the DVE or DVD has a
manufacturers warranty covering defects for two years from the date of final acceptance by the
Engineer in accordance with 5-11 and Section 608.
784-5 Method of Measurement.
784-5.1 General: The MFES, device server, DVE and DVD shall be measured for
payment in accordance with the following tasks.
922
Provide software-based decoders at no additional cost when furnished in
conjunction with DVEs, as shown in the plans or as directed by the Engineer.
A software-based DVD provided individually shall be paid under the pay item
below.
784-5.2 Furnish and Install: The Contract unit price for each MFES, device server,
DVE or DVD, furnished and installed, will include furnishing, placement, and testing of all
equipment and materials, and for all tools, labor, hardware, operational software package(s) and
firmware(s), supplies, support, personnel training, shop drawings, documentation, and
incidentals necessary to complete the work.
784-5.3 Furnish: The Contract unit price per each MFES, device server, DVE or DVD,
furnished, will include all equipment specified in the Contract Documents, plus all shipping and
handling costs involved in delivery as specified in the Contract Documents.
784-5.4 Install: The Contract unit price per each MFES, device server, DVE or DVD,
installed, will include placement and testing of all equipment and materials, and for all tools,
labor, hardware, operational software package(s) and firmware(s), supplies, support, personnel
training, shop drawings, documentation, and incidentals necessary to complete the work. The
Engineer will supply the equipment specified in the Contract Documents.
784-6 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 784-1ITS Managed Field Ethernet Switch-each.
Item No. 784-2ITS Device Server-each.
Item No. 784-3ITS Digital Video Encoder with Software Decoder-each.
Item No. 784-4ITS Digital Video Decoder-each.
923
SECTION 785
INTELLIGENT TRANSPORTATION SYSTEMS
INFRASTRUCTURE
785-1 Description.
Furnish and install ITS infrastructure components as shown in the Plans, meeting the
general requirements of this specification and the specific requirements for each component as
defined in 785-2 through 785-5.
Ensure that all materials furnished, assembled, fabricated, or installed are new products.
785-2 Grounding and Surge Protective Devices.
785-2.1 Description: Furnish and install grounding and surge protective devices (SPDs)
for all ITS devices to protect the devices from lightning, transient voltage surges, and induced
current. References for this section include, but are not limited to: UL 467, Grounding and
Bonding Equipment; UL 497A, Standard for Secondary Protectors for Communications Circuits;
UL 497B, Standard for Protectors for Data Communications and Fire-Alarm Circuits; UL 497C,
Standard for Protectors for Coaxial Communications Circuits; UL 752, Standard for BulletResisting Equipment; UL1008, Standard for Transfer Switch Equipment; UL 1449, Standard for
Surge Protective Devices; and the NEC. Ensure that lightning protection systems conform to the
requirements of NFPA 780, Standard for the Installation of Lightning Protection Systems.
785-2.2 Materials: Provide a grounding system that meets the minimum requirements of
this Section and those defined in Section 620. Ensure that all SPDs comply with the
environmental requirements of section A615 of the Minimum Specifications for Traffic Control
Signals and Devices (MSTCSD).
Install SPDs on all power, data, video and any other conductive circuit. Use only
equipment and components that meet the minimum requirements of this specification, and are
listed on the Departments Approved Product List (APL).
785-2.3 Installation Requirements:
785-2.3.1 General: A single point grounding system is required. Each ground rod
electrode assembly must have a minimum length of 20 feet. Individual ground rod electrode
assembly sections must have a minimum length of 8 feet. Ensure that ground rods are a
minimum 5/8 inch in diameter. Bond multiple grounding rod electrode assemblies to each other
with No. 2 AWG solid bare tinned copper wire that is exothermically welded at all connection
points.
Bond the grounding system to a main ground bar within the site equipment
cabinet. A single grounding rod electrode assembly bonded to the equipment cabinet constitutes
a minimal grounding system with a main ground rod and primary radial. If this primary radial
does not achieve a resistance to ground of 5 ohms or less, install an additional 20 foot grounding
rod electrode assembly and connect it to the main grounding rod electrode assembly. If the array
still does not achieve a resistance to ground of 5 ohms or less, install additional 20 foot
grounding rod electrode assemblies, spaced 40 feet apart, until 5 ohms is achieved. If a resistance
to ground measurement of 5 ohms or less between the grounding electrode and the soil cannot be
achieved with a total of four 20 foot rods, submit the site resistance measurement to the
Engineer. A grounding system consisting of four, 20 foot rods is acceptable in cases where soil
conditions prevent the grounding system from achieving a resistance to ground of 5 ohms or less.
924
Grounding systems formed from horizontally constructed conductive radials are permitted if site
conditions prohibit the use of vertically driven rods.
785-2.3.2 Grounding Specifications: Provide a grounding system as shown in
the Plans. Ensure that grounding rod electrodes are UL 467 listed. Make all connections to the
grounding electrode using exothermic welds. The main ground rod directly connected to the
main ground bar within the site cabinet must remain accessible for inspection, testing, and
maintenance. Place the main ground rod in the electrical pullbox nearest the site cabinet or as
shown in the Plans.
Install the main grounding rod electrode at the structural base of the ITS
device. Bond all metal components of the ITS device subsystem, such as the cabinets and steel
poles, to the grounding system with a grounding cable that uses a mechanical connection on the
equipment side and an exothermically welded connection at the down cable. Do not use split
bolts for grounding system connections.
Connect all grounding electrodes related to the ITS device and any
associated grounded electrical system within a 100 foot radius (but not beyond the edge of the
roadway) of the structural base of the ITS device, to a single point main grounding bar inside the
equipment cabinet or mounted to the base of the ITS structure and as shown in Plans.
Place multiple grounding rod electrode assemblies in a radial Y
configuration unless otherwise shown in the Plans. In the event that the Y configuration cannot
be placed in the right-of-way, change the configuration of the radials to make the grounding
array fit in the space available, and/or increase the length of the ground rods to a maximum of
40 feet provided that the sphere of influence radius is maintained.
785-2.3.3 Ground Resistance Testing and Certification: Measure the ground
resistance with an instrument designed specifically to measure and document earth/ground
resistance, soil resistivity, and current flow. Conduct the test by using the fall-of-potential
method. Provide the Engineer with written, certified test results for each testing location.
Illegible hand-written results are not acceptable. Provide the following information on the test
results:
1. The formal name or ID for the location where the test was performed;
2. The GPS latitude and longitude for the location where the test was performed;
3. The date on which the test was performed;
4. The make and model number, serial number, and last date of calibration (by an
independent testing facility within the previous 12 months) for the grounding resistance testing
device used;
5. Contact information (including name, signature, and employer name) for each
person conducting, witnessing, or certifying the test;
6. The local environmental and soil conditions at the time of testing;
7. A rough sketch of the site grounding system; a fall-of-potential graph, along
with the corresponding measured data points; and,
8. Page numbering showing the current page number and total page count (e.g.,
Page 1 of 3).
785-2.3.4 Air Terminals: Ensure that lightning protection systems and air
terminals installed conform to NFPA 780. Ensure that the air terminal extends at least 2 feet
above the object or area it is to protect and is bonded to the down conductor. Ensure that all ITS
devices attached to poles or structures having air terminals are within the zone of protection
determined by the 150 foot radius rolling sphere model described in NFPA 780.
925
Provide a lightning protection system as shown in the Plans. Provide
additional air terminals, static wires, and conductors as may be required to establish a zone of
protection in accordance with NFPA 780. Ensure that all air terminals are interconnected. Ensure
air terminals are terminated to the main grounding rod electrode. Use air terminals that are UL
listed.
785-2.4 Surge Protective Devices:
785-2.4.1 General: Provide all ITS field installation sites with both primary and
secondary surge protection on the AC power. Connect the primary surge protection at the service
entrance or main disconnect. Connect the secondary surge protection on the power distribution to
the equipment.
785-2.4.2 SPD at Power Entry Point: Install a SPD at the closest
termination/disconnection point where the supply circuit enters the ITS device cabinet. Locate
the SPD on the load side of the main disconnect and ahead of any and all ITS electronic devices.
Configure the SPD to operate at 120 volt single phase (i.e., line, neutral and ground) or
120/240 volt single phase (line 1, line 2, neutral and ground) as required to match the supply
circuit configuration. Ensure that the SPD maximum surge current rating is 80kA per phase or
greater. Ensure that the SPD has been labeled to indicate that the unit is listed and meets the
requirements of UL 1449, Third Edition.
Ensure that the SPD has a visual indication system that monitors the
weakest link in each mode and shows normal operation or failure status and also provides one set
of normally open (NO)/normally closed (NC) Form C contacts for remote alarm monitoring. The
enclosure for a SPD shall have a NEMA 4 rating.
785-2.4.3 SPD at Point of Use: Install a SPD at the point the ITS devices receive
120 volt power. Ensure that these devices comply with the functional requirements shown in
Table 785-1. Ensure that the units are rated at 15 or 20 amps load and are configured with
receptacles.
Ensure that these units have internal fuse protection and provide common
mode (L+N-G) protection.
785-2.4.4 SPD for Low-Voltage Power, Control, Data and Signal Systems:
Install a specialized SPD on all conductive circuits including, but not limited to, data
communication cables, coaxial video cables, and low-voltage power cables. Ensure that these
devices comply with the functional requirements shown in Table 785-1 for all available modes
(i.e. power L-N, N-G; L-G, data and signal center pin-to-shield, L-L, L-G, and shield-G where
appropriate).
Table 785-1
SPD Minimum Requirements
Circuit
Description
Clamping
Voltage
Data Rate
Surge
Capacity
Maximum Let-Through Voltage
12 VDC
15-20 V
N/A
5kA per mode
(8x20 s)
<150 Vpk
926
Table 785-1
SPD Minimum Requirements
Circuit
Description
Clamping
Voltage
Data Rate
Surge
Capacity
Maximum Let-Through Voltage
24 VAC
30-55 V
N/A
5kA per mode
(8x20 s)
<175 Vpk
48 VDC
60-85 V
N/A
5kA per mode
(8x20 s)
<200 Vpk
120 VAC at
POU
150-200 V
N/A
20kA per mode
(8x20 s)
<550 Vpk
Coaxial
Composite
Video
4-8 V
N/A
10kA per mode
(8x20 s)
<65 Vpk
(8x20 s/1.2x50s; 6kV, 3kA)
RS422/RS485
8-15 V
T1
13-30 V
Ethernet Data
7-12 V
Up to
10 Mbps
Up to
10 Mbps
10kA per mode
(8x20 s)
10kA per mode
(8x20 s)
1kA per mode
Up to 1 Gbps
(10x1000 s)
<30 Vpk
<30 Vpk
<30 Vpk
Install a SPD that has an operating voltage matching the characteristics of
the circuit. Ensure that these specialized SPDs are listed and meet the requirements of UL 497B
or UL 497C, as applicable.
785-3 Pole and Lowering Device.
785-3.1 Description: Furnish and install a steel or concrete pole, with or without a
lowering device, as shown in the Plans. Consider the lowering device and pole as two
interdependent components of a single unit, and provide them together to ensure compatibility of
the pole and lowering device.
785-3.2 Materials:
785-3.2.1 Pole: Use a concrete or steel pole in accordance with Design Standards,
Index Nos. 18111 or 18113 and listed on the Departments Qualified Products List (QPL).
For concrete poles, use concrete meeting the requirements of Section 346
and construct in accordance with Section 450. Obtain concrete poles from a manufacturing plant
that is currently on the Departments list of Producers with Accepted Quality Control Programs.
Producers seeking inclusion on the list shall meet the requirements of 105-3. Assume
responsibility for performance of all quality control testing and inspection required by
Sections 346 and 450; however the PCI personnel and plant certifications are not required.
Ensure that the pole-top tenon is rotatable.
927
785-3.2.2 Lowering Device: Use a lowering device as shown in the Plans. Use
only lowering device equipment and components that meet the requirements of these minimum
specifications, and are listed on the Departments Approved Product List (APL). The lowering
device must be permanently marked with the APL certification number, manufacturer name,
model number, and date of manufacture.
Ensure that the lowering device provides the electrical connections
between the control cabinet and the equipment installed on the lowering device without reducing
the function or effectiveness of the equipment installed on the lowering device or degrading the
overall system in any way. The lowering device system support arm must be capable of
withstanding service tension and shear up to 1 kip (kilopound) minimum.
Ensure that the lowering device includes a disconnect unit for electrically
connecting the equipment installed on the lowering devices equipment connection box to the
power, data, and video composite cables (as applicable); a divided support arm, a pole adapter
for the assemblys attachment to the rotatable pole-top tenon, and a pole-top junction box, as
shown in the Plans.
Ensure that all of the lowering devices external components are made of
corrosion-resistant materials that are powder-coated, galvanized, or otherwise protected from the
environment by industry-accepted coatings that withstand exposure to a corrosive environment.
All finished castings must have a smooth finish free from cracks, blow-holes, shrinks, and other
flaws. All roller fairlead frames shall be corrosion resistant stainless steel or aluminum.
The lowering device must be provided with a minimum of 100 feet of
composite power and signal cable prewired to the lowering device at the factory unless otherwise
shown in the Plans. Ensure there are no splices in prewired cable.
785-3.2.2.1 Equipment Connection Box: Provide an equipment
connection box for connecting the CCTV camera or other ITS device to the lowering device. The
equipment connection box must include a 1.5 inch National Pipe Thread (NPT) pipe connection
point for attaching a camera. Ensure that the equipment connection box has an ingress protection
rating of no less than IP55.
785-3.2.2.2 Disconnect Unit: Ensure that the disconnect unit has a
minimum load capacity of 600 pounds with a 4:1 safety factor. Ensure that the fixed and
movable components of the disconnect unit have a locking mechanism between them. Provide a
minimum of two mechanical latches for the movable assembly. Ensure that all load is transferred
from the lowering cable to the mechanical latches when the system is in the latched position.
Ensure that the fixed unit has a heavy-duty cast tracking guide and a means to allow latching in
the same position each time.
Ensure that the disconnect unit is capable of securely holding the
lowering device and the equipment installed on the lowering device. Use interface and locking
components that are stainless steel or aluminum.
785-3.2.2.2.1 Disconnect Unit Housing: Ensure that the
disconnect unit housing is provided with a gasket to seal the interior from dust and moisture.
Ensure that the disconnect unit housing has an ingress protection rating of no less than IP55.
785-3.2.2.2.2 Connector Block: Provide modular, self-aligning
and self-adjusting female and male socket contact halves in the connector block. Equip the
lowering device with enough contacts to permit operation of all required functions of the camera,
up to a maximum of 20 contacts. Provide at least two spare contacts. Provide contact connections
between the fixed and movable lowering device components that are capable of passing EIA-
928
232, EIA-422, EIA-485, and Ethernet data signals and 1 volt peak to peak (Vp-p) video signals,
as well as 120 VAC, 9-24 VAC, and 9-48 VDC power. Ensure that lowering device connections are
capable of carrying the signals, voltages, and current required by the devices connected to them
under full load conditions. Submit documentation showing pin assignment for approval.
Provide corrosion-resistant stainless steel hardware. Ensure
all components, including the connector block and contacts, are lubricated in accordance with the
manufacturers instructions. Ensure that male contacts used for grounding mate first and break
last. Ensure that all contacts and connectors are self-aligning and self-adjusting mechanical
systems. Provide a spring-assisted contact assembly to maintain constant pressure on the contacts
when the device is in the latched position.
Provide connector pins made of brass- or gold-plated
nickel, or gold-plated copper.
Ensure that the current-carrying male and female contacts
are a minimum of 0.09 inch in diameter and firmly affixed to the connector block. Ensure mated
connectors do not allow water penetration.
785-3.2.3 Lowering Tool: Provide a portable metal-frame lowering tool with
winch assembly and a cable with a combined weight less than 35 lbs., a quick release cable
connector, and a torque limiter that will prevent over-tensioning of the lowering cable. Ensure
that the lowering tool can be powered using a half-inch chuck, variable-speed reversible
industrial-duty electric drill to match the manufacturer-recommended revolutions per minute, or
supply a drill motor for the lowering tool as shown in the Plans.
Ensure that the lowering tool securely supports itself and the load. Ensure
that the lowering tool is equipped with a winch with a minimum drum size width of 3.75 inch
and a positive braking mechanism to secure the cable reel during raising and lowering
operations, and to prevent freewheeling. Ensure the lowering cable winds evenly and does not
bind on the lowering tool winch drum during operation. Ensure the winch includes a manual
winch handle that incorporates a non- shear pin type torque limiter that can be used repeatedly
and will prevent damage to the lowering system.
Use a lowering tool equipped with gearing that reduces the manual effort
required to operate the lifting handle to raise and lower a capacity load. Provide the lowering tool
with an adapter for operating the lowering device with the portable half-inch chuck drill using a
clutch mechanism and torque limiter.
Ensure that the lowering tool is manufactured of durable, corrosionresistant materials that are powder-coated, galvanized, or otherwise protected from the
environment by industry-accepted coatings that withstand exposure to a corrosive environment.
Provide a minimum of one lowering tool plus any additional tools as
required in the Plans. Upon a projects final acceptance, deliver the lowering tool to the
Department.
785-3.2.4 Lowering Cable: Provide a lowering cable with a minimum diameter
of 0.125 inches. The cable must be stainless steel Type 316 aircraft type (7 strands x 19 gauge)
with a minimum breaking strength of 1,760 lbs. Ensure the lowering cable assembly (as installed
with thimble and crimps on one end and a cable clamp inside the latch on the lowering device
end), has a minimum breaking strength of 1,760 lbs. Ensure all lowering cable accessories, such
as connecting links, have a minimum workload rating that meets or exceeds that of the lowering
cable. Ensure that the prefabricated components for the lift unit support system preclude the
lifting cable from contacting the power or video cables.
929
785-3.2.5 Wiring: Ensure that all wiring meets NEC requirements and follows
the equipment manufacturers recommendations for each device connected on the pole, at the
lowering device, and in the field cabinet.
785-3.2.6 External-mount Lowering System Enclosure for Mounting to
Existing Structures: Furnish and install an external-mount lowering system enclosure for
mounting to existing structures, as shown in the Plans. Ensure that the system includes external
conduit, cabling, and upper mounting/junction box that is able to accept the lowering device.
Ensure that the system includes a winch assembly permanently housed in a corrosion- resistant
lower lockable pole-mounted cabinet. Ensure the upper mounting/junction box includes a
maintenance access door with captive attachment hardware. Provide all necessary mounting
hardware, conduits, standoffs, and conduit mounts required for a complete and functional
system.
Ensure the cabinet minimum dimensions are 12 inches x 18 inches x
10 inches and that the cabinet and door do not interfere with the operation of the winch. The
cabinet must provide adequate clear area for operation of the winch manually and with an
electric drill.
The cabinet must be constructed of 5052 sheet aluminum with a minimum
thickness of 1/8 inch. All inside and outside edges of the cabinet must be free of burrs. The
outside surface of the cabinet must have a smooth, uniform natural aluminum finish. All welds
must be neatly formed, free of cracks, blow holes, and other irregularities. Cabinet hinges must
be vandal resistant and made of 14 gauge diameter stainless steel or 1/8 inch diameter aluminum
and include stainless steel hinge pins. Cabinet door must not sag. Door opening must be double
flanged. Door must include neoprene closed-cell gaskets permanently secured on the interior
door surfaces that contact the door opening. The cabinet must be NEMA 4 rated.
Door must include a pin tumbler lock. Provide locks keyed for use with a
#2 key unless otherwise directed. Provide two keys with each cabinet. The cabinet door handle
must include a lock hasp that will accommodate a padlock with a 7/16 inch diameter shackle.
Ensure external conduit used to connect the winch cabinet to the upper
mounting/junction box is galvanized Schedule 40 with NPT threads. The conduit must have a
minimum ID of 3 inches at the lower winch cabinet entrance and allow the lowering cable to
wind evenly on the winch drum without binding. All conduit couplings and connections between
the pole-mounted cabinet and upper mounting/junction box must be watertight.
785-3.3 Installation Requirements:
785-3.3.1 General: Ensure that the divided support arm and receiver brackets
self-align the contact unit with the pole centerline during installation, and that the contact unit
cannot twist when subjected to the design wind speeds defined in the FDOT Structures Manual,
Volume 9. Supply internal conduit in the pole for the power and video cabling if required by the
Engineer.
Ensure all pulleys installed for the lowering device and portable lowering tool
have sealed, self-lubricated bearings, oil-tight bronze bearings, or sintered bronze bushings.
Provide 1.25 inch diameter PVC conduit in the pole for the lowering cable. Verify
that a conduit mount adapter is furnished for the interface between the conduit and the internal
back side of the lowering device.
785-3.3.2 Concrete Poles: Install foundation and pole in accordance with 6414.2, except footing dimensions shall be in accordance with Design Standards, Index No. 18113.
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785-3.3.3 Steel Poles: Install foundation and pole in accordance with 649-5 and
649-6.
785-3.3.4 Lowering Device: Ensure that the lowering device can be safely
operated and is installed in a manner that does not place the operator directly under the device
when it is being raised or lowered.
Ensure the lowering device support arm self-aligns the disconnect unit and
attached device with the pole centerline and remains centered after installation without moving
or twisting. Ensure the connection between the lowering device and tenon is weather resistant to
prevent the entrance of water. For externally-mounted lowering systems, use conduit straps to
secure lowering cable conduit to the pole. Do not use stainless steel bands to secure conduit to
the pole. Place the stainless steel lowering cable inside conduit. Ensure that only the lowering
cable is in motion inside the pole when the lowering device is operated. Ensure that all other
cables remain stable and secure during lowering and raising operations. Label all wire leads with
their function, label spares as spares.
Ensure that crimps and other cable connection hardware associated with
the lowering cable cannot come in direct contact with the winch tool or guides when operating
the system. Ensure the correct length of lowering cable is installed and that the installed length
prevents cable slack and prevents cable from jumping off the winch spool. Ensure the lowering
cable strands do not twist or unwind when the lowering device is operated.
Provide manufacturer recommended field installation instructions,
inspection instructions (including recommended schedules and procedures), and operating
instructions.
785-4 ITS Field Cabinet.
785-4.1 Description: Furnish and install a cabinet for housing ITS equipment and
network devices including, but not limited to, managed field Ethernet switches, hub switches,
device servers, digital video encoders, fiber optic cable patch panels, and equipment racks for
non-intrusive vehicle detection systems. Use only equipment and components that meet the
requirements of these minimum specifications, and are listed on the APL.
785-4.2 Materials:
785-4.2.1 Cabinet Shell: Ensure the cabinet shell conforms to NEMA 3R
requirements. Ensure that the cabinet shell is constructed using unpainted sheet aluminum alloy
5052-H32 with a minimum thickness of 0.125 inches. Ensure that the cabinet has a smooth,
uniform natural aluminum finish without rivet holes, visible scratches or gouges on the outer
surface. Other finishes are acceptable if approved.
The minimum dimensions for cabinets are listed below.
Cabinet Type
336
336S
334
Table 785-2
Required Cabinet Dimensions in Inches
Height
Width
36-39
24-26
46-48
24-26
66-68
24-26
Depth
20-22
22-24
30-32
Ensure that the cabinet enclosure top is crowned to prevent standing water.
Construct the field cabinet so that it is weather resistant under all conditions. Ensure all exterior
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cabinet and door seams are continuously welded and smooth. All welds shall be neatly formed
and free of cracks, blow holes and other irregularities. Verify that all exterior cabinet welds are
gas tungsten arc (TIG) welds. Ensure that all internal cabinet welds are gas metal arc (MIG) or
TIG welds. Ensure that all inside and outside edges of the cabinet are free of burrs. Ensure that
all edges are filled to a radius of 0.03125 inches minimum. Use ER5356 aluminum alloy bare
welding electrodes conforming to AWS A5.10 requirements for welding on aluminum.
Procedures, welders and welding operators shall conform to AWS requirements as contained in
AWS B3.0 and C5.6 for aluminum.
Ensure that the cabinet is furnished with two lifting eye plates on either
side of the top for lifting the cabinet and positioning it. Ensure that each lifting eye opening has a
minimum diameter of 0.75 inches and that each eye is able to support the weight load of
1,000 lbs. Ensure that all external bolt heads are tamperproof.
785-4.2.2 Doors: Provide a cabinet with front and rear doors, each equipped with
a lock and handle. Ensure that each cabinet door is full size, matching the height and width
dimensions of the cabinet enclosure, and has no fewer than three stainless steel hinges or
alternately, one full-length piano hinge. Provide hinges that are made of 14 gauge stainless
steel and ensure that the stainless steel hinge pins are spot-welded at the top. Mount the hinges so
that they cannot be removed from the door or cabinet without first opening the door. Brace the
door and hinges to withstand a 100 lb. per vertical foot of door height load applied vertically to
the outer edge of the door when standing open. Ensure there is no permanent deformation or
impairment of any part of the door or cabinet body when the load is removed.
Ensure that both door openings are double flanged on all four sides, and
that the doors include a closed-cell, neoprene gasket seal that is permanently bonded to the inside
of each door such that the neoprene forms a weather-tight seal when the door is closed.
785-4.2.3 Latches: Provide all cabinets with a three-point latching system for the
doors. Ensure that the latching system consists of the following latching points.
1. Center of the cabinet (lock).
2. Top of the cabinet - controlled by the door handle.
3. Bottom of the cabinet - controlled by the door handle.
Ensure that latching points two and three remain in the locked position
until the main cabinet door lock is unlocked. Ensure that the locking mechanism is equipped with
nylon rollers to secure the top and bottom of the door.
Provide the cabinet with a door stop that retains the main door open in a
90 degree and 120 degree position.
Outfit the doors with an industrial standard pin tumbler lock with #2 key,
or an approved alternate, and hardware that allows the door to be secured using a padlock.
Provide two keys for each cabinet lock.
785-4.2.4 Rails: Provide the cabinet with four cabinet rails that form a cage for
the purpose of mounting miscellaneous wiring panels and various mounting brackets. Use rails
that extend the length of the cabinets sides, starting from the bottom of the enclosure. Provide
rails that are either 0.1345 inch thick plated steel or 0.105 inch thick stainless steel. Ensure that
the rails are keyhole designed with slots 2 inches on center with a top opening of 5/8 inch in
diameter to allow the insertion of a 5/8 inch by 1 inch carriage bolt. Ensure that the rails are 11/2 inches to 2 inches wide by 1/2 inch deep. Do not use unistruts or other rail types.
Provide rails that have been drilled and tapped for 10-32 screws or rack
screws with EIA universal spacing.
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785-4.2.5 Racks: Ensure that the cabinet includes a standard 19 inch EIA/TIA
equipment rack centered in the cabinet for mounting of the devices to be installed inside. Verify
that the clearance in the rack between the rails is 17.75 inches.
785-4.2.6 Shelf: Provide a level, rollout internal shelf with a minimum work area
measuring 10 inches by 10 inches. Ensure that the shelf is capable of sustaining a constant 20 lb.
load. Ensure that the shelf position is adjustable.
785-4.2.7 Sunshield: If the cabinet is provided with sunshields, as indicated in
the Plans, the sunshields must be mounted on standoffs that provide an air gap of at least of one
inch between the exterior cabinet walls and the sunshields. Ensure that the sunshields are
fabricated from 5052-H32 aluminum sheet that is 0.125 inches thick, and that sunshield corners
are rounded and smoothed for safety.
785-4.2.8 Ventilation: Ensure that the cabinet provides ventilation through the
use of a louvered vent at the bottom of the main door. Verify that the louvered vent depth does
not exceed 0.25 inches. Ensure that the intake vent is made rain tight through the use of a waterdeflecting ventilation panel on the inside of the main door securing the filter to the door. This
panel should form a shell over the filter to give it mechanical support, and should be louvered to
direct the incoming air downward.
Provide an easily removable, reusable filter held in place with a bottom
trough and a spring-loaded upper clamp. Provide a filter measuring no less than 16 inches by
12 inches by 7/8 inch thick. No incoming air shall bypass the filter. Ensure that the bottom
trough holding the filter is able to drain any accumulated moisture to the outside of the field
cabinet.
Equip the ITS field cabinet with dual thermostatically controlled fans
located inside at the top of the cabinet. Use UL-listed exhaust fans having a minimum air flow
rating of 100 cubic feet per minute. Ensure that the electric fan motors have ball or roller
bearings. Provide fans that are rated for continuous duty and have a service life of at least three
years. Vent the exhaust air from openings in the roof of the field cabinet.
Ensure the thermostats that activate the fans are mounted on the inside top
of the cabinet. Ensure that the thermostat is user adjustable to allow temperature settings ranging
from a minimum of 70F to a maximum of 160F. Ensure that the thermostat activates the fans
within plus or minus 3 degrees of the set temperature.
785-4.2.9 Electrical Requirements: Ensure that all equipment furnished
conforms to applicable UL, NEC, EIA, ASTM, ANSI, and IEEE requirements. Ensure that the
SPD is accessible from the front of any panel used in the cabinet. Connect the SPD for the
cabinets main AC power input on the load side of the cabinet circuit breaker.
Ensure that the wiring in the cabinet conforms to NEC requirements. Use
only conductors that are stranded copper. Lace all wiring.
785-4.2.9.1 Service Panel Assembly: Provide a service panel assembly to
function as the entry point for AC power to the cabinet and the location for power filtering,
transient suppression and equipment grounding. Provide branch circuits, SPDs, and grounding as
required for the load served by the cabinet, including ventilation fans, internal lights, electrical
receptacles, etc.
785-4.2.9.2 Terminal Blocks: Terminate electrical inputs and outputs on
terminal blocks where the voltage and current rating of the terminal block is greater than the
voltage and current rating of the wire fastened to it.
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Terminate conductors on terminal blocks using insulated terminal
lugs large enough to accommodate the conductor to be terminated. When two or more
conductors are terminated on field wiring terminal block screws, use a terminal ring lug for
termination of those conductors. Number all terminal block circuits and cover the blocks with a
clear insulating material to prevent inadvertent contact.
785-4.2.9.3 Ground Bus Bar: Ensure that ground bus bars are fabricated
from a copper alloy material compatible with copper wire. Use ground bus bars that have at least
two positions where a No. 2 AWG stranded copper wire can be attached.
Mount the ground bus bar on the side of the cabinet wall adjacent
to the service panel assembly for the connection of AC neutral wires and chassis ground wires. If
more than one ground bus bar is used in a cabinet, use a minimum of a No. 10 AWG copper wire
to interconnect them. Ensure that the equipment rack is connected to the ground bus bar within
the cabinet maintaining electrical continuity throughout the cabinet.
Follow the PANI recommendations of USDA-RUS-1751 for
connections to the ground bus bar. Producer (P) or electrical power and sources of stroke current
connections shall be on the left end of the bus bar. Absorbing (A) or grounding wires shall be
connected immediately right of the P connections. Non-isolated (N) connections such as doors
and vents shall be connected to the right of the A connections. Isolated (I) equipment grounds
from equipment in the cabinet shall be connected on the right end of the bus bar.
785-4.2.9.4 Power Distribution Assembly: Furnish a power distribution
assembly that fits in the EIA 19 inch rack and provides for protection and distribution of
120 VAC power unless otherwise shown in the Plans.
785-4.2.9.5 Interior Lighting: Unless otherwise shown in the Plans,
provide the field cabinet with two 20 watt fluorescent lamps and clear shatter-proof shield
assemblies which are mounted on the inside front and rear top of the cabinet. Ensure that these
lamps are unobstructed and able to cast light on the equipment. Equip the field cabinet with
door-actuated switches so that the lamps automatically turn on when either cabinet door is
opened and turn off when the doors are closed.
785-4.2.9.6 Generator and Auxiliary Power Connection: Unless
otherwise shown in the Plans, furnish a cabinet that has provisions for the connection of an
external power source, such as a portable generator, through a weatherproof, water-resistant,
secure interface. This feature should allow authorized personnel to access, connect, and secure an
external power source to the cabinet in order to restore power within 5 minutes of arrival time at
the cabinet. Provide the cabinet with either a manual or automatic transfer switch as shown in the
Plans. Provide a transfer switch rated equal to or higher than the design load of the cabinets
main breaker and the generator input twist-lock connector rating. Ensure that the transfer switch
provides a means of switching between normal utility power and auxiliary backup generator
power. Ensure that the switching time between sources is no longer than 250 milliseconds.
Ensure that the transfer switch meets UL 1008. Ensure that the transfer switch does not allow
simultaneous active power from more than one source and does not allow generator backflow
into normal utility AC circuits.
785-4.2.9.6.1 Manual Transfer Switch: Ensure the manual
transfer switch is a two-position switch. Label the switch positions as Generator Power and
Utility Power.
Equip the transfer switch with a Utility-on indicator,
which will illuminate when normal utility power service is available and the switch is in the
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Generator Power position. The indicator must turn off when the transfer switch is moved to the
Utility Power position. Ensure that the Utility-on indicator is clearly visible outside the cabinet
and that the indicators on/off state can be visually determined from a distance of 30 feet.
785-4.2.9.6.2 Automatic Transfer Switch: An automatic transfer
switch may be used instead of a manual transfer switch to provide for automatic transition from
generator power back to normal utility service after utility power is restored. Ensure that the
automatic transfer switch has indicators that display the status of connected power sources and
indicate which power source is actively energizing the cabinet.
If a relay circuit is used to provide switching, the normally
closed circuits must be connected to normal utility power. The relay shall be energized only by
the generator, not by the electric utility service. When energized, the relay must break the
connection to normal utility power and make connection to the generator power input. Any
automatic transfer switch or relay operated switch must include a bypass switch that disables
automatic switching and permits manual selection of the power sources connected to the cabinet.
785-4.2.9.6.3 Generator Access Panel: Include a generator
connection panel consisting of, at a minimum, the manual transfer switch and three-prong,
30 amp twist-lock connector with recessed male contacts for generator hookup. Locate and label
the transfer switch and twist lock connector on a panel easily accessible behind a lockable
exterior door. Ensure that this access door is labeled as Generator Access Door, equipped with
a tamper-resistant hinge, and that the door assembly is weatherproof and dustproof. The access
door shall be provided with a #2 lock unless otherwise specified in the Plans. The access door
must include a weatherproof opening for the generator cable. The generator hookup
compartment must be recessed into the cabinet and be deep enough to allow closing and locking
of the access door when the generator cable is connected. Limit the generator hookup
compartment and access panels intrusion into the cabinet interior to no more than 6 inches.
Avoid blocking access to any other equipment in the cabinet. Locate this generator panel as close
as possible to the main AC circuit breaker. Ensure that the bottom of the access panel is no less
than 24 inches above the bottom of the cabinet. Never locate the generator access panel on the
main cabinet door or back door.
Connect wiring from the Cabinet AC+ Input Terminal to
the transfer switch. Connect the alternate power sources wiring on the transfer switch to a
receptacle that can accept a 120 VAC generator cord. Install a power service wire between the
transfer switch and the existing power distribution panel in the cabinet.
785-4.3 Installation Requirements.
Mount the cabinet to a concrete base or attach it to a pole or support structure, as
shown in the Plans, and provide the cabinet with the necessary base or pole mount hardware.
Ensure that pole and structure mounted field cabinets have mounting brackets on the side so that
both cabinet doors are fully functional.
Supply ground-mounted field cabinets with a removable base plate. Ensure that
the cabinet has welded inside two aluminum plates for anchoring the cabinet to a concrete or
composite type base as shown in the Plans. Fabricate the plates from aluminum alloy 5052-H32.
Ensure the plates are a minimum of 4 inches wide by 0.125 inches thick. Ensure the cabinet
includes four 1 inch diameter holes for anchoring.
Make provisions for all telephone, data, control, and confirmation connections
between the ITS device and field cabinet, and for any required wiring harnesses and connectors.
935
Ensure that the cabinet manufacturers name and APL certification number appear
only on the inside of the main cabinet door, along with the year and month of the cabinets
manufacture. Attach this information to the door by a method that is water resistant. Provide the
field cabinet with a unique serial number that is engraved on a metallic plate epoxied to the
inside of the cabinet on the upper right-hand side wall.
Mount a heavy-duty resealable plastic bag on the backside of the main cabinet
door for containing cabinet prints, a list of terminal block connections, and other documentation
that may be subject to damage when exposed to sunlight or moisture.
Place all equipment in the cabinet according to the recommendations of the
manufacturers. A minimum clearance of 6 inches shall be provided between the top of the
cabinet and the top of any equipment placed on the top shelf of the cabinet. A minimum
clearance of 2 inches shall be provided between each side of the cabinet and the equipment
placed on the cabinet shelves.
785-5 ITS Equipment Shelter.
785-5.1 Description: Furnish and install an equipment shelter of concrete or concrete
composite in a size as detailed in the Plans and that is capable of providing a controlled
environment for housing the electronic communication equipment, power supplies, and related
components necessary for the proper operation of an ITS deployment.
785-5.2 Materials:
785-5.2.1 General: Ensure that the shelter comes complete with a secure door,
power distribution panels; a heating, ventilation, and air conditioning (HVAC) system; lightning
protection, grounding, and any other components necessary for a completely integrated
communication building. Ensure that the shelter is constructed and installed according to local
building codes.
Ensure that all materials and installation practices are in accordance with
the applicable OSHA requirements in 29 Code of Federal Regulations (CFR) Part 1926, Safety
and Health Standards for Construction.
Provide an equipment shelter capable of withstanding minimum loads as
follows: wind, 150 MPH; floor, 200 lbs. per square foot; slab, 200 lbs. per square foot; roof,
100 lbs. per square foot. Provide drawings that are signed and sealed by a registered Professional
Engineer indicating the shelter meets these minimum values.
Provide the shelters exterior with a concrete aggregate finish. Ensure that
the shelter has a bullet-resistant exterior surface in accordance with UL 752. Ensure that the
shelters exterior color is earth tone to blend with its surroundings. Alternative exterior finishes
or colors must be approved.
Ensure that the equipment shelters heat transfer coefficient does not
exceed 0.07 British Thermal Units (BTUs) per hour per square foot per degree Fahrenheit (F) for
the roof insulation and 0.28 BTUs per hour per square foot per degree F for the exterior wall
insulation.
785-5.2.2 Shelter Floor and Foundation: Ensure that the equipment shelter floor
is constructed of concrete or concrete composite material.
Ensure that the foundation is a monolithic slab with footing, and that the
top of the foundation is a minimum of 2 feet above final grade, or as shown in the Plans.
Provide an equipment shelter with sufficient cross bracing to prevent the
shelters structure from bending or breaking during moving, towing, or hoisting, and to ensure
936
minimum warping after the shelter has been placed on the foundation with the communication
equipment installed.
Ensure that the equipment rooms interior floor covering is an industrialgrade vinyl flooring fastened to the shelter floor with waterproof glue. Provide an air gap
between the equipment shelter floor and the slab, or alternatively, construct the slab with a vapor
barrier of 0.2-inch polyethylene sheeting beneath the concrete and a layer of #30 asphalt
impregnated membrane above the slab to prevent moisture penetration. Insulate the floor with
polystyrene foam to provide a minimum insulating factor of R-11.
785-5.2.3 Door: Ensure that the exterior door is an insulated, bullet-resistant,
galvanized steel door with baked enamel finish, a door check, and doorstop. Ensure that the
exterior door is 36 inches in width by 78 inches in height with a mortised deadbolt security
common-keyed lock. Provide the Department with the keys to the doors lock. Ensure that the
door has a handle on both the inside and outside.
785-5.2.4 Walls: Supply the walls with a vapor shield to prevent moisture
penetration. Insulate the walls using a minimum insulating factor of R-14. Provide interior
surfaces that have a white textured finish wall covering with molding on all corners. Ensure that
all floor/wall intersections have 4 inch vinyl baseboards installed using waterproof glue.
785-5.2.5 Ceiling and Roof: Ensure that the ceiling is no less than 8 feet above
the floor and is capable of supporting the proposed electrical fixtures and cable trays. Construct
the roof section with a 1/8 inch per foot minimum pitch for drainage. Fill all voids between the
ceiling and roof with minimum Type R-21 insulation and include a vapor shield.
785-5.2.6 Entrance: Provide the shelters entrance with concrete steps and hand
rail installed so that the distance from the grade or final step to the shelter floor does not exceed
8 inches.
785-5.2.7 Lighting: Supply a sufficient quantity of fluorescent light fixtures to
provide a uniform initial light level of 125 to 150 foot candles at 4 feet above the floor with a
3:1 ratio of maximum to minimum light levels as measured throughout the shelters interior.
Mount an interior light switch adjacent to the entry door.
Provide one 35 watt, high-pressure sodium floodlight that is vandal
resistant and mounted on the outside near the entrance door. Provide this floodlight with a
photocell and interior light switch. Provide an interior emergency light.
785-5.2.8 HVAC System: Provide exterior vertical wall-mounted air conditioners
for the equipment shelter. Ensure that the HVAC system has an alarm that indicates failure (i.e.,
a dry contact closure alarm point). Provide an adjustable time delay initially set to 5 minutes to
prevent compressor damage or generator stall if electric service is prematurely restored following
a power failure.
Ensure that the HVAC unit has a hard start device installed to reduce the
starting current required during a cold start or under high-head pressure conditions. Ensure that
the unit is capable of safely operating when the outside temperature falls below 60F, allowing
continuous interior equipment cooling and dehumidification in cold weather. Ensure that the unit
has sufficient capacity to cool from a 95F ambient temperature to 75F, including the equipment
heat load.
785-5.2.9 Cable Trays: Provide cable trays that are 12 inches wide and of
sufficient strength to support the transmission lines, control and data wires, and alarm wires
associated with communication equipment. Use cable trays constructed of aluminum or painted
steel. Suspend the cable trays from the ceiling. Ensure that all cable trays are fabricated in an
937
open ladder type arrangement to permit easy cable routing. In addition, electrically bond by
mechanical means all rack and cable tray units together. Use flat washers to facilitate rack
bonding on nonpainted surface areas. After bonding, cover these areas with an antioxidant
compound. Ensure that cable trays and rack frames are connected to the shelter interior ground.
Ensure that clearance height between the floor and bottom of the cable
tray is no less than 86 inches.
Equip the cable trays with overhead quad receptacles for 120 VAC and 20A
twist-lock receptacles for 240 VAC, as shown in the Plans. Put each receptacle on its own breaker.
785-5.2.10 Equipment Rack: Ensure that the equipment shelter includes one or
more standard 19 inch EIA/TIA equipment racks for mounting of the devices to be installed, as
indicated in the Plans. Secure the top of each rack to the cable tray above using C channel or Jhook hardware. Ensure that the racks meet the equipment installation needs in terms of rack
height and load requirements. Include provisions for vertical and horizontal cable management
and for power strips. Secure the racks to the floor in the location shown in the Plans or as
directed.
785-5.2.11 Fire/Smoke Detection and Suppression: Include with the equipment
shelter one smoke detector that operates on alternating current. Mount the smoke detector on the
ceiling and ensure that it includes a dry contact closure that will activate during smoky
conditions.
Where the equipment shelter is to be furnished with an automatic fire
protection system, ensure that it is an FM-200 waterless, residue-free fire suppression system
that conforms to NFPA and ISO 14520 standards.
If a fire extinguisher is specified, mount on the wall near the door a handheld carbon dioxide fire extinguisher suitable for use on electrical fires. Verify that the
extinguisher has a valid inspection tag and is refillable.
785-5.2.12 Alarm Specification: Wire and terminate all alarms on a Contractorprovided Type 66 block. Label each termination. Provide the following equipment shelter
alarms:
1. A magnetic dry contact door alarm.
2. A dry contact air conditioner failure alarm for each installed unit.
3. Dry contact fire alarms.
4. Dry contact high- and low-temperature alarms with thresholds
adjustable between 50 and 90F.
5. A power failure alarm that is wired from a dedicated circuit breaker.
6. A main fuse alarm that is wired from the main fused disconnect.
785-5.2.13 Electrical Specifications: Ensure that the standard electrical
configuration for the shelter is single-phase 120/240 VAC at 60 Hz with a 150 A minimum
service and a 42 circuit distribution panel. Provide the necessary power service drop and site
specific power needs for the equipment shelter installation, following the requirements of
Section 639.
785-5.2.13.1 Primary AC Powered Surge Protective Device (SPD):
Provide the equipment shelter with a primary AC SPD that meets or exceeds all of the
requirements of 785-2.4.1 and 785-2.4.2 that is connected to the electrical system at all times,
whether the site is operating on utility or emergency power.
785-5.2.13.2 SPDs at Point of Use: Provide the equipment shelter with
SPDs that meet or exceed all requirements in 785-2.4.3 and 785-2.4.4. These devices will
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generally have special requirements for installation and interface with the ITS circuits or devices
as shown in the Plans. Ensure that all outlets within the equipment shelter are protected.
785-5.2.14 Communication Cable Wall Entry: Provide the equipment shelter
with four 4-inch diameter ports with weather-sealed boot systems for telephone/signal cable and
fiber optic cable entry. Locate these ports as shown in the Plans.
785-5.2.15 Circuit Termination Backboard: Provide each equipment shelter
with a backboard for the termination of communication circuits. Provide a backboard of 3/4 inch
AC grade plywood no less than 48 inches square and painted with two coats of gray, flameretardant paint. Ensure that all ground wires and conductors are insulated from the backboard,
which must be mounted securely to the wall and able to support the weight of the hardware
fastened to it.
785-5.3 Installation Requirements.
785-5.3.1 General: Provide a drawing that depicts the details of the proposed
equipment shelter installation, including site layout, fencing, and all other features. Submit this
drawing for approval prior to the start of construction.
Provide concrete in accordance with Section 346. Perform all concrete
work in accordance with Section 400. Obtain precast products from a plant that is currently on
the Departments list of Producers with Accepted Quality Control Programs. Producers seeking
inclusion on the list shall meet the requirements of 105-3.
Contact local building officials for permit applications and submit them
for approval and execution. The Contractor shall be responsible for obtaining all permits and
their associated applications, filling out the applications, obtaining a Department signature, and
then submitting the permit application to the regulating agency.
785-5.3.2 Electrical Installation: Provide for electrical power to the equipment
shelter and ensure that power is properly connected. Route all wires and cables in a neat, orderly
fashion. Electrical connectors and all costs associated with providing power shall be the
Contractors responsibility. Provide underground power service unless otherwise specified in the
Plans.
Provide all electrical connections from the service drop to the equipment
shelters receptacles. Wire the receptacles, switches, and light fixtures using a minimum of
No. 12 AWG copper wires. Run all wire in a minimum 0.75 inch inside diameter electrical
metallic tubing. Divide the electrical loads among as many load centers as necessary to contain
the quantity of circuit breakers required to protect the equipment shelter facility.
Ensure that the load centers contain separate, appropriately sized circuit
breakers for the HVAC units, each major branch as is necessary, each receptacle, and each
remaining location in the 42 circuit panel. Ensure that the shelter includes duplex receptacles on
each of the four walls at a height of 18 inches above the floor, as shown in the Plans. Protect
each wall with a separate 20 A circuit breaker. Provide a separate 20 A single-pole circuit
breaker to protect the lighting circuits.
785-5.3.3 Provision for Backup Power: Ensure that the main power enters the
equipment shelter at a primary power switch to allow for the disconnection of commercial
power, and then is routed to an automatic transfer switch that will switch to emergency generator
power in the event commercial power is lost. Also ensure that emergency generator power enters
the equipment shelter through a power switch prior to connection to the automatic transfer switch
panel. Ensure that the equipment shelter is able to utilize a mobile emergency generator during
power outages. Route the main power from the automatic transfer switch to a manual transfer
939
switch located with the mobile emergency generator connection installed on the outside of the
shelter. The emergency generator connection shall allow Department personnel to power the site
from a portable generator in the event that both the commercial power and emergency power is
lost. Route the resulting main power to a 42 circuit distribution panel and through the associated
AC surge protective devices, as described in the Plans.
785-5.3.4 Grounding Installation: Install all grounds for the equipment shelter
on the side of the building that utilities, communication cables, and fiber enter. Install the main
ground bar on a suitable wall of the building. Connect all earth grounds to this point, including
the grounding system for the SPDs. Make all connections to SPDs according to the
manufacturers recommendations.
Ensure that the grounding system is bonded at a single point so that the
communication cables, AC power, emergency generator, and equipment frames are connected by
the shortest practical route to the grounding system. Protect the lead lengths from each device to
the SPD.
Use an exothermic bonding process for all external connections. Ensure
that external connections and ground rods remain accessible for inspection, testing, and
maintenance during and after construction.
Use compression type connection for all interior connections to bond
ground conductors to equipment in the shelter. For connections to bus bars, use mechanical
connections having two bolts on a double-lug connector. After achieving a firm connection to the
connectors, apply an anti-oxidant compound.
Ensure that all ground connections to fence components are mechanical
bonds. After a firm connection has been achieved, apply an anti-oxidant compound.
For connection of conductors to interior equipment, such as panels and
cable trays, use two bolts on a double-lug connector, or clamps appropriate to the size and type
of wire and the requirements of the equipment being grounded. Crimp and solder all wires
connected to lugs or clamps for reliable electrical contact. Remove all non-conducting surface
coatings before each connection is made. Apply an anti-oxidant compound. Install star washers,
or another means that accommodates the fasteners used, to achieve reliable electrical connections
that will not deteriorate.
Ensure that ground conductors are downward coursing and vertical, and as
short and straight as possible. Ensure that the minimum bending radius for interior equipment
shelter grounds is 8 inches. Avoid sharp bends and multiple bends in conductors in all cases.
Follow the PANI recommendations of USDA-RUS-1751 for connections
to the ground bus bar. Producer (P) or electrical power and sources of stroke current connections
shall be on the left end of the bus bar. Absorbing (A) or grounding wires shall be connected
immediately right of the P connections. Non-isolated (N) connections such as doors and vents
shall be connected to the right of the A connections. Isolated (I) equipment grounds from
equipment in the cabinet shall be connected on the right end of the bus bar.
785-5.3.4.1 Interior Grounding: Install a No. 2 AWG solid bare copper
wire approximately 1 foot below the ceiling on each wall and mount it using insulated standoffs.
Ensure that the wire encircles the equipment room, forming a ring or continuous loop along the
upper interior perimeter ground, and includes the wall area above the door. Mechanically
connect the cable trays to the upper interior perimeter ground using stranded copper wires with
green insulation and bolted terminal connectors at the cable tray ends. Make all points where
940
cable tray sections meet electrically continuous by use of a short jumper wire with terminals
attached at each end.
Directly bond all other metallic objects, such as door frames and
doors, air conditioners, alarm systems, wall-mounted communication equipment, etc., to the
closest interior perimeter ground with the shortest possible stranded copper wire with green
insulation. Bond the door to the doorframe using flexible welding cable.
785-5.3.4.2 Exterior Grounding: Install an exterior grounding system
consisting of multiple ground rods around the perimeter of the equipment shelter to achieve the
resistance to ground required in 785-2.3. Space the rods according to 785-2.3.2 and drive them
into the ground using the proper tool to prevent rod deformation. Place the rods a minimum of
2 feet from the building foundation in a suitable access point. Ensure that 6 inches to 10 inches
of the ground rod is accessible for inspection, testing, and maintenance during and after
construction. Bond the ground rods together using No. 2 AWG solid bare tinned copper wire and
an exothermic bonding process. Bury the bonding wires a minimum of 18 inches below grade.
Also bond the following items to the shelters grounding system using No. 2 AWG solid bare
tinned copper wire:
1. Metal building parts not grounded by the internal grounding
rings, such as downspouts and siding.
2. Ground rods provided by power or telephone utilities for
grounding of AC power or surge protection devices, as permitted by local codes.
3. Shelter support skids, bases, or foundations, if applicable.
4. Any metal object larger than 4 square feet.
5. External metal fencing.
785-5.3.4.3 Punch Block SPD Grounding: For all Type 66 punch blocks,
install No. 2 AWG solid bare tinned copper wire to ground external line surge protection
devices. Install the No. 2 AWG solid bare tinned copper wire in accordance with the SPD
manufacturers recommendations and mechanically connect them to the shelters interior
perimeter ground.
785-5.3.5 Site Preparation: Ensure that all provisions of Section 110 are met in
preparing the site. Coordinate the extent and schedule for all land clearing activities with the
Engineer to ensure that there is no interference with concurrent operations at the site. Comply
with all environmental protection requirements.
785-5.3.6 Fencing: Furnish Type B chain-link perimeter fencing and gates
according to the requirements of Section 550. Install the fence to form a rectangle or square
shape, unless otherwise specified in the Plans. Allow for a minimum space of 5 feet between the
fence and any enclosed item. Ensure that the fencing materials, including posts and bracing, are
metal and comply with Section 965.
Construct the fence in accordance with Design Standards, Index No. 802.
Ensure that the basic fence is a minimum height of 6 feet and is topped with barbed wire that is
held outward from the fence at a 45 degree angle with galvanized hardware. Fasten the fence
fabric to a top rail installed on top of the fence.
Ensure that all gates are made of the same material as the fence. Construct
sliding gates in accordance with Design Standards, Index No. 803 and configure as shown in the
Plans. Provide a hardened, four digit combination gate lock. Set the combination as directed.
941
785-5.3.7 Fence Grounding: Ensure that the metal Type B fence is grounded to
fence perimeter ground wires consisting of No. 2 AWG solid bare tinned copper wires that
encircle the entire compound to achieve the resistance to ground required in 785-2.3.
Exothermically bond any splices in the ground wire. Bury the fence
perimeter ground wire a minimum of 2.5 feet below finished grade. Bond all fence posts to the
fence perimeter ground wire using No. 2 AWG solid bare tinned copper wire. Bond the gate and
gatepost together with a flexible ground, such as welding cable wires. Ground the gatepost to the
fence perimeter ground wire using No. 2 AWG solid bare tinned copper wire. Exothermically
bond all connections to the fence perimeter ground wire.
Connect the fences top rail to each corner post and in the middle of each
side. Ground the fence fabric with No. 2 AWG solid bare tinned copper wire connected to the
fence posts. Connect the fence perimeter wires to the ground rods of the equipment shelters
ground system with No. 2 AWG solid bare tinned copper wire, as shown in the Plans.
Ensure that all ground leads are No. 2 AWG solid bare tinned copper
wires for all above- and underground grounding wire installations. Ensure that all exothermic
bonds are appropriate for the application. Do not use welding or other forms of bonding without
prior written approval.
785-5.3.8 Weed Prevention: Treat the fenced area with a Department approved
herbicide and cover it with weed prevention material. Place a woven plastic weed barrier on the
ground before gravel installation. Install the barrier with a minimum 10% overlap for each
barrier section and secure the edges of the mat with stakes.
785-5.3.9 Compound Gravel: Place gravel or crushed rock covering all
unimproved areas inside the new fenced area to a depth of 6 inches. Ensure that the size does not
exceed 3 inches in diameter so that foot traffic is not difficult.
785-5.3.10 Site Restoration: Provide performance turf in accordance with
Section 570.
785-5.4 Inspection and Verification.
785-5.4.1 General: Perform an inspection that is witnessed by the Engineer.
Notify the Engineer at least 10 days prior to completion of the installation. After installation of
the shelter equipment, verify in conjunction with the Engineer that all equipment is correctly
installed and functional.
For grounding system inspections, notify the Engineer at least five days
prior to completion of the installation. Do not backfill below-grade grounding installations and
grounding connections until inspected and approved. Record all test results in a standardized
format approved by the Engineer prior to testing. All recorded test report data shall be dated,
witnessed, and signed by at least one representative of the Department and the Contractor.
Remedy all deficiencies at no cost to the Department.
785-5.4.2 Mechanical Inspection: Inspect all equipment to be mounted to the
shelter walls to ensure adequate support has been provided. Test the HVAC system for adequate
heating, cooling, and dehumidification. Inspect the building for the proper sealing of
transmission lines, waveguide ports, telephone/signal cables, and ground wire penetrations.
Correct any deficiencies at no cost to the Department.
785-5.4.3 Electrical Inspection: Verify that the shelter lights and smoke
detectors operate properly. Verify proper power load balances and provide a report to the
Engineer prior to acceptance of the site. Correct any deficiencies at no cost to the Department.
942
785-5.4.4 Grounding Inspection: Inspect the grounding system for proper
connection types, tightness, and workmanship, as well as conformance to the approved design.
Repair with new bonds any exothermic bonds that are deemed unsatisfactory. Repair or replace
any mechanical connections that are deemed unsatisfactory. Measure the resistance at each
ground rod using a clamp-on earth tester. The measurement at any individual rod will be the
cumulative resistance of all rods in a parallel circuit. The grounding system resistance must be no
more than 5 . Correct all deficiencies at no cost to the Department.
785-5.4.5 Site Inspection: Inspect the site and verify that it is free of debris, and
that excavations are backfilled and restored.
785-5.4.6 Performance Period: Following the completion of all acceptance
testing and inspections, subject the installed site to a minimum 20 day performance period, or
alternately, the operational test period for the ITS deployment project, whichever is greater.
For the purpose of a successful performance period, failure of operation is
defined as the failure of a major site component (i.e., HVAC systems, lighting, alarms, fire or
smoke detection, etc.). Degradation of performance is not a failure if function and proper
operation is maintained. Conduct the performance verification with the Engineer present. Upon
acceptance of the test criteria, the 20 day performance period shall begin.
Accomplish this performance testing during a period of time not to exceed
45 consecutive days after equipment shelter installation and inspection. If a successful
performance period cannot be accomplished within 45 consecutive days after the shelter
installation and inspection, the Department reserves the right to deem the Contractor in default
and enforce the provisions set forth in the Contract.
785-6 Warranty.
785-6.1 General: Ensure that the manufacturer will furnish replacements for any part or
equipment found to be defective during the warranty period at no cost to the Department or
maintaining agency within 10 calendar days of notification.
785-6.2 Lowering Devices: Ensure that the lowering devices have a manufacturers
warranty covering defects for a minimum of three years from the date of final acceptance by the
Engineer in accordance with 5-11 and Section 608.
785-6.3 Surge Protective Devices: Ensure that the SPD has a manufacturers warranty covering
failures for a minimum of 10 years from the date of final acceptance by the Engineer in
accordance with 5-11 and Section 608.
The term failure for warranty replacement is defined as follows:
Parallel-connected, power-rated SPD units are considered in failure mode when
any of the visual indicators shows failure mode when power is applied to the terminals at the
units rated voltage, or the properly functioning over-current protective device will not reset after
tripping.
Series-connected, low-voltage power, data, or signal units are considered in the
failure mode when an open circuit condition is created and no data/signal will pass through the
SPD device or a signal lead is permanently connected to ground.
In the event that the SPD, including any component of the unit, should fail during the
warranty period, the entire SPD shall be replaced by the manufacturer at no cost to the
Department or maintaining agency.
785-6.4 ITS Field Cabinet: Ensure that the ITS field cabinet has a manufacturers warranty
covering defects for a minimum of two years from the date of final acceptance in accordance
with 5-11 and Section 608.
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785-6.5 ITS Equipment Shelter: Ensure that the equipment shelter, its components, and
hardware have a manufacturers warranty covering defects for a minimum of one year from the
date of final acceptance in accordance with 5-11 and Section 608.
785-7 Method of Measurement.
785-7.1 General: Poles, with or without the lowering devices; ITS field cabinets and
equipment shelters shall be measured for payment in accordance with the following tasks.
The work specified for grounding and transient voltage surge suppression will not
be paid for directly, but will be considered incidental to the installation of ITS devices and
systems.
785-7.2 Furnish and Install: The Contract unit price per pole furnished and installed
will include furnishing, placement, and testing of all equipment and materials, and for all tools,
labor, cables, hardware, operational software packages and firmwares, supplies, support,
personnel training, shop drawings, documentation, and incidentals necessary to complete the
work.
Except in the case of a retrofit, the work specified for furnishing and installing a
lowering device will not be paid for directly, but will be considered incidental to the installation
of a steel or concrete pole.
The Contract unit price for each ITS field cabinet, furnished and installed, will
include furnishing, placement, and testing of all equipment and materials, and for all tools, labor,
hardware, supplies, support, personnel training, shop drawings, documentation, and incidentals
necessary to complete the work.
The Contract unit price for each ITS equipment shelter, furnished and installed,
will include furnishing, placement, and testing of the shelter, all its materials and equipment, and
for all tools, labor, equipment, hardware, site preparation, site restoration, fencing, supplies, shop
drawings, documentation, and incidentals necessary to complete the work.
785-7.3 Furnish: The Contract unit price per pole furnished, will include all equipment
specified in the Contract Documents, plus all shipping and handling costs involved in delivery as
specified in the Contract Documents.
Except in the case of a retrofit, the work specified for furnishing a lowering
device will not be paid for directly, but will be considered incidental to the furnishing of a steel
or concrete pole.
The Contract unit price per each ITS field cabinet, furnished, will include all
equipment specified in the Contract Documents, plus all shipping and handling costs involved in
delivery as specified in the Contract Documents.
The Contract unit price per ITS equipment shelter, furnished, will include all
equipment specified in the Contract Documents, plus all shipping and handling costs involved in
delivery as specified in the Contract Documents.
785-7.4 Install: The Contract unit price per pole installed will include placement and
testing of all equipment and materials, and for all tools, labor, hardware, operational software
packages and firmwares, supplies, support, personnel training, shop drawings, documentation,
and incidentals necessary to complete the work. The Engineer will supply the equipment
specified in the Contract Documents.
Except in the case of a retrofit, the work specified for installing a lowering device
will not be paid for directly, but will be considered incidental to the installation of a steel or
concrete pole.
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The Contract unit price per each ITS field cabinet, installed, will include
placement and testing of all equipment and materials, and for all tools, labor, hardware, supplies,
support, personnel training, shop drawings, documentation, and incidentals necessary to
complete the work. The Engineer will supply the equipment specified in the Contract
Documents.
The Contract unit price per ITS equipment shelter, installed, will include
placement, and testing of the shelter, all its materials and equipment, and for all tools, labor,
equipment, hardware, site preparation, site restoration, fencing, supplies, shop drawings,
documentation, and incidentals necessary to complete the work. The Engineer will supply the
equipment shelter specified in the Contract Documents.
785-8 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 785-1
ITS Pole, per each.
Item No. 785-2
ITS Field Cabinet, per each.
Item No. 785-3
ITS Equipment Shelter, per each.
945
SECTION 786
INTELLIGENT TRANSPORTATION SYSTEMS VEHICLE DETECTION AND DATA COLLECTION
786-1 Description.
Furnish and install a nonintrusive vehicle detection system as shown in the Plans. Ensure
that the vehicle detection system is capable of vehicle presence detection and traffic data
collection meeting the general requirements of 786-1 through 786-6 and the specific
requirements for each system as defined in 786-7 through 786-10. Use only equipment and
components that meet the requirements of these minimum specifications, and are listed on the
Departments Approved Product List (APL).
786-2 Materials.
786-2.1 Detector: Provide a vehicle detection system that can, at a minimum, produce
vehicle presence, volume, speed, and occupancy data for each detected lane. Provide a vehicle
detection system utilizing one of the following four technologies, as shown in the Plans.
1. A microwave vehicle detection system (MVDS) that uses a Federal
Communications Commission (FCC) certified, low-power microwave radar beam to detect
vehicle presence and generate volume, occupancy, and speed data as defined in 786-7.
2. A video vehicle detection system (VVDS) that uses one or more video cameras
to collect and analyze video signals for detecting vehicle presence and generating volume,
occupancy and speed data as defined in 786-8.
3. A magnetic traffic detection system (MTDS) whose magnetic detector probe is
a transducer that detects vehicle presence by converting changes in the vertical component of the
earths magnetic field to changes in inductance, and which then generates volume, occupancy,
and speed data as defined in 786-9.
4. An acoustic vehicle detection system (AVDS) having a passive acoustic
detector that responds to vehicle-generated acoustic signals to detect vehicle presence and
generate volume, occupancy, and speed data as defined in 786-7.
786-2.2 Communications: Ensure that the vehicle detection system generates and
transmits traffic data either in serial format using an Electronic Industries Alliance (EIA)
standard EIA-232 communication port or an Internet Protocol (IP) interface. Ensure that the
vehicle detection system can generate contact closures emulating the output of a pair of 6 foot by
6 foot loops with leading edges placed 16 feet apart, as detailed in Design Standards, Index
No. 17900, Traffic Monitoring Site.
Verify that the detection system is IP addressable. Ensure that all device
communication addresses are user programmable.
Ensure that the detection system supports Point-to-Point Protocol (PPP), Point to
Multi-Point Protocol (PMPP) (i.e., polled protocols), and Ethernet protocols. Ensure that the
setup program assigns an IP address to the detection unit. Ensure that the vehicle detection
system responds to a polling request from the transportation management center (TMC) for
traffic data. Verify that the detection unit responds with the accumulated traffic parameter
measurements from the period since the last request was issued.
Verify that the detection system stores all system configuration and traffic
parameter data within internal nonvolatile memory. Verify that traffic data can be locally and
946
remotely transferred by issuing requests from a personal computer (PC) across the
communication network connecting the detector and the TMC operator workstation or other PC.
786-2.3 Configuration and Management: Ensure that the vehicle detection system is
provided with computer software that allows an operator to program, operate, and read current
status of all system features and functions using a laptop computer or remote TMC workstation.
Furnish software that is compatible with the Departments SunGuide Software System. Ensure
that any software-based applications do not interfere with SunGuide software when the two are
installed and used together on a shared hardware platform. Ensure that the software application
provides PC desktop display of the detection zones and control of any vehicle detector connected
to the network.
Provide software licenses as required in the Plans. Ensure that the detection
system software offers an open API and software development kit available to the Department at
no cost for integration with third party software and systems.
Ensure that an operator using a locally connected laptop computer can conduct
system setup, calibration, diagnosis, and data retrieval operations. Ensure that the detection
system is capable of having its configuration data saved to a laptop computer or TMC operator
workstation, which can later transfer the data back to the detection system for reloading.
Ensure that the detection system operator can use a laptop computer or TMC
workstation to edit previously defined detection configurations to permit adjustments to the
detection zones size, placement and sensitivity, and to reprogram the detectors parameters.
Ensure that the laptop computer and the detection system can communicate when
connected directly by an EIA-232 cable. Ensure that the laptop computer and detection system
can communicate across the ITS systems communication network using the NTCIP standards
described in this document. Ensure that the software allows communication between multiple
users and multiple field devices concurrently across the same communication network.
Once programmed, ensure that no periodic adjustments are required to the
detection zones unless physical roadway conditions change, such as lane shifts or closures.
786-2.4 Electrical Requirements: Ensure that the vehicle detection system field
hardware meets the requirements in the FCCs 2005 Code of Federal Regulation (CFR), Title 47,
Part 15. The detector shall not interfere with any known equipment.
Ensure the vehicle detection system operates using a nominal input voltage at the
field cabinet of 120 volts of alternating current (VAC). Ensure that the systems power supply will
operate with an input voltage ranging from 89 to 135 VAC. For any device requiring a source
input other than the standard 120 VAC, supply the appropriate means of conversion.
Furnish all equipment with the appropriate power and communication cables.
Install the power cable and the communication cables according to the manufacturers
recommendation. Ensure that the cables comply with NEC sizing requirements as presented in
NEC Article 210-19(a), Fine Print Note (FPN) No. 4, and meet all other applicable standards,
specifications and local code requirements.
Ensure that the power cable running between the detection system and its
electrical service is in a separate conduit. Do not install communication cables in the same
conduit as power cables carrying voltage greater than 24 VDC/VAC or current in excess of
1.5 amps. Do not install the power and communication cables in the same pull boxes.
Cut all wires to their proper length before assembly. Do not double back any wire
to take up slack. Neatly lace wires into cables with nylon lacing or plastic straps. Secure cables
with clamps and provide service loops at all connections.
947
In the event that power to the vehicle detection system or a subcomponent thereof
is interrupted, ensure that the equipment automatically recovers after power is restored. Ensure
that all programmable system settings return to their previous configurations and the system
resumes proper operation.
786-2.4.1 MVDS Electrical: Ensure that the MVDS operator is able to select and
use 12 to 24 volts of direct current (VDC) and 115 VAC at 60 Hz.
Ensure that the detector is FCC certified and that the FCCs identification
number is displayed on an external label. Ensure that the detector transmits within a frequency
band of 10.525 gigahertz, plus or minus 25 megahertz, or another FCC approved spectral band.
786-2.4.2 VVDS Electrical: Ensure that the VVDS camera and positioner (if so
equipped) have an operating voltage of 24 VAC or 10 to 28 VDC. If the VVDS camera or related
ancillary device requires operating voltages other than these, provide an appropriate voltage
converter.
Ensure that the VVDS camera and the machine vision processor (MVP)
do not exceed a maximum power consumption of 200 watts.
786-2.4.3 AVDS Electrical: Ensure that the AVDS operates at 8 to 24 VDC. If the
device requires operating voltages other than these, provide an appropriate voltage converter.
786-2.5 Environmental Requirements: Provide detection systems that meet all
specifications during and after being subjected to an ambient operating temperature range of
minus 30 to 165F with a maximum noncondensing relative humidity as defined in the
environmental requirements section of the NEMA TS 2 standard.
Verify that the detection system manufacturer certifies that its device has
successfully completed environmental testing as defined in the NEMA TS 2 standard. Verify that
vibration and shock resistance meet the requirements of Sections 2.1.9 and 2.1.10, respectively,
of NEMA TS 2.
Ensure that no item, component, or subassembly emits a noise level
exceeding the peak level of 55 decibels adjusted (dBa) when measured at a distance of 3.3 feet
away from its surface.
Ensure that system components comply with the environmental
requirements detailed in the NEMA TS 2 standard.
786-2.5.1 Detector Housing: Furnish and install an environmentally
resistant and tamper-proof sensor enclosure for any detector assembly exposed to the elements.
Ensure that the enclosure is environmentally sealed upon installation and that it is light in color.
786-2.5.2 Wind Loads: Ensure that the detection system, mounting
hardware, and any related material that is exposed to the environment can withstand 150 mph
wind speeds and meet the requirements of the FDOT Structures Manual, Volume 9.
786-3 Performance.
786-3.1 Detection Accuracy: Provide a vehicle detection system capable of meeting the
minimum total roadway segment accuracy levels of 95% for volume, 90% for occupancy, and
90% for speed for all lanes, up to the maximum number of lanes that the device can monitor as
specified by the manufacturer.
786-3.2 Calculation of Volume, Occupancy, and Speed Accuracy: To verify
conformance with the accuracy requirements in this Section, perform evaluations by comparing
sample data collected from the vehicle detection system with ground truth data collected during
the same time by human observation or by another method approved by the Engineer. Base the
vehicle detection systems performance evaluation on sample data taken over several time
948
periods under a variety of traffic conditions. Weight each data sample to represent the
predominant conditions over the course of a 24 hour period. Samples will consist of 15 and
30 minute data sets collected at various times of the day. Representative data periods and their
assigned weights are provided in Table 1.
Table 1 Data Collection Periods
Period
Intended To Represent
Duration
Early morning (predawn) [EM]
12:30 AM 6:30 AM
15 minutes
Dawn [DA]
6:30 AM 7:00 AM
30 minutes
AM Peak [AMP]
7:00 AM 8:00 AM
15 minutes
Weight
24
2
4
Late AM Off-Peak [LAOP]
8:00 AM 12:00 Noon
15 minutes
16
Noon [NO]
12:00 Noon 1:00 PM
15 minutes
Afternoon Off-Peak [AOP]
1:00 PM 5:00 PM
15 minutes
16
PM Peak [PMP]
5:00 PM 6:00 PM
15 minutes
Dusk [DU]
6:00 PM - 6:30 PM
30 minutes
Night [NI]
6:30 PM - 12:30 AM
15 minutes
24
Total Sum of Weights
96
For instance, the sample gathered for the Late AM Off-Peak period is intended to
represent typical traffic conditions between 8:00 AM and 12:00 noon. Since the sample periods
duration is 15 minutes and the actual period of time represented is 4 hours, the multiplication
factor or weight assigned is 16, the number of 15 minute intervals in a 4 hour period.
786-3.3 Calculation of Volume Accuracy: Compute volume accuracy as described in
this subsection.
Determine individual lane volume accuracy per period by calculating the
percentage of absolute difference of the total volume measured by the detection system and the
true volume computed using the method the Engineer approves, divided by the true volume for
the period under consideration.
In Equation 1, EM represents the early morning period. The variable i represents a
lane in a roadway and could vary from 1,, N, where N is the maximum number of lanes on the
roadway segment. Substitute other lane numbers and periods as necessary to determine the
accuracy for each lane during each period (i.e., dawn, AM peak, late AM off-peak, etc.).
Variables used in the following calculations are identified as follows:
VT = Total volume
VD = Vehicle detection data (in this case, count data)
GT = Ground truth measurement utilizing a reliable method approved by
the Engineer
VA = Volume accuracy
786-3.3.1 Equation 1 Early Morning Lane Volume Accuracy Expressed in
Percentage:
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VAEM ,lni 100
where:
VTEM ,VD ,lni VTEM ,GT ,lni
VTEM ,GT ,lni
x100
VAEM ,lni = Volume accuracy for early morning traffic conditions in the i th lane.
VTEM ,VD ,lni = Total volume for the 15 minute early morning period using the
vehicle detector in the i th lane.
VTEM ,GT ,lni = Total volume for the 15 minute early morning period in the i th lane
using human observation or another method approved by the Engineer.
The period volume accuracy will be the arithmetic mean of the lane
volume accuracy over all lanes.
In Equation 2, EM represents the early morning period and N is the
maximum number of lanes in the roadway segment under test. Substitute other periods as
necessary to determine the accuracy for each period (i.e., dawn, AM peak, late AM off-peak,
etc.).
786-3.3.2 Equation 2 Early Morning Period Volume Accuracy Expressed in
Percentage:
VAEM
N
VAEM , ln i
i 1
where:
VAEM = Average volume accuracy for early morning traffic conditions for all
lanes on the roadway segment.
VAEM ,lni = Volume accuracy for early morning traffic conditions in the i th lane.
Calculate the roadway segment accuracy over all periods using
Equation 3. Calculate the volume accuracy using Equation 2 for each individual period,
multiplied by its corresponding weight, as shown in Table 1. Next, add the products for all
periods and divide the sum by 96 to obtain the overall system accuracy.
786-3.3.3 Equation 3 Total Roadway Segment Accuracy Expressed in
Percentage:
VATotal
VAEM x24 VADA x2 VAAMP x4 VALAOP x16 VANO x4 VAAOP x16 VAPMP x4 VADU x2 VANI x24
96
where:
VATotal = Volume accuracy for all lanes for all periods discussed in Table 1
VAEM = Volume accuracy for early morning traffic conditions
VADA = Volume accuracy for dawn traffic conditions
950
VAAMP = Volume accuracy for AM peak traffic conditions
VALAOP = Volume accuracy for late AM off-peak traffic conditions
VANO = Volume accuracy for noon traffic conditions
VAAOP = Volume accuracy for afternoon off-peak traffic conditions
VAPMP = Volume accuracy for PM peak traffic conditions
VADU = Volume accuracy for dusk traffic conditions
VANI = Volume accuracy for night traffic conditions
Position the detector and configure the detection zones so that a vehicle is
detected when 70% or more of the vehicle width is inside a lane, and not detected when 15% or
less of the vehicle width is in the lane. Use the detection zone configuration to minimize the
occurrence of a double count for the same vehicle, while ensuring that it will be counted at least
once.
786-3.4 Calculation of Speed and Occupancy Accuracy: Calculate speed accuracy as
discussed in this subsection. Calculate occupancy in a manner similar to the speed computation
methodology described below.
The difference between the volume accuracy and speed accuracy computation is
that the volume of a particular lane can be aggregated over a period of time, while speed cannot.
For computing the accuracy of the detector speed measurement, the average speed readings
obtained from the detection system are compared to ground truth values on a particular roadway
segment.
Equation 4 represents the ground truth average speed computation procedure for a
particular lane during a specific time period. Equation 5 represents the average speed
computation procedure for a particular lane during a specific time period using data gathered
from the detection system.
In Equations 4 and 5, the time period described is the early morning period,
represented by EM, and the variable k represents a vehicle traveling on the roadway and could
vary from 1,, K, where K is the maximum number of vehicles in lane i during the time period
under consideration. The variable i represents a lane in a roadway and could vary from 1,, N,
where N is the maximum number of lanes on the roadway segment. Substitute other lanes and
periods as necessary and compute the accuracy for each lane for all time periods.
Variables used in the following calculations are identified as follows:
SA = Speed accuracy
S = Speed of an individual vehicle
veh = Vehicle
786-3.4.1 Equation 4 Early Morning Average Ground Truth Vehicle
Speed:
S Avg , EM ,GT , ln i
1 K
S EM ,GT , ln i , vehk
K k 1
Where:
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SAAvg ,EM ,GT ,lni represents the average ground truth vehicle speed for the i th lane
during the early morning period.
S EM ,GT ,lni ,vehk represents the true speed for the k th vehicle in the I th lane during the
early morning period using human observation or another method approved by the Engineer.
786-3.4.2 Equation 5 Early Morning Average Vehicle Detector Speed
Measurement:
S Avg ,EM ,VD ,lni
S
k 1
EM ,VD ,lni ,vehk
where:
S Avg ,EM ,VD ,lni represents the average speed recorded by the vehicle detector for the
th
i lane during the early morning period.
S EM ,VD ,lni ,vehk represents the speed for the k th vehicle in the I th lane during the
early morning period using the vehicle detector.
The lane speed period accuracy is computed as a percentage of the absolute
difference of the average lane speed calculated using detection system data and the average lane
true speed calculated in Equation 4 (or using another method approved by the Engineer), divided
by average ground truth lane speed for the period.
In Equation 6, EM represents the early morning period. The variable i represents a
lane on a roadway and could vary from 1,,N, where N is the maximum number of lanes on the
roadway segment. Substitute other lanes as necessary to determine the accuracy for each period
(i.e., dawn, AM peak, late AM off-peak, etc.).
786-3.4.3 Equation 6 Early Morning Lane Speed Accuracy Expressed in
Percentage:
SAAvg ,EM ,lni 100
S Avg ,EM ,VD ,lni S Avg ,EM ,GT ,lni
S Avg ,EM ,GT ,lni
100
where:
SAAvg ,EM ,lni represents the average speed accuracy during early morning traffic
conditions for all vehicles that traveled in lane i of the roadway segment.
The period speed accuracy will be the arithmetic mean of the lane speed accuracy,
computed using Equation 6, over all lanes.
In Equation 7, EM represents the early morning period. The variable i represents a
lane on a roadway and could vary from 1,, N, where N is the maximum number of lanes on the
roadway segment. Substitute data as necessary to determine the accuracy for each period (i.e.,
dawn, AM peak, late AM off-peak, etc.).
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786-3.4.4 Equation 7 Early Morning Speed Accuracy Expressed in
Percentage:
SAEM
N
SAAvg ,EM ,lni
i1
where:
SAEM represents the average speed accuracy during early morning traffic
conditions for all lanes on the roadway segment.
Calculate the roadway segment accuracy over all periods using the following
equation. This equation is a weighted average to account for variations in each of the sample
detection periods over the course of a 24 hour period. First, calculate the speed accuracy for each
individual period using Equation 7. Next, multiply the individual period by its corresponding
weight as shown in Table 1. Add the products for all periods and divide the sum by 96 to obtain
the overall system accuracy.
786-3.4.5 Equation 8 Total Roadway Segment Accuracy Expressed in
Percentage:
SATotal
[SAEM x24 SADAx2 SAAMPx4 SALAOPx16 SANO x4 SAAOPx16 SAPMPx4 SADU x2 SANI x24]
96
where:
SATotal = Speed accuracy for all lanes for all periods discussed in Table 1
SAEM = Speed accuracy for early morning traffic conditions
SADA = Speed accuracy for dawn traffic conditions
SAAMP = Speed accuracy for AM peak traffic conditions
SALAOP = Speed accuracy for late AM off-peak traffic conditions
SANO = Speed accuracy for noon traffic conditions
SAAOP = Speed accuracy for afternoon off-peak traffic conditions
SAPMP = Speed accuracy for PM peak traffic conditions
SADU = Speed accuracy for dusk traffic conditions
SANI = Speed accuracy for night traffic conditions
786-4 Installation.
Install, configure and demonstrate a fully functional vehicle detection system, as shown
in the Plans. Connect all field hardware and TMC components to the existing communication
network, and provide all materials specified in the Contract Documents. Install all equipment
according to the manufacturers recommendations or as directed by the Engineer.
Ensure that the MVDS, the VVDS and AVDS can be mounted on existing poles or sign
structures, or on new poles, for a side-fire configuration. Utilize prestressed concrete or steel
poles that comply with Section 641, Section 649, or 785-3, as appropriate. The support structure
and network communication infrastructure shall be paid for under separate pay items.
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786-5 Testing.
786-5.1 Design Approval Test (DAT) Specifications: DATs will be conducted by the
Traffic Engineering Research Laboratory (TERL). An APL approval and certification number is
evidence of successful testing by TERL. The Department may accept test results from an
independent testing laboratory to satisfy the requirement that certain features and functions have
been witnessed and documented as performing satisfactorily.
Arrange and conduct the tests and satisfy all inspection requirements prior to
submission for the Engineers inspection and acceptance. Furnish all necessary test equipment.
Use a radar gun to calibrate speed detection, following the manufacturers recommended
calibration procedures.
At a minimum, demonstrate the following:
1. Use a laptop computer provided as part of the support equipment to
configure the installation.
2. Verify that configuration data is stored in nonvolatile memory.
3. Download previously stored configuration data.
4. Verify that vehicles traveling at the test site can be detected across
multiple travel lanes to the accuracy specified herein.
5. Drive a test car of known length and speed through the detection zone.
Compare the output from the vehicle detector to this known value to verify the accuracy of
detection. Repeat this measurement at least 10 times.
6. Install the detection system sensor at the site for test setup. Place a
video camera at the same point along the roadway, above the sensor location, as determined
appropriate by the Engineer. Produce a video recording of the test to obtain a manual count, then
compare those results with those from the detection system to determine the accuracy of the
sensor. Alternative verification methods may be considered by the Engineer.
7. Verify the volume counts and speed measurements for each installed
assembly using the test software running on the laptop computer connected locally to the
detectors EIA-232/485 communication port. Repeat this test remotely from the TMCs operator
workstation. Verify the accuracy of traffic parameters specified herein by using permanent or
temporary traffic detection devices of known accuracy.
786-5.2 Field Acceptance Test (FAT) Specifications: Develop and submit a test plan
for FATs to the Engineer for consideration and approval. Ensure that the FAT test plan
demonstrates compliance to all requirements.
Inspect all vehicle detection system field components to ensure proper installation
and cable termination.
Adjust and verify the detector settings by comparing each sensors recorded
traffic volumes and speed with those actually observed. Remotely repeat this test from the TMC.
Verify the accuracy of traffic parameters using permanent or temporary traffic detection methods
or devices of known accuracy.
Notify the Engineer at least 14 calendar days prior to the proposed test date. The
Contractor shall at a minimum:
1. Furnish all equipment, appliances, and labor necessary to test the
installed vehicle detection system and the network communication device, and to perform the
following tests before any connections are made:
a. Perform a continuity test on the detector cables to ensure that
anomalies, such as openings, shorts, crimps or defects, are not present.
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b. Perform continuity tests on the detectors stranded conductors
element using a meter having a minimum input resistance of 20,000 per volt and show that
each conductor has a resistance of not more than that specified by the wire/cable manufacturer.
c. Measure the insulation resistance between isolated conductors
and between each conductor, ground, and shield using a meter designed for measuring insulation
resistance. The resistance must be greater than 100 M. Perform all resistance testing after final
termination and cable installation, but prior to the connection of any electronic or field devices.
d. Replace any cable that fails to meet these parameters, or if any
testing reveals defects in the cable, and retest new cable as specified in this Section.
2. Furnish and calibrate all test equipment.
3. Demonstrate the following after installation of the vehicle detection
system, other hardware, power supplies, and connecting cables:
a. Verify that physical construction has been completed as
specified in the Plans.
b. Inspect the quality and tightness of ground and surge protector
connections.
c. Check power supply voltages and outputs.
d. Verify that device connections to power sources are as specified
in the Plans.
e. Verify that the installation of specified cables and connections
between all detectors and the field cabinet are as specified in the Plans.
f. Demonstrate that the remote system is fully operational and
performing all specified types of detection, including data storage functions, with a laptop
computer.
g. Verify that the network interface device is receiving and
transmitting data from the remote site to the ITS network.
786-6 System Acceptance Criteria.
Upon request, furnish independent laboratory testing documentation certifying adherence
to the standards and specifications required herein, along with adherence to the stated wind force
criteria using a minimum effective projected area (EPA), the actual EPA, or an EPA greater than
that of the detection assembly to be attached.
Within 3 calendar days of successful test completion, deliver to the Engineer a written
completion notice and a copy of all test results. Include in this completion notice the
documentation of any discrepancies found during testing. Also include assembly installation
locations and successful test completion dates. If any component fails to pass required testing,
replace the part and retest according to the requirements above, then resubmit the test results to
the Engineer.
The Engineer shall specify the defect or failure in the work for any work rejected.
Notification of acceptance or rejection of the work shall be by delivery of written notice to the
Contractor.
786-7 Microwave Vehicle Detection System (MVDS).
786-7.1 Description: Furnish and install a MVDS as shown in the Plans and directed by
the Engineer.
786-7.2 Materials: Ensure that the MVDS is a true-presence microwave radar that uses
the frequency modulated continuous wave (FMCW) principle. Ensure that the detector transmits
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a low-power, frequency modulated microwave signal in a fixed beam. Ensure that any
nonbackground targets reflect the signal back to the microwave radar detector, where the targets
are detected and their range measured.
Provide an MVDS assembly for the project site that consists of microwave radar
sensor(s) in enclosed housing(s) (i.e., the detectors), as shown in the Plans and directed by the
Engineer. Provide an installation kit with mounting brackets; home run cable for the transmission
and receipt of data and communications between the field detector and the communication
system hardware; and all required power and data cables, as detailed in the Plans.
786-7.2.1 MVDS Detector: Furnish a microwave vehicle detector that determines
vehicle presence by the return or reflection of radar output waves, and that upon this return, the
MVDS generates data and/or a contact closure signal that corresponds to vehicle presence.
Ensure that the contact pairs are able to connect directly to the traffic
controllers. Ensure that the detector accumulates and transmits short-term statistical data on each
zone using a serial communication port or an IP connection. Ensure that the MVDS is capable of
logging and storing traffic data for all programmed detection zones for a minimum of 7 days in
10 second data intervals.
Provide a detector that is capable of resolving closely spaced vehicles.
Ensure that the MVDS setup program enables the operator to select whether data is output as
contact closures emulating standard loop detector outputs, and/or as accumulated statistical data
using detector serial ports. Verify that the sensor holds a vehicles presence in the specified
detection zone until the vehicle is clear of the zone. Ensure that the sensor does not tune out
stationary vehicles within a detection zone and thereby give a false clear status to the lane, even
if a vehicle has stopped for a period exceeding 30 minutes.
Provide an assembly manufactured in such a way as to prevent reversed or
improper installation. Ensure that the MVDS design provides high-voltage exposure protection
to personnel during equipment operation, adjustments, and maintenance.
Ensure that the MVDS provides speed-trap emulation and has the ability
to automatically detect sensor settings, baud rates, loop spacing, and communication port settings
to select an operational mode.
Ensure that the detector has the ability to self-tune and allow manual
calibration via supplied vendor software. Ensure that the MVDS is capable of autocalibration and
autoconfiguration, and that it does not transmit any signals outside its FCC-approved frequency.
Provide a setup program that allows the operator to define detection zones within the detectors
field of view. Ensure that the detector automatically configures zones, requiring minimal external
tuning. Verify that the unit is not adversely affected by varied weather conditions, such as rain,
fog, heat, or wind.
Ensure that the MVDS can compute, store, and provide all required traffic
parameter measurements per detection zone in user-selected time intervals from 0 to 60 minutes,
including, but not limited to, 10 seconds, 20 seconds, 30 seconds, 60 seconds, 5 minutes,
10 minutes, 15 minutes, 30 minutes, and 60 minutes. The MVDS shall log and store vehicle
volume, occupancy, and speed data for a minimum of 7 days regardless of collection interval.
Data storage within the MVDS shall utilize a first in/first out architecture such that the oldest
stored data record is overwritten with the newest data record when the storage device is at full
capacity.
786-7.3 Installation of MVDS: Mount the MVDS detector as detailed in the Plans. In
either configuration, mount the detector level from side to side. Ensure that the vertical and
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horizontal clearance of the installed detection device complies with Vol. I, Chapter 2 of the
Departments Plan Preparation Manual.
Ensure that the MVDS sensor has a 200 foot range, and that the viewing angle is a
minimum of 40 degrees vertical and a maximum of 15 degrees horizontal. Verify that all
detection zones are contained within the specified elevation angle according to the
manufacturers recommendations and that the MVDS is capable of fully detecting all vehicles in
a maximum of eight lanes. Ensure that the configuration also provides accurate collection of all
data types as detailed in this specification.
Mount the detector in a NEMA 4X polycarbonate box, and verify that the
electrical connection is located on the bottom of the box.
Provide a housing that can be pole- or wall-mounted, as indicated in the Plans.
Supply a universal mounting bracket that is adjustable on two axes for optimum alignment.
Attach the mounting bracket with approved stainless steel bands that are
0.75 inches wide and 0.025 inches thick, or mount to a concrete structure using two stainless
steel expansion bolts of sufficient length and diameter to support 100 pounds.
When installing a detector near metal structures, such as buildings, bridges or sign
supports, mount the sensor and aim it so that the detection zone is not under and does not pass
through any structure to avoid distortion and reflection. In forward-looking configurations, the
detector shall be mounted over the center of each lane.
Ensure that the detector is factory calibrated to comply with all applicable
standards, specifications, and requirements. Ensure that the detector does not require further
adjustment after initial setup, and that no periodic calibration is required.
Provide an interface to external equipment with a single connector. Ensure that
the connector provides power to the unit and allows generation of contact closure output pairs for
interface with traffic controller inputs. Ensure that the connector includes serial communication
lines for programming, testing, and interfacing with the modem at a minimum 9,600-baud rate
and that it has at least 26 pins. Ensure that the serial ports data format is standard binary nonreturn to zero (NRZ) modulation with 8-bit data, 1-stop bit, and no parity.
Ensure that the home run cable is a polyurethane-jacketed cable approved by the
Engineer, with polyvinyl chloride (PVC) insulated conductors. The home run cable shall have a
300 volt rating and a temperature rating of 200F. Ensure that the cable is equipped with #20 or
#22 AWG conductors.
Supply a test cable and converter to connect the detector to a laptop computer for
testing and configuration. Verify that the test cable and converter are compliant with current
EIA 232 and Universal Serial Bus specification standards for protocol converters. The male DB9 and USB connectors for laptop computers equipped with only a USB port shall support the
automatic handshake mode, transmission rates of 230 kilobits per second (kbps), and remote
wakeup and power management features. Verify that the test cable and converter are compatible
with the operating systems recommended for SunGuide software, and are USB powered.
Crimp or solder the detector connector pins to the cable conductors. Assemble
and test the cable prior to onsite installation and pulling. Cut all wires to their proper length
before installation. Do not doubled back wire to take up slack. Neatly lace wires into cable with
nylon lacing or plastic straps, and secure cables with clamps. Provide service loops at all
connections.
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Perform continuity tests on the detectors stranded conductors using a meter
having a minimum input resistance of 20,000 per volt and show that each conductor has a
resistance of not more than 16 per 984.25 feet of conductor.
Measure the insulation resistance between isolated conductors and between each
conductor, ground, and shield using a meter designed for measuring insulation resistance. The
resistance must be infinity. Perform all resistance testing after final termination and cable
installation, but prior to the connection of any electronic or field devices.
786-8 Video Vehicle Detection System (VVDS).
786-8.1 Description: Furnish and install a VVDS as shown in the Plans and directed by
the Engineer.
786-8.2 Materials: Provide a VVDS consisting of one or more cameras together with a
MVP, necessary cabling, installation hardware, and central monitoring equipment.
786-8.2.1 Detection-only VVDS: Ensure that the VVDS performs vehicle
detection and data collection functions by analyzing video signals in order to detect moving and
stopped vehicles within the video image.
786-8.2.2 Dual-use VVDS: For VVDS, where surveillance capability is also
desired, provide dual-use equipment that is suited for both detection of vehicles and surveillance
of the roadway.
During surveillance, provide a mechanism that automatically suspends the
VVDS vehicle detection functions. Should the system be configured to provide real-time traffic
data to the TMC at regular intervals, any responses to TMC polling requests during periods when
the camera is in motion or otherwise not viewing the area designated for vehicle detection shall
indicate that the system is being used in a surveillance capacity, and that traffic data is either
unavailable or should be disregarded. The intent of this requirement is to prevent the inclusion of
erroneous data in real-time TMC systems due to the fact that the camera may not be resting in a
position that allows preconfigured detection zones to produce valid data.
786-8.2.3 Video Vehicle Detection Camera: Ensure that the camera is
compatible with the current version of the Departments SunGuide Software System.
Use a camera that produces National Television System Committee
(NTSC) composite video output of 1 volt peak-to-peak (Vp-p) at 75 . Use either a dome-type
or external positioner-type camera assembly. Ensure that the VVDS camera can transmit images
directly to the MVP.
Ensure that VVDS cameras, as well as any MVPs integrated in camera
housings, meet the environmental requirements as detailed in 782-1.2.8.
Ensure that the VVDS camera conforms to one of the two options
described below, as shown in the Plans.
786-8.2.3.1 Dual-use Camera: Provide a VVDS camera that also
functions as a closed-circuit television (CCTV) roadway surveillance system through the use of
pan-tilt-zoom (PTZ) control by the operator. If utilized in this dual manner, ensure that the
VVDS meets the following requirements:
1. Perform video vehicle detection and collect traffic data as its
primary function, with surveillance as the secondary function.
2. Allow the VVDS operator to move the camera using PTZ
control to view traffic conditions.
3. Return the VVDS camera to its preconfigured detection state
when switched back from surveillance mode. Ensure that the positioner has a preset position
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return accuracy of plus or minus 0.36 degrees, or less than 0.10% or better, as required in 7821.2.3.
Ensure that dual-use cameras are either dome-type or external
positioner-type cameras as shown in the Plans, and that they meet the requirements detailed in
782-1.2.1.
Ensure that the lens meets the requirements of 782-1.2.2.
Use camera housings that meet the requirements of 782-1.2.7.
Provide mounting hardware as required in 782-1.3.
Use PTZ mechanisms that meet the requirements of 782-1.2.3 for
dome type cameras and 782-1.2.4 for external positioner type cameras.
Ensure that the camera meets the mechanical specifications in
782-1.2.7 and the electrical specifications in 782-1.2.6.
786-8.2.3.2 Detection-only Camera: Provide a fixed-mount camera that
is either black-and-white or, alternately, color with automatic switchover from monochrome to
color and vice versa, as shown in the Plans.
Ensure that any detection-only camera provides the following
features and capabilities:
1. Minimum resolution of 470 horizontal and 350 vertical
TV lines.
2. User-selectable automatic gain control (AGC) that is
peak-average adjustable to 30 decibels (dB).
3. A minimum signal-to-noise ratio of 50 dB.
4. User-selectable gamma settings of 0.45 and 1.0.
5. Automatic electronic shutter that is user selectable from
1/60 to 1/10,000 of a second.
Ensure that the detection-only camera has a minimum 10x
motorized optical zoom lens with automatic iris. Ensure that the lens is capable of automatic and
manual focus and iris control and has a minimum focal length of 0.14 inches to 3.2 inches.
Ensure that the lens depth of field provides a clear image of roadside areas under all lighting
conditions and has a maximum aperture of at least f/1.6.
Use camera housings that meet the requirements of 782-1.2.7.
Provide mounting hardware as required in 782-1.3.
Ensure that the camera meets the mechanical specifications in
782-1.2.7 and the electrical specifications in 782-1.2.6.
786-8.2.4 Machine Vision Processor (MVP): Include with the field hardware an
MVP for analyzing the video input and for computing, storing, and reporting the collected
vehicle detection data. Use an MVP that also supports the installation at the TMC by providing
video feeds transmitted from field locations over the communications network infrastructure, as
shown in the Plans.
786-8.2.4.1 Detection: Ensure that the MVP emulates standard inpavement loops by producing vehicle volume, occupancy, and speed data for every detection
zone.
Ensure that the MVP resolves closely spaced vehicles and rejects
adjacent lane vehicles.
Ensure that the MVP is able to process images of approaching or
receding traffic, or both, in the same field of view.
959
Ensure that the MVP can provide presence and pulse detection
modes for each detection zone. In presence mode, the detection zone shall be active as long as a
vehicle occupies the zone. In pulse mode, ensure that the detection zone provides a momentary,
on/off detection that does not remain active, even if the vehicle stays within the zone.
Ensure that the MVP can compute, store, and provide all required
traffic parameter measurements per detection zone in user-selected time intervals from 0 to
60 minutes, including, but not limited to, 10 seconds, 20 seconds, 30 seconds, 60 seconds,
5 minutes, 10 minutes, 15 minutes, 30 minutes, and 60 minutes. Ensure that the MVP logs and
stores vehicle volume, occupancy, and speed data for a minimum of one day, regardless of the
collection interval. Data storage within the MVP shall utilize a first in/first out architecture such
that the oldest stored data record is overwritten with the newest data record when the storage
device is at full capacity.
786-8.2.4.2 Remote Monitoring: Ensure that the VVDS operator can
observe real-time detection activity by viewing the video output from the cameras, with the
detection zones depicted as flashing overlays indicating the current detection status (on/off).
Ensure that this real-time output also includes display of each zones cumulative volume
statistics, as dictated by operator preferences.
Ensure that the MVP can be polled for vehicle volume, occupancy,
speed, and event alarm data. Ensure that the MVP can collect and store data locally at timed
intervals and report the data to the TMC. During normal operation, ensure that the MVP can
respond to each polling request by transmitting the most recently collected interval of traffic data
to the device or application that initiated the request.
Should the communication link to the TMC be damaged or
otherwise disconnected, ensure that the MVP stores collected data in its internal nonvolatile
memory. Ensure that the data collected during the communication outage is made available for
retrieval by TMC software once the link is restored.
Ensure that all MVP configuration settings and user preferences
are savable in electronic format for storage on a PC.
786-8.2.4.3 Video Inputs and Outputs: Use an MVP that accepts input
of NTSC composite video output of 1 Vp-p by way of BNC connectors.
Ensure that the MVP can transmit streaming video from the field
site to the TMC based on the Joint Photographic Experts Group (JPEG) video compression
standard, Moving Picture Experts Group-2 (MPEG-2), or another video compression standard
acceptable to the Engineer. Ensure that the streaming video is recordable as a data file on a PC
for later playback and editing, and is capable of transmission at a minimum communication link
speed of 9.6 kbps.
786-8.2.4.4 Contact Closure Inputs and Outputs: Ensure that the MVP
produces detection information both as contact closures emulating standard loop detector outputs
and as accumulated statistical data output that is transmitted via the MVPs data port.
Ensure that contact closure emulation provides multiple
programmable electrical outputs that change state when a vehicle is present within a detection
zone (i.e., emulating the output of standard loop detector amplifiers). Ensure that the MVP can
be configured to associate multiple detection zones to a single output and multiple outputs to a
single zone.
960
786-8.2.4.5 Serial Interface: Ensure that the unit can transfer traffic
parameter data from nonvolatile memory to the TMC using a standard EIA-232 communication
port with a DB-9 connector.
786-8.2.4.6 Network Interface: Ensure that the MVP has an Ethernet
communications interface that allows connection to multiple MVPs and remote network access
to perform all functions normally accomplished through direction connection to the MVP.
Provide an RJ-45 connector on the MVPs front panel for network
connection.
Ensure that the MVP is addressable, with the operator able to
assign a unique address to the device during setup. Ensure that a MVP that shares a data
connection with other MVPs responds only to data requests and commands that contain its
unique address.
786-8.2.4.7 Configuration and Management:
786-8.2.4.7.1 Programming: Ensure that the MVP utilizes
nonvolatile memory for storage of configuration information, collected traffic data, and MVP
firmware. Configuration information consists of all user-definable parameters, including, but not
limited to, detection zone placement; data acquisition and logging parameters; baud rate settings;
data collection intervals; input and output configurations; and calibration settings. Ensure that the
MVP retains its programming indefinitely in nonvolatile memory. Ensure that, once
programmed, no periodic adjustments are required to the MVP unless physical roadway
conditions are changed, as with lane shifts or closures.
Ensure that the MVP supports firmware updates through
the serial port or by network download. Ensure that the firmware updates do not require the
physical removal of hardware or disassembly of the MVP.
786-8.2.4.7.2 Monitoring: Ensure that the MVP can provide at
least eight assignable outputs. Ensure that the MVP supports the number of camera inputs shown
in the Plans. Ensure that the MVP is able to provide at least eight detection zones for each VVDS
camera. Ensure that the MVP contact closure outputs can mimic the operation of the zone to
which they are associated.
786-8.2.5 Mechanical Specifications: Use an MVP that is shelf- and
rack-mountable, or is contained in the cameras environmental enclosure.
Ensure that the shelf- and rack-mountable MVP fits in a standard EIA
19 inch rack and does not exceed 7 inches in height. Ensure that the MVP does not require
shielding from other electronic devices, such as power supplies and communication equipment.
786-8.2.6 Central Monitoring Equipment: Ensure that the VVDS provides the
capability for operator control and detection zone designation through the use of a PC having a
keyboard and mouse.
Provide the VVDS operator with the ability to position the detection zones
from the TMC or by using a laptop computer at the field site. Ensure that the detection zones can
be drawn on the video image from the VVDS camera and rendered in varying sizes and shapes to
allow for the best coverage of viewable roadway lanes, ramps, and shoulders. Ensure that it is
possible to download, upload, save, and edit a particular cameras detection zone configurations
from the TMC.
Ensure that a VGA computer monitor is able to display the video from the
VVDS camera and the detection zones superimposed on the video image, along with individual
vehicle actuations, in real time, as they occur.
961
Furnish the system with software that allows configuration, setup, data
logging, and retrieval via direct and remote connection of a PC to the MVP. Ensure that the
software allows the operator to perform any calibration necessary; set detector count periods;
adjust detection sensitivity, communication addresses, baud rates, operational modes (i.e., pulse,
presence, etc.), and output pulses; retrieve data; and utilize, operate, and adjust all features and
functions of the VVDS. Ensure that the VVDS has the capability to provide long-loop, delay,
and directional detection.
786-8.3 Installation of VVDS: Adjust the cameras and program the MVPs so all lanes
have detection zones that generate data to the specified accuracy requirements. Ensure that the
position, size and sensitivity of each detection zone are fully programmable from onsite or
remote locations, and that the vehicle detection system retains its programming in nonvolatile
memory for an indefinite time.
In cases where the proposed site for the MVP is more than 500 feet from the
VVDS camera (i.e., a field cabinet housing that is not installed on the same structure as the
camera), use fiber optic cable as specified in the Plans as the communication medium. Select the
type of interface device between the VVDS camera and fiber optic cable, and between the fiber
optic cable and the MVP, depending on the specific camera output (i.e., video or serial data, or
both).
Alternate communication media, such as wireless and cellular networks, may be
considered by the Engineer on a project by project basis.
786-8.3.1 Camera Placement and Aiming: Install the VVDS camera at the
minimum mounting heights described below. Verify that detection quality is not degraded due to
excess movement and vibration of the assembly. Ensure that the cameras furnished are factory
calibrated to conform to the performance specifications herein. Verify that any existing cameras
utilized are compatible and properly configured. Do not use cameras that require further
adjustment after initial setup, or that require periodic calibration.
Ensure that the VVDS manufacturers representative is present to assist in
the installation and setup process for each individual VVDS field site.
786-8.3.2 Roadside Camera Placement: Mount roadside VVDS cameras at a
prescribed height, with the camera facing at an angle that will enable the cone of view to include
the upstream and/or downstream traffic flow.
Verify that the height ratio to the closest point in the detection zone is
2 feet away for every 1 foot of camera mounting height; therefore, the preferred camera
mounting height of 70 feet requires a minimum 140 foot distance to the closest detection area.
The maximum distance from the camera is 5 feet to every 1 foot in height, or 350 feet away from
the camera. Due to the use of the zoom feature for detection zone definition, the maximum
mounting height of a camera is not limited as it relates to the field of view.
During installation, tilt the VVDS camera well below the horizon, then
zoom to the detection area to eliminate environmentally generated glare and improve the
cameras image.
Submit a graphical depiction of each camera site, its pole location,
mounting height, the ratio of distance away from the camera versus the mounting height, the
cameras mounting type (i.e., pole or structure), camera aiming procedures, and the placement of
the proposed detection zone for each lane.
786-8.3.3 Over-the-Road Camera Placement: For mounts over the travel lane,
place the camera at the preferable horizontal distance-to-mounting height ratio between 2:1 and
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5:1 to count vehicles, and at a maximum ratio of 10:1 to detect the presence of vehicles only. The
preferred mounting height over the travel lane shall be a minimum of 30 feet. The Engineer may
consider alternate heights as recommended by the manufacturer.
Ensure that the VVDS cameras mounted over the road on mast arms or
similar structures electronically dampen vibration so as to allow this type of installation.
786-9 Magnetic Traffic Detection System (MTDS).
786-9.1 Description: Furnish and install a MTDS as shown in the Plans and directed by
the Engineer.
786-9.2 Materials: Provide a magnetic detector that is able to resolve closely
spaced vehicles and reject adjacent lane vehicles. Ensure that the operator is able to select
whether data is output as contact closures, mimicking standard loop detector outputs, or as
accumulated statistical data using the detectors serial port.
At a 9,600-baud rate, the MTDS should meet the stated accuracy requirements
applicable to data collected from each of four travel lanes in a given direction of travel in all
prevalent traffic, weather, and lighting conditions. In addition, ensure that the MTDS also meets
the following performance specifications:
1. The MTDS shall have a magnetic field of 0.2 to 0.8 oersted (Oe).
2. The units inductance (i.e., red to green wires) shall be 50 to
63 microHenries (H) per probe, plus a nominal inductance of 16.5 H per 100 feet of lead-in
cable and 23 H per 100 feet of home run cable.
3. The DC resistance between sensor leads (i.e., red to green wires) shall
be 1.2 to 1.8 per probe, plus a nominal resistance of 3 per 100 feet of lead-in cable and
1.7 per 100 feet of home run cable.
4. The DC resistance of each sensor lead to the earth at 500 VDC shall be
greater than 100 megohms (M).
5. The transducers gain (i.e., sensitivity) shall be 5 nanoHenries (nH) per
millioersted (mOe) per probe at 0.4 Oe ambient field intensity.
6. The systems peak-to-peak drive current shall be 14 and
80 milliamperes (mA).
Ensure that the detector system is equipped with channel detect outputs and status
output, plus fault and status light emitting diode (LED) indicators for each input channel.
Equip the detector system with a front panel that conforms to the EIA-232
communication port and 44 contact rear-edge connectors (i.e., 22 double-sided contacts). Ensure
that the front of the detector is equipped with the appropriate switches, including a frequency
selector switch, a reset switch, and mode/sensitivity switches.
Provide detector units that match the selected probes as part of the manufacturers
recommended detection assembly and that are compatible with the SunGuide software. Ensure
that each detector has four detector inputs and has the ability to accommodate up to four probes
per channel.
Ensure that the detector can self-tune to its detection zone with no external
adjustments other than physical alignment. There shall be no external tuning controls of any
kind.
Ensure that the system operator is able to view real-time traffic activity data from
the TMC and is able to set the parameters for count periods, probe sensitivities, communication
addresses, bit rates, modes of operation (i.e., pulse, presence, long loop, delay, or directional
detection), output pulses, and enable power line filtering through use of the MTDS software.
963
Ensure that the detector system has a transceiver monitoring circuit that will
change the output relay to the fail-safe position in the event of a component failure.
Ensure that the detector system can be rack-mounted and is compatible with
requirements in the NEMA TS 1 and TS 2 standards for card racks, and with Model 170 and
2070 input files. Ensure that the MTDS has 44 contact edge connectors. Provide a detector with a
separate rack-mounted card rack from the detectors manufacturer.
786-9.2.1 Detector Probe and Carrier: Ensure that the magnetic detector probe
is a transducer that detects vehicles by converting changes in the vertical component of the
earths magnetic field to changes in inductance. One probe centered under each monitored lane
shall be sufficient to provide the accuracy specified herein, except in projects where motorcycles
must be detected. In these cases, determine the number of required probes according to the
manufacturers recommendations.
Ensure that the carriers hold the magnetic probes firmly under a lane in a
fixed, vertical alignment and lateral position as they are inserted into conduits installed beneath
the pavement. Ensure that the carriers interlocking mechanism maintains the probes alignment
within plus or minus 20 degrees from vertical alignment. Install the probes within 3 inches of the
desired carrier position.
Verify that probes may be easily repositioned or readjusted to improve
vehicle-sensing accuracy or to reflect changing traffic characteristics in permanent installations
or work zones. Determine the proper configuration for the probe sets based on the number of
probes used, their depth, and the traffic or roadway characteristics.
786-9.2.2 Carrier, Conduit and Pull Box: Install the magnetic probes and
carriers in a 3 inch nonferrous conduit. Provide the conduits under a separate pay item. Ensure
that the conduit is PVC Schedule 80 conduit, or its structural and dimensional equivalent in high
density polyethylene (HDPE) pipe. Mechanical joints are allowed only if the carrier sections can
slide freely over the joints.
Ensure that the pull box, provided for under a separate pay item, conforms
to Section 635. Ensure that the pull box is a minimum of 2 feet in diameter, or a minimum of
2 feet square. The nominal depth for either square or round pull boxes shall be 3 feet.
Provide the home run and lead-in cables according to the MTDS
manufacturers recommendations. Equip the probes with a lead-in cable assembled by the
manufacturer. Ensure that the lead-in cables length is adequate to connect the probe to a splice
at the pull box.
Ensure that up to four probes can be connected to the same lead. The leadin cable shall be a maximum of 1,000 feet in length.
Connect the lead-in cables to the field cabinet with a four-conductor home
run cable. Provide the kits to splice the probes lead-in cables to the home run cables according
to the MTDS manufacturers recommendations. Ensure that each sensors lead-in cable length
allows sufficient, but not excessive, slack for splicing connections to the shielded home run cable
at the pull box. Solder, insulate, and waterproof the splices using underground-rated splice kits
with an encapsulation compound. Ensure that a combined home run and lead-in cable can have a
length of up to 2,500 feet.
786-9.2.3 MTDS Cabling: Ensure that the lead-in cable is a polyurethanejacketed cable with two PVC insulated conductors and includes #22 AWG conductors.
786-9.3 Installation of MTDS: Install the magnetic traffic detector below the roads
surface, employing horizontal directional drilling or other methods approved by the Engineer.
964
Prior to drilling, furnish a sufficient number of bore logs at 5 foot intervals across the installation
site to characterize the soils, sediments, clays, groundwater, and related subsurface conditions.
Install and maintain the MTDS probes as detailed in the Plans without the
need to close traffic lanes. Do not damage the roads surface or disturb the pavement in any way.
Trenching may be utilized during installation in non-paved areas.
Prepare shop drawings that detail the complete MTDS, and all other
components to be supplied and constructed. Provide detailed drawings with the exact location
and placement of system components, and include the installation details for required cables.
Install all cabling according to the manufacturers recommendations.
Adjust and program the system components so that all lanes generate data
meeting the required accuracy specifications. Follow the manufacturers recommendations for
setting the sensitivity, depending on the expected vehicle mix. Install all electrical and
communication conduits as specified in the Plans. Install the 3 inch conduit at a depth of
21 inches, plus or minus 3 inches, extending from under the roads surface to the roadside pull
box as described herein. Provide the conduit separately, according to the manufacturers
recommendations. Extend the installed conduit 2 inches to3.5 inches into the terminating
roadside pull box to facilitate installation of the probes in their carriers.
Ensure that the conduits vertical alignment does not vary more than
0.25 inches per 1 foot of the horizontal length. Ensure that the conduit slopes downward slightly
to drain any accumulated water from the conduit. Install a removable cap on the conduit at the
far end of the pull box. Drill a weep hole measuring 0.1875 inches in the caps bottom, facing
downward. After all connections are completed, enclose the conduits end in the pull box with a
filter material that will let water enter and escape while preventing soil sediment intrusion.
Provide details of the spacing of the probes in the Plans and adapted to any local conditions.
Ensure that the field cabinets wiring is in accordance with the functions
assigned to the vehicle detector module pins. Ensure that all conductor pairs in the field cabinet
between the home run cable conductor pair terminations and the traffic detector card sensor input
are twisted at six or more turns per 1 foot.
Neatly bundle, tie-wrap and label all cables. Label each lead-in cable, as
well as its detector, with the lane number.
Use the installation kits required for inserting and removing the probes,
labeling probe cables, and closing off conduit ends according to the manufacturers
recommendations. At the splice box, splice the home run cables to the detector probe lead-in
cables, as specified in 786-9.2.2 herein and according to the probe manufacturers recommended
practices. Mechanically connect the spliced wires together by soldering. Seal the soldered cable
assemblies with an encapsulating compound from the splice kit. Permanently label the lead-in
and home run cables at both the splice and in the field cabinet. Splice the lead-in cable to the
home run cable according to the manufacturers recommendations to ensure a reliable connection
in the environmental conditions encountered by the MTDS.
Mount and install the detector assembly so that movement and vibration of
the assembly does not degrade detection quality. Ensure that the detectors are well calibrated to
ensure that they perform as required. Ensure that no further adjustments or calibration will be
required after the initial setup. During installation, measure the MTDS loop resistance, loop
inductance, crosstalk, and inductance change for each probe array. Record these results for each
set of sensors. Verify that the resistance between sensor leads does not exceed the following
limits: leads shall have resistance of less than 2 per probe; lead-ins shall have resistance of less
965
than 3 per 100 feet; and home run cables shall have resistance of less than 1.7 per 100 feet.
After verifying that each detector probes loop resistance is within these acceptable limits, seal
and encapsulate the splices using the manufacturers recommended splicing kit and procedures.
Check each probe set for continuity using an ohmmeter according to the probe manufacturers
recommendations.
786-10 Acoustic Vehicle Detection System (AVDS).
786-10.1 Description: Furnish and install an AVDS as shown in the Plans and directed
by the Engineer.
786-10.2 Materials: Ensure that a single AVDS acoustic detector is able to measure
traffic flow parameters for five adjacent lanes on a lane-by-lane basis. Ensure that the acoustic
detector works in both a side-fire (roadside) mounted configuration and in an overhead-mounted
configuration.
Ensure that the detector can identify and distinguish acoustic signals from
multiple approaching vehicles with a different signal level and a different wave front, or arrival
angle.
Ensure that the acoustic detector can process in real time every received acoustic
signal generated by passing or stationary (i.e., idling) vehicles. Ensure that the system produces
detection information both as contact closures emulating standard loop detector outputs and as
accumulated statistical data output that is transmitted via the AVDS data port.
Provide an AVDS that emulates a dual-loop speed trap configuration for speed
measurement. Ensure that the AVDS assembly includes relay contacts that close when a vehicle
is present within the defined detection zone, and whose relay contacts can be connected to traffic
controllers.
Ensure that the AVDS can accumulate short-term statistical data for each detected
lane and transmit the data to the TMC after each data collection interval. Ensure that the AVDS
can compute, store, and provide all required traffic parameter measurements per detection zone
in user-selected time intervals from 2 to 180 seconds, including, but not limited to, 10 seconds,
20 seconds, 30 seconds, 60 seconds, 90 seconds and 120 seconds.
Ensure the acoustic detector resolves closely spaced vehicles and rejects adjacent
lane vehicles.
Ensure that the AVDS is able to log and save data for up to 7 days, regardless of
the data collection interval.
Ensure that detection quality is not degraded due to vibration or movement of the
detector assembly due to wind or other factors.
Ensure that the acoustic detector is factory calibrated and able to perform as
required herein. The unit shall not require periodic adjustment after initial setup and
configuration.
Ensure that the AVDS equipment connections prevent reversed assembly or
improper installations. Ensure that the AVDS does not produce false detection due to in-lane
non-vehicle generated noise, or out-of-lane and off-road noise.
Ensure that the AVDS assembly meets the accuracy requirements detailed herein
whether the sensor is mounted on a pole, mast arm, sign structure, bridge or overpass. Accuracy
requirements are applicable to data collected from each of five lanes in a given direction of travel
in all prevalent weather and traffic conditions, from free-flow to stop-and-go operations.
Verify that the AVDS is equipped with presence and passage detection modes.
966
Ensure that the AVDS has a minimum designed mean time between failures
(MTBF) of 10 years, or 87,600 hours, while operating continuously in its application.
Ensure that the AVDS does not produce false detection due to in-lane non-vehicle
generated noise, or out-of-lane and off-road noise.
786-10.3 Installation of AVDS: Verify that the acoustic detector setback distance and
mounting height for the side-fire mounted configuration is set to produce the required detection
accuracy from the lanes that need to be covered, according to the manufacturers
recommendations. A 25 foot to 40 foot mounting height shall produce the degree of accuracy
these specifications require. From a side-fire mounted position, taking into account the necessary
clear zone, the detectors required location for the production of data to the specified accuracy
shall not exceed 40 feet.
Ensure that the acoustic detector is programmed so all lanes have detection zones
generating data that meets the accuracy specifications.
786-11 Guaranty Provisions.
Ensure that the MVDS, including, but not limited to, the microwave detection sensor, the
network interface devices, and all required cables, have a manufacturers warranty covering
defects in assembly, fabrication and materials of 2 years from the date of final acceptance by the
Engineer in accordance with 5-11 of all work to be performed under the Contract.
Ensure that the VVDS, including, but not limited to, the camera, mounting equipment
and MVP, have a manufacturers warranty of 5 years from the date of final acceptance by the
Engineer, in accordance with 5-11, of all the work to be performed under the Contract.
Ensure that the MTDS, including, but not limited to, the underpavement probes, carriers
and detectors, have a manufacturers warranty of 5 years from the date of final acceptance by the
Engineer in accordance with 5-11 of all work to be performed under the Contract.
Ensure that the AVDS has a manufacturers warranty covering defects in assembly,
fabrication, and materials for a minimum of 3 years from the date of final acceptance by the
Engineer in accordance with 5-11 of all work to be performed under the Contract.
If the manufacturers warranties for the detection systems and components are for longer
periods, then those longer period warranties will apply.
Ensure that the manufacturers warranty is fully transferable from the Contractor to the
Department. Ensure that these warranties require the manufacturer to furnish replacements for
any part or equipment found to be defective during the warranty period at no cost to the
Department within 10 calendar days of notification by the Department.
786-12 Method of Measurement.
The detection system shall be measured for payment in accordance with the following
tasks.
786-12.1 Furnish and Install: The Contract unit price for an MVDS, VVDS, MTDS or
AVDS at each detection site, furnished and installed, will include furnishing, placement, and
testing of all materials and equipment, and for all tools, labor, equipment, hardware, operational
software packages and firmwares, supplies, support, personnel training, shop drawings, warranty
documentation, and incidentals necessary to complete the work.
786-12.2 Furnish: The Contract unit price for an MVDS, VVDS, MTDS or AVDS at
each detection site, furnished, will include providing all equipment specified in the Contract
Documents, plus all shipping and handling costs involved in delivery as specified in the Contract
Documents.
967
786-12.3 Install: The Contract unit price for an MVDS, VVDS, MTDS or AVDS at each
detection site, installed, will include placement and testing of all materials and equipment, and
for all tools, labor, equipment, hardware, operational software packages and firmwares, supplies,
support, personnel training, shop drawings, warranty documentation, and incidentals necessary to
complete the work. The Engineer will supply the equipment specified in the Contract
Documents.
786-13 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section.
Payment will be made under:
Item No. 786-1
ITS Vehicle Detection System each.
968
DIVISION III MATERIALS
AGGREGATES
SECTION 901
COARSE AGGREGATE
901-1 General.
901-1.1 Composition: Coarse aggregate shall consist of naturally occurring materials
such as gravel, or resulting from the crushing of parent rock, to include natural rock, slags,
expanded clays and shales (lightweight aggregates) and other approved inert materials with
similar characteristics, having hard, strong, durable particles, conforming to the specific
requirements of this Section.
Coarse aggregate for use in pipe backfill under wet conditions, underdrain
aggregate, or concrete meeting the requirements of Section 347 may consist of reclaimed
portland cement concrete meeting the requirements of 901-5. Coarse aggregate for use in
bituminous mixtures may consist of reclaimed portland cement concrete meeting the
requirements of 901-5, except that the reclaimed concrete shall be from a concrete mix which
was produced and placed in accordance with applicable Department Specifications.
Materials substantially retained on the No. 4 sieve, shall be classified as coarse
aggregate.
Approval of mineral aggregate sources shall be in accordance with 6-2.3.
901-1.2 Deleterious Substances: All coarse aggregates shall be reasonably free of clay
lumps, soft and friable particles, salt, alkali, organic matter, adherent coatings, and other
substances not defined which may possess undesirable characteristics. The weight of deleterious
substances shall not exceed the following percentages:
Coal and lignite (AASHTO T 113).................................1.00
Soft and friable particles (AASHTO T 112)* .................2.00
Clay lumps (AASHTO T 112)* ......................................2.00
Plant root matter (visual inspection in
AASHTO T 27)****.....................................................0.005
Wood and wood matter (visual inspection in
AASHTO T 27)****.....................................................0.005
Cinders and clinkers........................................................0.50
Free shell** .....................................................................1.00
Total Material passing the No. 200 sieve (FM 1-T 011)
At Source with Los Angeles Abrasion less than or equal
to 30 ................................................................................2.50
At Source with Los Angeles Abrasion greater than
30.....................................................................................1.75
At Point of Use................................................................3.75
Fine-Grained Organic Matter (AASHTO 194) ...............0.03
Chert (less than 2.40 specific gravity SSD)
(AASHTO T-113)*** .....................................................3.00
969
* The maximum percent by weight of soft and friable particles and clay lumps
together shall not exceed 3.00.
** Aggregates to be used in asphalt concrete may contain up to 5% free shell.
Free shell is defined as that portion of the coarse aggregate retained on the No. 4 sieve consisting
of loose, whole, or broken shell, or the external skeletal remains of other marine life, having a
ratio of the maximum length of the particle to the shell wall thickness exceeding five to one.
Coral, molds, or casts of other shells, and crushed clam and oyster shell indigenous to the
formation will not be considered as free shell.
*** This limitation applies only to coarse aggregates in which chert appears as an
impurity. It is not applicable to aggregates which are predominantly chert.
**** Plant root matter, and wood and wood matter shall be considered deleterious
when any piece exceeds two inches in length or 1/2 inch in width.
The weights of deleterious substances for reclaimed Portland cement concrete
aggregate shall not exceed the following percentages:
Bituminous Concrete ......................................................1.00
Bricks ..............................................................................1.00
Wood and other organic substances (by weight)***** ....0.1
Reinforcing Steel and Welded Wire Fabric ......................0.1
Plaster and gypsum board .................................................0.1
Joint Fillers .......................................................................0.1
***** Supersedes requirement for other coarse aggregate
901-1.3 Physical Properties: Coarse aggregates shall meet the following physical
property requirements, except as noted herein:
Los Angeles Abrasion (FM 1-T 096) .... maximum loss 45%
Soundness (Sodium Sulfate) AASHTO T104 .......................
.............................................................. maximum loss 12%*
Flat or elongated pieces** ............................ maximum 10%
* For source approval - aggregates exceeding soundness loss limitations will be
rejected unless performance history shows that the material will not be
detrimental for portland cement concrete or other intended usages.
** A flat or elongated particle is defined as one having a ratio between the
maximum and the minimum dimensions of a circumscribing prism exceeding five
to one.
901-1.4 Gradation: Coarse aggregates shall conform to the gradation requirements of
Table 1, when the stone size is specified. However, Table 1 is waived for those aggregates
intended for usage in bituminous mixtures, provided the material is graded on sieves specified in
production requirements contained in 6-2.3, and meets uniformity and bituminous design
requirements.
TABLE 1
Standard Sizes of Coarse Aggregate
Amounts Finer than Each Laboratory Sieve (Square Openings), weight percent
Size
Nominal Size
3 1/2
2 1/2
1 1/2
4 inches
3 inches
2 inches
1 inch
No. Square Openings
inches
inches
inches
970
TABLE 1
Standard Sizes of Coarse Aggregate
Amounts Finer than Each Laboratory Sieve (Square Openings), weight percent
Size
Nominal Size
3 1/2
2 1/2
1 1/2
4 inches
3 inches
2 inches
1 inch
No. Square Openings
inches
inches
inches
3 1/2 to 1 1/2
1
100
90 to 100
25 to 60
0 to 15
inches
2 1/2 inches to 1
2
100
90 to 100 35 to 70 0 to 15
1/2 inches
2 1/2 inches to
24
100
90 to 100
25 to 60
3/4 inch
3 2 inches to 1 inch
100
90 to 100 35 to 70 0 to 15
2 inches to No. 4
357
100
95 to 100
35 to 70
1 1/2 inches to
3/4 inch
1 1/2 inches to
467
No. 4
5 1 inch to 1/2 inch
1 inch to 3/8 inch
56
4
57
6
67
68
7
78
8
89
9
10
1 inch to No. 4
3/4 inch to 3/8
inch
3/4 inch to No. 4
3/4 inch to No. 8
1/2 inch to No. 4
1/2 inch to No. 8
3/8 inch to No. 8
3/8 inch to No.
16
No. 4 to No. 16
No. 4 to 0
100
90 to 100 20 to 55
100
95 to 100
100
90 to 100
100
90 to 100
100
95 to 100
100
100
-
TABLE 1 (Continued)
Standard Sizes of Coarse Aggregate
Amounts Finer than Each Laboratory Sieve (Square Openings), weight percent
Nominal Size
Size
Square
3/4 inch 1/2 inch 3/8 inch
No. 4
No. 8
No. 16 No. 50
No.
Openings
3 1/2 inches to 1
1
0 to 5
1/2 inches
2 1/2 inches to 1
2
0 to 5
1/2 inches
971
TABLE 1 (Continued)
Standard Sizes of Coarse Aggregate
Amounts Finer than Each Laboratory Sieve (Square Openings), weight percent
Nominal Size
Size
Square
3/4 inch 1/2 inch 3/8 inch
No. 4
No. 8
No. 16 No. 50
No.
Openings
2 1/2 inches to
24
0 to 10
0 to 5
3/4 inch
2 inches to 1
3
0 to 5
inch
2 inches to No.
357
10 to 30
0 to 5
4
1 1/2 inches to
4
0 to 15
0 to 5
3/4 inch
1 1/2 inches to
467
35 to 70
10 to 30
0 to 5
No. 4
1 inch to 1/2
5
20 to 55 0 to 10
0 to 5
inch
1 inch to 3/8
56
40 to 85 10 to 40 0 to 15
0 to 5
inch
57 1 inch to No. 4
25 to 60
0 to 10
0 to 5
3/4 inch to 3/8
6
90 to 100 20 to 55 0 to 15
0 to 5
inch
3/4 inch to No.
67
90 to 100
20 to 55 0 to 10
0 to 5
4
3/4 inch to No.
68
90 to 100
30 to 65 5 to 25 0 to 10
0 to 5
8
1/2 inch to No.
7
100
90 to 100 40 to 70 0 to 15
0 to 5
4
1/2 inch to No.
78
100
90 to 100 40 to 75 5 to 25 0 to 10
0 to 5
8
3/8 inch to No.
8
100 85 to 100 10 to 30 0 to 10
0 to 5
8
3/8 inch to No.
89
100 90 to 100 20 to 55 0 to 30 0 to 10
0 to 5
16
9
No. 4 to No. 16
100
85 to 100 10 to 40 0 to 10
0 to 5
10
No. 4 to 0
100
85 to 100
The gradations in Table 1 represent the extreme limits for the various sizes
indicated which will be used in determining the suitability for use of coarse aggregate from all
sources of supply. For any grade from any one source, the gradation shall be held reasonably
uniform and not subject to the extreme percentages of gradation specified above.
901-2 Natural Stones.
972
Course aggregate may be processed from gravels, granites, limestones, dolomite,
sandstones, or other naturally occurring hard, sound, durable materials meeting the requirements
of this Section.
901-2.1 Gravels: Gravel shall be composed of naturally occurring quartz, free from
deleterious coatings of any kind. The minimum dry-rodded weight AASHTO T19 shall be
95 lb/ft3.
Crushed gravel shall consist of a minimum of 85%, by weight, of the material
retained on the No. 4 sieve, having at least three fractured faces.
901-2.2 Granites: Coarse aggregate produced from the crushing of granites shall be
sound and durable. For granites to be used in bituminous mixtures and surface treatments, the
Los Angeles Abrasion requirement of 901-1.3 is modified to permit a maximum loss up to
50 (FM 1-T 096). Maximum amount of mica schist permitted is 5% (FM 5-584).
901-2.3 Limestones, Dolomite and Sandstone: Coarse aggregates may be produced
from limestone, dolomite, sandstones, and other naturally occurring hard, durable materials
meeting the requirements of this Section.
Pre-Cenozoic limestones and dolomite shall not be used as crushed stone
aggregates either coarse or fine for Asphalt Concrete Friction Courses, or any other asphalt
concrete mixture or surface treatment serving as the final wearing course. This specifically
includes materials from the Ketone Dolomite (Cambrian) Newala Limestone (Mississippian),
and Northern Alabama and Georgia.
As an exception to the above up to 20% fine aggregate from these materials may
be used in asphalt concrete mixtures other than Friction Courses which serve as the final wearing
course.
901-2.4 Cemented Coquina Rock: For Cemented Coquina Rock to be used in
bituminous mixtures, the Los Angeles Abrasion requirement of 901-1.3 is modified to permit a
maximum loss up to 50 (FM 1-T 096) provided that the amount of material finer than No. 200
generated during the Los Angeles Abrasion test is less than 18%.
901-3 Manufactured Stones.
901-3.1 Slags: Coarse aggregate may be produced from molten nonmetallic by-products
consisting essentially of silicates and aluminosilicates of calcium and other bases, such as aircooled blast-furnace slag or phosphate slag, provided it is reasonably uniform in density and
quality, and reasonably free from deleterious substances as specified in 901-1.2. In addition, it
must meet the following specific requirements:
Sulphur content .................................................. not more than 1.5%
Dry rodded weight AASHTO T 19 ...................... minimum 70 lb/ft3
Glassy Particles ................................................... not more than 10%
Slag shall not be used as an aggregate for Portland cement concrete.
For Air-Cooled Blast Furnace Slag, the Los Angeles Abrasion requirement of
901-1.3 is modified to permit a maximum loss up to 50 (FM 1-T 096) provided that the amount
of material finer than No. 200 sieve generated during the Los Angeles Abrasion test is less than
18%.
901-4 Lightweight Aggregates.
901-4.1 Lightweight Coarse Aggregate for Bituminous Construction: Lightweight
coarse aggregate may be produced from naturally occurring materials such as pumice, scoria and
973
tuff or from expanded clay, shale or slate fired in a rotary kiln. It shall be reasonably uniform in
quality and density, and free of deleterious substances as specified in 901-1.2, except that the
term cinders and clinkers shall apply to those particles clearly foreign to the extended aggregate
in question.
In addition, it must meet the following specific requirements:
Material passing the No. 200 Sieve
................................ maximum 3.00%, (FM 1-T 011)
Dry loose weight (AASHTO T 19)* ....... 33-55 lb/ft3
Los Angeles Abrasion (FM 1-T 096) maximum 35%
Ferric Oxide (ASTM C 641) ......... maximum 1.5 mg
* Source shall maintain dry-loose unit weight within plus or minus 6% of
Quality Control average. Point of use dry-loose unit weight shall be within plus or minus 10% of
Source Quality Control average.
901-4.2 Lightweight Coarse Aggregate for Structural Concrete: The requirements of
901-4.1 are modified as follows:
Aggregates shall not be produced from pumice and scoria.
Los Angeles Abrasion (FM 1-T 096, Section 12) shall be 45%, maximum.
Gradation shall meet the requirements of AASHTO M195 for 3/4 inch, 1/2 inch
and 3/8 inch.
901-5 Reclaimed Portland Cement Concrete.
The reclaimed portland cement concrete shall be crushed and processed to provide a
clean, hard, durable aggregate having a uniform gradation free from adherent coatings.
The Contractors (Producers) crushing operation shall produce an aggregate meeting the
applicable gradation requirements. The physical property requirements of 901-1.3 for soundness
shall not apply and the maximum loss as determined by the Los Angeles Abrasion (FM 1-T 096)
is changed to 50.
The sources of reclaimed portland cement concrete will be treated as a mine and subject
to the requirements of Section 6 and Section 105. These sources shall qualify as facilities
generating clean debris, defined in Rule 62-701.200(15), Florida Administrative Code (FAC), as
uncontaminated concrete exempt from solid waste regulation in accordance with Rule 62701.220(2)(f), FAC.
If the Department determines that the concrete has been contaminated with petroleum
products or lead-based paint, the concrete shall not be considered clean debris and the source
shall be required to be permitted and to perform testing in accordance with Rule 62-701, FAC,
subject to any ensuing enforcement action by the Florida Department of Environmental
Protection.
Concrete shall be asbestos free.
Operators of demolition recycling facilities shall demonstrate that they are in compliance
with 40 Code of Federal Regulations (CFR) 61.141 and 61.145. Notification requirements from
each owner or operator of a demolition or renovation activity supplying reclaimed concrete shall
be available at the recycling facility.
901-6 Exceptions, Additions and Restrictions.
Pertinent specification modifications, based on material usage, will be found in other
Sections of the specifications.
974
SECTION 902
FINE AGGREGATE
902-1 General.
902-1.1 Composition: Fine aggregate shall consist of natural silica sand,
screenings, local materials, or subject to approval, other inert materials with similar
characteristics, or combination thereof, having hard, strong, durable particles, conforming
to the specific requirements of this Section.
Approval of construction aggregate sources shall be in accordance with 63.
902-1.2 Deleterious Substances: All fine aggregate shall be reasonably free of
lumps of clay, soft or flaky particles, salt, alkali, organic matter, loam or other extraneous
substances. The weight of deleterious substances shall not exceed the following
percentages:
Shale..................................................................................1.0
Coal and lignite .................................................................1.0
Cinders and clinkers..........................................................0.5
Clay Lumps .......................................................................1.0
902-2 Silica Sand.
902-2.1 Composition: Silica sand shall be composed only of naturally occurring
hard, strong, durable, uncoated grains of quartz, reasonably graded from coarse to fine,
meeting the following requirements, in percent total weight.
Sieve Opening Size
No. 4
No. 8
No. 16
No. 30
No. 50
No. 100
No. 200
Percent Retained
0 to 5%
0 to 15%
3 to 35%
30 to 75%
65 to 95%
93 to 100%
minimum 96%
Percent Passing
95 to 100%
85 to 100%
65 to 97%
25 to 70%
5 to 35%
0 to 7%
maximum 4%
Silica sand from any one source, having a variation in Fineness Modulus
greater than 0.20 either way from the Fineness Modulus of target gradations established
by the producer, may be rejected.
902-2.2 Organic Impurities: Silica sand shall be subject to the colorimetric test
for organic impurities. If the color produced is darker than the standard solution, the
aggregate shall be rejected unless it can be shown by appropriate tests that the impurities
causing the color are not of a type that would be detrimental to portland cement concrete.
Such tests shall be in accordance with AASHTO T21 and AASHTO T71. When tested
for the effect of organic impurities on strength of mortar, the strength ratio at seven and
28 days, calculated in accordance with Section 11 of AASHTO T71, shall not be less
than 95%.
975
902-3 Sands for Miscellaneous Uses.
902-3.1 Anchor Bolts and Pipe Joints: Sand for setting anchor bolts, pipe joints
or other similar uses shall meet the quality requirements of 902-2, except that gradation
requirements are waived.
902-3.2 Brick Masonry: Sand for brick masonry shall meet the quality
requirements of 902-2, except for gradation requirements. All the materials shall pass the
No. 8 sieve, and be well graded from coarse to fine.
902-3.3 Sand-Cement Riprap: Sand for sand-cement riprap shall meet the
quality requirements of 902-2, except for gradation requirements. The material shall meet
the following gradation limits:
Sieve Size
No. 4
No. 100
No. 200
Percent Passing
minimum 97%
maximum 20%
maximum 5%
902-4 Filter Material for Underdrains.
Silica sand for use as filter material for Types I through IV underdrains shall meet
the requirements of 902-2, except that the requirements of 902-1.2 and 902-2.2 shall not
apply. The aggregate shall be reasonably free of organic matter and other deleterious
materials. The gradation requirements of 902-2.1 shall apply except no more than 2%
shall pass the No. 200 sieve.
Filter material for Type V underdrain shall meet the above requirements except
that there shall be no more than 1% of silt, clay and organic matter, that the aggregate
shall have a Uniformity Coefficient of 1.5 or greater, and that 10% diameter shall be
No. 70 to 35 sieve. The Uniformity Coefficient shall be determined by the ratio D60
divided by D10, where D60 and D10 refer to the particle diameter corresponding to 60%
and 10% of the material which is finer by dry weight.
902-5 Screenings.
902-5.1 Composition: Screenings shall be composed of hard, durable particles,
either naturally occurring, such as gravel screenings, or resulting from the crushing or
processing of the parent rock, to include natural rock, slags, expanded clays or shales
(lightweight aggregates), or other approved inert materials with similar characteristics.
Aggregates classified as screening shall conform to the following
gradation requirements:
Sieve Size
3/8 in.
No.4
Percent Passing
100%
75 to 100%
902-5.2 Specific Requirements:
902-5.2.1 Screenings from Department Approved Sources of Coarse
Aggregate: Processed screenings from fully approved sources of coarse aggregate are
subject to gradation. Should coarse aggregate source approval status change, or
976
unsatisfactory in-service history develop, additional control requirements may be
implemented.
Screenings for use in hot bituminous mixture may consist of
screenings from the processing of reclaimed portland cement concrete pavement to
produce coarse aggregate.
902-5.2.2 Screenings from Other Sources: Screenings, from sources
other than Department Approved Sources of Coarse Aggregate, must meet the following
additional general requirements:
Modified Los Angeles Abrasion: 95% statistical probability of
meeting maximum loss of 23%.
Specific Gravity*
Absorption*
Soundness*
Sulfur*
Phosphate*
Extraneous Substances*
*Specific specification requirements based on material usage
found in appropriate Bituminous or Portland Cement Sections.
Based on specific material characteristics, processing techniques
and in-service history on Department projects, specific source requirements may be
assigned.
902-5.2.3 Screenings for Use in Portland Cement Concrete: Screenings
produced from either the Miami Oolite, Miami Ft. Thompson, or Loxahatchee Ft.
Thompson Formations may be substituted for silica sand for use in concretes, except for
concrete pavements, approach slabs, bridge decks and precast superstructure segments.
(However, screenings will be permitted in the concrete when the bridge deck or approach
slab is to be covered with an asphalt concrete surface course.)
These screenings must meet the gradation requirements of
AASHTO M6, Section 6.1, as well as the maximum percent passing the No. 200 sieve,
Fineness Modulus, and Organic requirements of 902-2 Silica Sand. In addition, the
saturated, surface dry specific gravity shall be at least 2.48.
902-6 Local Materials.
Local materials shall be composed of hard, strong, durable particles, either
naturally occurring, such as natural sands, or resulting from the crushing or processing of
parent rock, to include natural sand and rock, slags, expanded clays or shales (lightweight
aggregate), or other approved inert materials with similar characteristics.
Aggregates classified as local material shall conform to the following gradation
requirements:
Sieve Size
3/8 in.
No. 10
No. 200
Percent Passing
100%
85 to 100%
maximum 15%
977
In addition to meeting the requirements of 902-1.2, the material shall not contain
excessive quantities of other deleterious substances, such as roots, cans, debris, etc. If
clay size material is present, it shall not exceed 7%, as determined by AASHTO T88, and
it shall be of a type which will not produce clay balls when used. The aggregate must be
suitable for designated use, as determined by laboratory tests. If the deposit consists of
stratified layers of varying characteristics and gradation, the producer shall employ such
means as necessary to secure a uniform material.
Local materials will not be required to be produced under the requirements of 63.3, provided they can meet the above requirements.
902-7 Exceptions, Additions and Restrictions.
Other specification modifications, based on material usage may be found in the
appropriate sections of the Specifications.
978
FLEXIBLE-PAVEMENT MATERIALS (INCLUDING MATERIALS FOR
STABILIZING)
SECTION 911
LIMEROCK MATERIAL FOR
BASE AND STABILIZED BASE
911-1 General.
This Section governs materials to be used on construction of limerock base and limerock
stabilized base.
911-2 Furnishing of Material.
Except as might be specifically shown otherwise, all limerock material and the sources
thereof shall be furnished by the Contractor. Approval of mineral aggregate sources shall be in
accordance with 6-3.3. Any limerock material occurring in State-furnished borrow areas shall
not be used by the Contractor in constructing the base, unless permitted by the Plans or other
Contract Documents.
911-3 Composition.
The minimum of carbonates of calcium and magnesium in the limerock material shall be
70%. The maximum percentage of water-sensitive clay mineral shall be 3%. Determination shall
be at the option of the Engineer.
911-4 Liquid Limit and Plasticity Requirements.
911-4.1 Material for Limerock Base: The liquid limit shall not exceed 35 and the
material shall be non-plastic.
911-4.2 Material Used in Limerock Stabilized Base: The liquid limit shall not exceed
35 and the plastic index shall not exceed 10.
911-5 Mechanical Requirements.
911-5.1 Deleterious Material: Limerock material shall not contain cherty or other
extremely hard pieces, or lumps, balls or pockets of sand or clay size material in sufficient
quantity as to be detrimental to the proper bonding, finishing, or strength of the limerock base.
911-5.2 Gradation and Size Requirements:
911-5.2.1 For Limerock Base: At least 97% (by weight) of the material shall
pass a 3-1/2 inch sieve and the material shall be graded uniformly down to dust. The fine
material shall consist entirely of dust of fracture. All crushing or breaking-up which might be
necessary in order to meet such size requirements shall be done before the material is placed on
the road.
911-5.2.2 For Limerock Stabilized Base: For this use, the limerock material
shall meet the requirements of 911-5.2.1 except that 97% shall pass the 1-1/2 inch sieve.
911-6 Limerock Bearing Ratio Requirements.
Limerock material used in construction of limerock base shall have an average LBR
value of not less than 100. The average LBR value of material produced at a particular source
shall be determined in accordance with an approved quality control procedure.
979
SECTION 913
SHELL MATERIAL
913-1 General.
913-1.1 Composition: Shell materials to be used for shell base or shell stabilized base,
shall consist of naturally occurring deposits formed essentially of broken mollusk shell, corals
and the skeletal remains of other marine invertebrates. Live or steamed shell, or man-made
deposits as a by-product of the shellfish industry will not be permitted.
Approval of mineral aggregate sources shall be in accordance with 6-3.3.
913-1.2 Deleterious Substances: Shell materials shall be reasonably free of lumps of
clay, organic matter, and other substances not defined which may possess undesirable
characteristics. The material shall not contain silica sand in sufficient quantity to prevent
bonding.
913-1.3 Physical and Chemical Properties: Shell materials shall meet the following
physical and chemical requirements:
Limerock Bearing Ratio (LBR) (FM 5-515) - The material shall have an average
LBR value of not less than 100. Material represented by any individual LBR value of less than
90 is unacceptable.
Plasticity (AASHTO T89 and AASHTO T90) - That portion of the material
passing the No. 40 sieve shall be non-plastic.
Carbonates (FM 5-514) - The minimum percentage of carbonates of calcium and
magnesium shall be 50.
913-2 Dredged Shell.
913-2.1 Definition: Dredged shell shall be defined as those shell materials meeting the
requirements of 913-1, which are dredged from ocean, bay or lake deposits.
913-2.2 Gradation Requirements: Materials classified as dredged shell shall meet the
following gradation requirements:
Passing 3-1/2 inch sieve
Passing No. 4 sieve
Passing No. 200 sieve
97% (maximum dimension not to exceed 6 inches)
maximum 50%
maximum 7.5% (by weight)
913-3 Bank-Run Shell.
913-3.1 Definition: Bank-run shell shall be defined as those shell materials meeting the
requirements of 913-1 which are presently found as dry land deposits.
913-3.2 Gradation Requirements: Materials classified as bank-run shell shall meet the
following gradation requirements:
980
97% (maximum dimension not
to exceed 6 inches)
maximum 80%
maximum 20% (washed)
Passing 3-1/2 inch sieve
Passing No. 4 sieve
Passing No. 200 sieve
913-4 Exceptions, Additions and Restrictions.
Other specification modifications, based on material usage, may be found in applicable
Sections of the specifications.
981
SECTION 913A
SHELL - ROCK MATERIAL
913A-1 General.
Shell-rock materials to be used for shell-rock base shall be defined as naturally occurring
heterogeneous deposits of limestone with interbedded layers or lenses of loose and cemented
shell, to include cemented sands (calcitic sandstone). This material shall be mined and processed
in a manner that will result in a reasonably homogenous finished product.
Approval of mineral aggregate sources shall be in accordance with 6-3.3.
913A-2 Deleterious Substances.
Shell-rock materials shall not contain lumps of clay, organic matter, cherty or other
extremely hard materials, or other substances not defined, in sufficient quantity as to be
detrimental to the finishing, strength, or performance of the base. The material shall not contain
loose, free silica sand in sufficient quantity to prevent bonding of the base, or to result in a
surface which is susceptible to distortion under construction traffic, or accumulation of loose
sand on the finished surface which precludes bonding of the bituminous tack coat with the base,
nor shall the material contain more than 50% loose, free shells, corals or skeletal remain of other
marine invertebrates (retained on the No. 4 sieve). Materials shall contain no water sensitive clay
minerals.
913A-3 Physical and Chemical Properties.
Shell-rock material shall meet the following physical and chemical properties:
Limerock Bearing Ratio (LBR) (FM 5-515) - Production of this material shall be
controlled so as to meet the following requirements for LBR value:
The average of test values shall not be less than 100.
No individual test value shall be less than 90.
No two consecutive test values between 90 and 100.
Plasticity (AASHTO T89 and AASHTO T90) - That portion of the material
passing the No. 40 sieve shall be non-plastic.
Carbonates (FM-5-514) - The minimum of the average percentage of carbonates
of calcium and magnesium shall be 50. Material represented by any individual carbonate LOT
average of less than 45% is unacceptable.
Gradation Requirements - Materials classified as shell-rock shall be graded
uniformly down to dust and in addition, meet the following specific requirements:
Passing 3-1/2 inch sieve (maximum dimension not to exceed
6 inches) ............................................. minimum 97%
Passing No. 4 sieve ........................... maximum 70%
Passing No. 200 sieve ....... maximum 20% (washed)
982
SECTION 914
STABILIZATION MATERIALS
914-1 General.
This Section governs materials to be used in subgrade stabilization. Meet the following
requirements:
Plasticity Index (AASHTO T90)
Liquid Limit (AASHTO T89)
Passing a 3-1/2 inch screen (AASHTO T27)
LBR
Maximum 10
Maximum 40
Minimum 97%
No Requirement
914-2 Materials for Stabilizing (Limerock Bearing Ratio-LBR).
914-2.1 Commercial Materials: Materials may be either limerock, shell rock, cemented
coquina or shell base sources approved in accordance with 6-2.3.
914-2.2 Local Materials: Local materials used for stabilizing may be soils or recyclable
materials such as crushed concrete, roof tiles and asphalt coated base or reclaimed pavement
provided the following limits for organic content are met.
Average Organic Content* (FM 1-T267)
Individual Organic Content Sample (FM 1-T267)
Maximum 2.5%
Maximum 4%
*Note: A minimum of three samples per source.
If the organic content exceeds the allowable values and RAP or RAP-blended material is used as stabilizing material, the
Engineer may allow FM 5-563 (with the exception of gradation analysis) in lieu of FM 1-T267 after mixing. The maximum
allowable test result is 4.7%.
Materials that contain hazardous substances or contaminates shall not be used.
If toxic substances, elements or compounds are suspected to exist at
concentrations exceeding limits defined by the Environmental Protection Agency (EPA),
qualifying tests shall be performed. Test methods for these substances shall be those mandated
by EPA and analyzed by a certified laboratory.
983
SECTION 915
CEMENTED COQUINA SHELL MATERIAL
915-1 Composition.
Cemented coquina shell materials to be used as cemented coquina base or stabilized base,
shall be defined as naturally occurring deposits formed essentially of broken mollusk shell,
corals and the skeletal remains of other marine invertebrates, which are presently found as dry
land deposits and which have been cemented together by carbonates or other natural cementing
agents.
Approval of mineral aggregate sources shall be in accordance with 6-3.3.
915-2 Deleterious Substances.
Cemented coquina shell materials shall be reasonably free of lumps of clay, organic
matter, and other substances not defined which may possess undesirable characteristics. The
material shall not contain loose, free silica sand in sufficient quantity to prevent bonding.
915-3 Physical and Chemical Properties.
Cemented coquina shell shall meet the following physical and chemical properties.
Limerock Bearing Ratio (LBR) (FM-515) - The material shall have an average LBR
value of not less than 100. Material represented by any individual LBR value of less than 90 is
unacceptable.
Plasticity (FM 1-T089 and FM 1-T090) - That portion of the material passing the No. 40
sieve shall be non-plastic.
Carbonates (FM 5-514) - The average percentage of carbonates of calcium and
magnesium shall be 45%. Material represented by any individual carbonate and magnesium LOT
average of less than 40.5% is unacceptable.
915-4 Gradation requirements.
Cemented coquina shall have the following gradation requirements:
97% (maximum dimension not to exceed 6
inches)
maximum 70%
maximum 20% (by washing)
Passing 3-1/2 inch sieve
Passing No. 4 sieve
Passing No. 200 sieve (dry weight)
915-5 Exceptions, Additions and Restrictions.
Other specification modifications, based on material usage, may be found in applicable
Sections of the specifications, or revisions thereto.
984
SECTION 916
BITUMINOUS MATERIALS
916-1 Superpave PG Asphalt Binder:
916-1.1 Requirements: Superpave Performance Graded (PG) asphalt binders, identified
as PG 52-28, PG 58-22, PG 64-22, PG 67-22, and PG 76-22, shall meet the requirements of 9161.2, AASHTO M320-10 Table 1 and the following additional requirements:
1. The intermediate test temperature at 10 rad/s. for the Dynamic Shear
Rheometer test AASHTO T315-10 shall be 25C for grades PG 64 and higher.
2. An additional high temperature grade of PG 67 is added for which the high test
temperature at 10 rad/sec for the Dynamic Shear Rheometer test AASHTO T315-10 shall be
67C.
3. All PG asphalt binders having a high temperature designation of PG 67 or
lower shall be prepared without modification.
4. All PG asphalt binders having a high temperature designation higher than
PG 67 shall be produced with a styrene-butadiene-styrene (SBS) or styrene-butadiene (SB)
elastomeric polymer modifier and resultant binder shall meet all requirements of this Section; in
addition the phase angle at 76C (AASHTO T15-10) shall be a maximum of 75 degrees.
5. Do not substitute a PG binder with a high temperature PG grade higher than the
specified PG grade, (for example, if a PG 58-22 is specified, do not supply a PG 64-22 or
higher).
For all PG binder used in all hot mix asphalt, silicone may be added to the PG
binder at the rate of 25 cubic centimeters of silicone mixed to each 5,000 gallons of PG binder. If
a disbursing fluid is used in conjunction with the silicone, the resultant mixture containing the
full 25 cubic centimeters of silicone shall be added in accordance with the manufacturers
recommendation. The blending of the silicone with the PG binder shall be done by the supplier
prior to the shipment.
All PG binder and asphalt rubber binder for friction course mixes and for other
hot mix asphalt products containing reclaimed asphalt pavement (RAP) shall contain 0.5% heat
stable anti-strip additive by weight of PG binder unless specifications for the hot mix asphalt
product requires testing by FM 1-T 283 and the test results indicate it is not required, or the
mixture contains hydrated lime. Where FM 1-T 283 indicates an anti-strip additive is required, it
shall be from 0.25% to 0.75%. The anti-strip additive shall meet the requirements of 916-5. The
anti-strip additive shall be introduced into the PG binder by the supplier during loading.
916-1.2 Qualified Products List (QPL): The Superpave PG asphalt binders supplied
under this specification shall be one of the products included on the QPL as specified in 6-1.
Manufacturers seeking evaluation of their product shall submit an application in accordance with
Section 6 and include a report of test results from an independent laboratory confirming the
material meets the requirements of this section. Any marked variation from the original test
values for a material below the established limits or evidence of inadequate quality control or
field performance of a material will be considered to be sufficient evidence that the properties of
the material have changed, and the material will be removed from the QPL.
For each binder grade, the supplier may be required to submit to the State
Materials Office, a split sample of material representative of test results submitted with the
Product Evaluation Application. In addition, for modified binders, the original PG binder grade,
the modifier product designation, and amount added shall be indicated on the Product Evaluation
985
Application and in the Quality Control Program below. Suppliers shall not ship any PG binder
until notified that the product is on the QPL and an approved Quality Control Program meeting
the requirements of 916-1.3 has been implemented.
916-1.3 Quality Control Program: The supplier of Superpave PG asphalt binder shall at
a minimum have a Quality Control Program meeting the requirements of this Section based on
AASHTO R26-01 (2009). The Quality Control Program shall be submitted in electronic format
to the State Materials Office for approval.
The requirements for the Quality Control Program apply to the supply location of
PG binders for the use on Department projects. The supply location of PG binder may represent
refinery production, terminal distribution, blending, processing, and/or modification location.
Rack blending (blending from two tank sources) will be permitted to meet the requirements for a
PG asphalt binder product. Any special handling requirements such as rack blending and
manufacture of polymer modified asphalt shall be described in the Quality Control Program.
916-1.3.1 Identification of Personnel and Supply Locations: The suppliers
primary and secondary representatives responsible for Quality Control (QC) shall be identified
by name, title, address, telephone, fax and e-mail address. At least one of the representatives
shall be located at the supply location. The supply locations shall be identified by name, address
and telephone.
916-1.3.2 Specification Compliance and Quality Control (QC) Testing:
Specification compliance testing shall consist of complete testing of each PG binder shipped in
accordance with AASHTO M320-10 and 916-1.1 of these specifications. Results of specification
compliance testing shall be available to the supplier within five working days of sampling.
Specification compliance testing shall be conducted by a testing laboratory that participates at
least annually in the AASHTO Materials Reference Laboratory (AMRL) Proficiency Sample
Program for Performance Graded Asphalt Binder. The primary testing lab and any other labs to
be used for specification compliance testing shall be identified in the suppliers Quality Control
Program. The results from each AMRL Proficiency Sample for each testing laboratory shall be
forwarded by the supplier for each supply location in electronic format to the State Materials
Office. Acceptable performance in the AMRL Proficiency Sample Program shall be a minimum
of 3 for each test. A rating of less than 3 shall require identification of appropriate action on the
part of the supplier and be acceptable to the State Materials Engineer.
QC testing as a minimum shall consist of testing a representative sample
of each PG binder shipped by the supplier in accordance with AASHTO T315-10 Test Method
for Determining Rheological Properties of Asphalt Binder using a Dynamic Shear Rheometer
(DSR).
Results of QC testing shall be available to the supplier within 5 hours of
sampling. A QC test result outside the specification limits will require immediate sampling and
testing for specification compliance and appropriate action taken. The QC testing and location
where the test will be done shall be identified in the suppliers Quality Control Program.
916-1.3.3 Frequency of Sampling and Testing: Sampling of PG binders shall be
done in accordance with AASHTO T40-02 (2006). Initial specification compliance test results
shall be required for each PG binder grade for each new LOT of material which will be further
subjected to QC testing in accordance with 916-1.3.2. A new LOT will occur when the material
in a tank changes and the specification compliance test may no longer be representative of the
material in the tank. This may be due to an incoming bulk shipment of material, change in
986
refinery run, the manufacture of a product, or a blend of material in a tank. Additional testing is
as follows:
(1) Any PG binder shipped to a Department project during any one
calendar month shall be tested at least once during that month for specification compliance in
accordance with 916-1.3.2.
(2) When being shipped to Department projects, samples shall be obtained
by the supplier and tested for QC testing in accordance with 916-1.3.2. A single, 1-quart
representative sample of each PG binder shall be obtained and tested by the supplier each
calendar week; for each rack blended PG binder; additional representative samples shall be
obtained daily. Each QC sample and additional daily rack blended samples shall be adequately
identified and retained for not less than 8 weeks at the supply location. Any PG binder not
shipped to Department projects is not required to be sampled or tested.
(3) Split samples of any PG binder will be provided when requested by a
representative of the Department. In this situation, three representative 1-quart samples will be
obtained by the supplier under the direction of the Department. One sample will be submitted to
the State Materials Office, one will be tested by the supplier for specification compliance and
one will be tested by the supplier for quality control. The method of obtaining the three
representative 1-quart samples is to obtain a single gallon sample, which is then stirred and
poured into three 1-quart cans. When split samples are requested by the Department, the results
from both parties will be made available within 10 working days.
(4) For each rack blended PG binder, identify minimum daily Process
Control Testing in the QC Plan.
916-1.3.4 Reporting: A monthly report by the supplier containing specification
compliance and QC test results for each PG binder LOT shall be submitted by the supplier in
electronic format using the form provided by the Department to the State Materials Office within
7 days following the end of the calendar month. Test results for split samples shall also be
included. Process Control Test results shall not be included. Copies of these monthly reports and
supporting test reports shall be available at the supply location for a minimum of 3 years.
The report shall consist of the specification compliance testing and QC
testing of the following as applicable by these specifications.
SUPERPAVE PG ASPHALT BINDER
Test and Method
Conditions
Specification
Minimum/Maximum
Value
Original Binder
Superpave PG Asphalt
Binder Grade
Qualified Products List
Number
Polymer Modifier Type
Solubility, AASHTO T 4403 (2007)
Flash Point,
AASHTO T 48-06 (2010)
Report
Report
(PG 76-22 Only)
Report
in Trichloroethylene
Minimum 99.0%
COC
Minimum 450F
987
Rotational Viscosity,
AASHTO T 316-11
275F
Maximum 3 Pa-s
G*/sin , Test Temperature @
Dynamic Shear Rheometer,
Minimum 1.00 kPa
10 rad/sec, C
AASHTO T 315-10
Maximum 75 degrees
Phase Angle, , (PG 76-22 Only)
Rolling Thin Film Oven Test Residue (AASHTO T 240-09)
Rolling Thin Film Oven,
Mass Change%
Maximum 1.00
AASHTO T 240-09
G*/sin , Test Temperature @
Dynamic Shear Rheometer,
Minimum 2.20 kPa
AASHTO T 315-10
10 rad/sec, C
Pressure Aging Vessel Residue (AASHTO R 28-09) at 100C
G*sin ,
Dynamic Shear Rheometer,
Maximum 5000 kPa
AASHTO T 315-10
10 rad/sec. @ 25C
S (Stiffness), @
Maximum 300 Mpa
Creep Stiffness,
60 sec.
AASHTO T 313-10
M-value, @
Minimum 0.300
60 sec.
916-1.3.5 Notification and Evaluation: In the event that a specification
compliance test is outside specification requirements or a QC test is outside limits established by
the supplier as part of his Quality Control Program, shipments of that product to Department
projects will cease immediately and the Contractor and the State Materials Office will be notified
and the product retested for specification compliance (re-sampling as appropriate). Where the
retest for specification compliance meets all requirements, shipments of that product may
resume. Where off-specification material has been shipped and the retest confirms the original
test, the Contractor and State Materials Office will be informed of the steps taken to achieve
specification compliance on the product shipped.
Where off-specification materials have been shipped, further shipment of
that product to Department projects shall remain suspended until the cause of the problem is
evaluated and corrected by the supplier to the satisfaction of the State Materials Engineer.
916-1.3.6 Certification and Verification: The supplier shall furnish certification
on the bill of lading for each shipment of PG binder delivered to a Department project that
includes: the quantity, the Superpave PG asphalt binder grade (including QPL number), PG
binder LOT designation, the customer name, the delivery location, a statement that the binder is
in conformance with 916-1 and the suppliers Quality Control Program, and the quantity of
silicone and anti-strip agent addition, as applicable, including product designation (QPL number
as applicable). Any special handling or temperature requirements shall be indicated on the
certification and are solely the responsibility of the Contractor to follow.
The Department may sample and test PG binder from the suppliers storage
tank, the delivery vehicle, and/or Contractors storage tank to verify and determine compliance
with this and other specification requirements. Where these tests identify material outside
specification requirements, the State Materials Engineer may require the supplier to cease
shipment of that PG binder product. Further shipment of that PG binder product to Department
projects may remain suspended until the cause of the problem is evaluated and corrected by the
supplier as necessary to the satisfaction of the State Materials Engineer.
988
916-2 Cut-Back Asphalts.
916-2.1 Requirements: Rapid-curing, cut-back asphalt shall conform with the
requirements of AASHTO M81-92 (2008), except that the penetration range shall be from 60120 instead of 80-120.
For Grade RC-3000, in addition to the requirements shown in Table 1 of
AASHTO M81-92 (2008) the following values shall be added to the requirements for distillation
test:
Distillate, Percentage by Volume of
Total Distillate to 680F
to 320F
to 374F
to 437F
Grade RC-3000
Maximum
0
10
40
All other requirements for the distillation test (and for other properties included in
the table) shall be as shown in Table 1 of AASHTO M81-92 (2008).
Medium-curing, cut-back asphalt shall conform with the requirements of
AASTHO M82.
916-2.2 Sampling, Certification, and Verification: Sampling of cut-back asphalts shall
be done in accordance with AASHTO T40-02 (2006). For each tank of cut-back asphalt
delivered to or prepared at the asphalt terminal, the asphalt supplier shall submit a sample to the
State Materials Office for testing before use. A pretest number will then be assigned by the State
Materials Office which shall be furnished with all cut-back asphalt delivered to the project. The
pretest number shall be valid for three months from the date of issue.
The Department may sample and test pre-tested cut-back asphalt from the
suppliers storage tank, the Contractors transport tank and/or distributor to verify and determine
compliance with this and other specification requirements. Where these tests identify material
outside specification requirements, the State Materials Engineer may require the supplier to
cease shipment of that pretested cut-back asphalt product. Further shipment of that pretested cutback asphalt product to Department projects may remain suspended until the cause of the
problem is evaluated and corrected by the supplier as necessary to the satisfaction of the State
Materials Engineer.
916-3 Emulsified Asphalts.
916-3.1 Requirements: Anionic emulsified asphalt shall meet the requirements of
AASHTO M140-08 with the exception that the cement mix test will be waived when the asphalt
is used in non-mix application, such as tack coats and primes. Cationic emulsified asphalt shall
meet the requirements of AASHTO M208-01 (2009). Additional emulsions permitted by
specifications shall meet the following requirements:
HIGH FLOAT EMULSIONS
Test
Conditions
Saybolt Furol Viscosity
Tests on Emulsion:
122F
989
Asphalt Emulsion
Grade AE-60
Minimum/Maximum
75/400 seconds
Settlement
Storage Stability
Sieve Test
Demulsibility
Residue by Distillation
Oil Portion
Penetration (0.1 mm)
Absolute Viscosity
Ductility
Float Test
Solubility
Test
Saybolt Furol Viscosity
Settlement
Storage Stability
Sieve Test
Demulsibility
Residue by Distillation
Oil Portion
Penetration (0.1 mm)
Absolute Viscosity
Ductility
Float Test
Solubility
Test
Saybolt Furol Viscosity
Settlement
Storage Stability
Sieve Test
Demulsibility
Residue by Distillation
Oil Portion
5 days (a)
24 hour (b)
50 mL CaCl2 0.10 N
500F. Dist.
Tests on Residue:
77F, 100 g, 5 seconds
140F
77F,
50 mm/minute
140F
in Trichloroethylene
Conditions
Tests on Emulsion:
122F
5 days (a)
24 hour (b)
50 mL CaCl2 0.10 N
500F. Dist.
Tests on Residue:
77F, 100 g, 5 seconds
140F
77F, 50 mm/minute
140F
in Trichloroethylene
Conditions
Tests on Emulsion:
122F
5 days (a)
24 hour(b)
50 mL CaCl2 0.10 N
500F. Dist.
990
maximum 5%
maximum 1%
maximum 0.10%
minimum 75%
minimum 65%
maximum 1% by volume
minimum 40
minimum 3,200 poise
minimum 400 mm
minimum 1,200 seconds
minimum 97.5%
Asphalt Emulsion
Grade AE-90
Minimum/Maximum
75/400 seconds
maximum 5%
maximum 1%
maximum 0.10%
minimum 75%
minimum 65%
maximum 2% by volume
minimum 70
minimum 1,600 poise
minimum 400 mm
minimum 1,200 seconds
minimum 97.5%
Asphalt Emulsion
Grade AE-150
Minimum/Maximum
75/400 seconds
maximum 5%
maximum 1%
maximum 0.10%
minimum 75%
minimum 65%
maximum 3% by volume
Tests on Residue:
77F, 100 g, 5 seconds
140F
77F, 50 mm/minute
140F
in Trichloroethylene
Penetration (0.1 mm)
Absolute Viscosity
Ductility
Float Test
Solubility
Test
Conditions
Saybolt Furol Viscosity
Settlement
Storage Stability
Sieve Test
Demulsibility
Residue by Distillation
Oil Portion
Penetration (0.1 mm)
Absolute Viscosity
Ductility
Float Test
Solubility
Tests on Emulsion:
122F
5 days (a)
24 hour (b)
50 mL CaCl2 0.10 N
500F. Dist.
Tests on Residue:
77F, 100 g, 5 seconds
140F
77F, 50 mm/minute
140F
in Trichloroethylene
minimum 125
minimum 800 poise
minimum 400 mm
minimum 1,200 seconds
minimum 97.5%
Asphalt Emulsion
Grade AE-200
Minimum/Maximum
minimum 45 seconds
maximum 5%
maximum 1%
maximum 0.10%
minimum 75%
minimum 62%
maximum 8% by volume
minimum 150
minimum 400 poise
minimum 1,200 seconds
minimum 97.5%
(a) The test requirement for settlement may be waived when the emulsified asphalt is used in less than 5 days.
(b) The 24-hour (one day) storage stability test may be used instead of the 5 day settlement test.
Test
Saybolt Furol Viscosity
Storage Stability
Sieve Test
Demulsibility
Residue by Distillation
Naphtha Content
SPECIAL MS-EMULSION
Conditions
Tests on Emulsion:
77F
24 hour
50 mL CaCl2 0.10 N
Minimum/Maximum
minimum 45 seconds
maximum 1%
maximum 0.10%
minimum 65%
minimum 62%
maximum 8% by volume
500F. Dist.
Tests on Residue:
Penetration (0.1 mm)
77F, 100 g, 5 seconds
minimum 50
Ductility
77F, 50 mm/minute
minimum 400 mm
Absolute Viscosity
140F
minimum 800 poise
Solubility
in Trichloroethylene
minimum 97.5%
Maximum application temperature shall be 170F.
EMULSIFIED ASPHALT GRADE CRS-2H
991
Test
Saybolt Furol Viscosity
Settlement
Storage Stability
Demulsibility
Conditions
Tests on Emulsion:
122F
5 days (a)
24 hour (b)
35 mL 0.8% Sodium Dioctyl
Sulfosuccinate (c)
Particle Charge
Sieve Test
Residue
Penetration (0.1 mm)
Ductility
Solubility
Minimum/Maximum
100/400 seconds
maximum 5%
maximum 1%
minimum 40%
positive
maximum 0.1%
minimum 65%
Tests on Residue:
77F, 100 g, 5 seconds
77F, 50 mm/minute
in Trichloroethylene
80/140
minimum 400 mm
minimum 97.5%
(a) The test requirement for settlement may be waived when the emulsified asphalt is used in less than 5 days.
(b) The 24-hour (one day) storage stability test may be used instead of the 5 day settlement test.
(c) The demulsibility test shall be made within 30 days from date of shipment.
ASPHALT EMULSION PRIME (AEP)
Conditions
Minimum/Maximum
Tests on Emulsion:
Saybolt Furol Viscosity
77F
20/150 seconds
Settlement
5 days (a)
maximum 5%
Storage Stability
24 hour (b)
maximum 1%
Sieve Test
maximum 0.1%
Residue
minimum 55%
Naphtha Content
500F. Dist
maximum 12% by volume
Tests on Residue:
Penetration (0.1 mm)
77F, 100 g, 5 seconds
40/200
Ductility
77F, 50 mm/minute
minimum 400 mm
Solubility
in Trichloroethylene
minimum 97.5%
Test
(a) The test requirement for settlement may be waived when the emulsified asphalt is used in less than 5 days.
(b) The 24-hour (one day) storage stability test may be used instead of the 5 day settlement test.
ASPHALT EMULSION GRADE RS-1h
Conditions
Minimum/Maximum
Tests on Emulsion:
Saybolt Furol Viscosity
77F
20/100 seconds
Storage Stability
24 hour
maximum 1%
Demulsibility
35 mL 0.02N CaCl2 (a)
minimum 60%
Sieve Test
maximum 0.10%
Residue by Distillation
minimum 55%
Naphtha Portion
500F. Dist (b)
maximum 3% by volume
Tests on Residue From Distillation Test:
Test
992
Penetration (0.1 mm)
77F, 100 g,
5 seconds
140F
77F,
50 mm/minute
in Trichloroethylene
Viscosity
Ductility
Solubility
minimum 60
minimum 1,600 poise
minimum 400 mm
minimum 97.5%
(a) The demulsibility test shall be made within 30 days from the date of shipment.
(b) When RS-1H has been modified to include naphtha, the 24-hour storage stability test will be waived.
Test
Saybolt Furol Viscosity
Storage Stability
Sieve Test
Naphtha Content
Residue
EMULSION PRIME (RS TYPE)
Conditions
Tests on Emulsion:
77F
24 hour
Tests on Residue:*
77F, 100 g, 5 seconds
140F
in Trichloroethylene
Penetration (0.1 mm)
Viscosity
Solubility
Minimum/Maximum
minimum 75 seconds
maximum 1.0%
maximum 0.1%
5/15% by volume
minimum 55%
minimum 50
minimum 800 poise
minimum 97.5%
* Residue by distillation shall be in accordance with AASHTO T 59-09 except that the maximum temperature shall be 329, plus
or minus 10F [165, plus or minus 5C] and the sample shall be maintained at this temperature for 20 minutes.
Tests
Tests on Emulsion:
Saybolt Furol Viscosity
Sieve Test (a)
Residue by Distillation (b)
Particle Charge Test (c)
Test on Residue: (d)
Flash Point
Viscosity
EPR-1 PRIME (e)
Conditions
Minimum/Maximum
77F
6/24 seconds
maximum 0.1%
minimum 20%
positive
COC
140F
minimum 410F
600/1000cSt
(a) Distilled water shall be used in place of 2% sodium oleate solution.
(b) Residue by distillation shall be in accordance with AASHTO T 59-09 with the exception that a 50 g sample is heated to 300F
[149C] until foaming ceases, then cooling immediately and calculating results.
(c) Caution: this material has a positive particle charge, and therefore should not be mixed with materials having a negative
particle charge.
(d) Residue by distillation shall be in accordance with AASHTO T 59-09 except that the maximum temperature shall be 329,
plus or minus 10F [165, plus or minus 5C] and the sample shall be maintained at this temperature for 20 minutes.
(e) EPR-1 Prime shall not be diluted. In the event that EPR-1 Prime is not used in a 12 hour period, the material shall be
thoroughly mixed by circulation or other suitable means prior to use.
Test
EMULSIFIED ASPHALT GRADE CRS-1h
Conditions
Minimum/Maximum
Tests on Emulsion:
993
Saybolt Furol Viscosity
Storage Stability
Demulsibility
Sieve Test
Residue by Distillation
Naphtha Portion
Particle charge
Penetration (0.1 mm)
Viscosity
Ductility
Solubility
77F
24 hour
35 ml 0.8% Sodium Dioctyl
Sulfosuccinate (a)
500F. Distillation
500F. Distillation. (b)
20 100 seconds
maximum 1%
minimum 60%
maximum 0.10%
minimum 55%
maximum 3% by volume
positive
Tests on Residue From Distillation Test:
77F, 100 g, 5 seconds
minimum 45
140F
minimum 1600 poise
77F
minimum 400 mm
in Trichloroethylene
minimum 97.5%
(a) The demulsibility test shall be made within 30 days from the date of shipment.
(b) When CRS-1 has been modified to include naphtha, the 24 hour storage stability will be waived.
EMULSIFIED ASPHALT GRADE NTSS-1hm
Conditions
Minimum/Maximum
Tests on Emulsion:
Saybolt Furol Viscosity
77F
20 500 econds
Storage Stability
24 hour
maximum 1%
Settlement
5 days
maximum 5%
Residue by Distillation
minimum 50%
Naphtha Content
500F. Distillation
maximum 1% by volume
Sieve Test
maximum 0.30% (a)
Test
Tests on Residue From Distillation Test:
Penetration (0.1 mm)
77F, 100 g, 5 seconds
Softening Point ASTM D 36
Dynamic Shear Rheometer
G* sin&, 186.8F @ 10 rad/sec
AASHTO T 315-10
Solubility
in Trichloroethylene
maximum 20
minimum 149F
minimum 1.00 kPa
minimum 97.5%
(a) Sieve test may be waived if no application problems are present in the field.
916-3.2 Sampling, Certification, and Verification: For each tank of emulsified asphalt
delivered to or prepared at the asphalt terminal, the asphalt supplier shall submit a sample to the
State Materials Office for testing before use. A pretest number will then be assigned by the State
Materials Office which shall be furnished with all emulsified asphalt delivered to the project.
The pretest number shall be valid for 3 months from the date of issue.
The Department may sample and test pretested emulsified asphalt from the
suppliers storage tank, the Contractors transport tank and/or distributor to verify and determine
compliance with this and other specification requirements. Where these tests identify material
outside specification requirements, the State Materials Engineer may require the supplier to
cease shipment of that pretested emulsified asphalt product. Further shipment of that pretested
emulsified asphalt product to Department projects may remain suspended until the cause of the
994
problem is evaluated and corrected by the supplier as necessary to the satisfaction of the State
Materials Engineer.
916-4 Liquid Anti-strip Agents.
916-4.1 Requirements: Liquid anti-strip agents shall be tested in accordance with FM 5508. Tensile strength ratios will be calculated for the following two conditions and expressed as
percentages: 1) conditioned mixture without anti-strip to unconditioned mixture without antistrip and 2) conditioned mixture with anti-strip to unconditioned mixture without anti-strip. A
20% gain in tensile strength ratio for condition 2 as compared to condition 1 shall be required.
916-4.2 Qualified Products List (QPL): Liquid anti-strip agents supplied under this
specification shall be one of the products included on the QPL. Manufacturers seeking evaluation
of their product shall submit an application in accordance with Section 6 and include a report of
test results from an independent laboratory confirming the material meets the requirements of
this section. In lieu of submitting test results from an independent laboratory, the Department
will evaluate the material. For each liquid anti-strip agent, the supplier will submit to the State
Materials Office one pint of a representative sample of liquid anti-strip agent when submitting
the QPL application to the Departments Product Evaluation Section.
Any marked variation from the original test values for a material below the
established limits or evidence of inadequate quality control or field performance of a material
will be considered sufficient evidence that the properties of the material have changed, and the
material will be removed from the QPL.
916-4.3 Mix Design Verification: Inclusion of a liquid anti-strip agent on the QPL does
not guarantee that the anti-strip will be approved for use in an asphalt mixture. Specifications
may require subsequent moisture susceptibility testing per FM 1-T283 for the particular mix
design. Results from this testing may indicate the need for a larger dosage rate of anti-strip agent
(up to 0.75% maximum) or a different anti-strip agent to meet the specification requirements.
995
SECTION 917
MINERAL FILLER
917-1 Composition.
Mineral filler shall consist, in general, of limerock dust, portland cement, slag dust,
hydrated lime, or any other inert mineral matter from sources approved by, the Engineer. The
mineral filler shall be thoroughly dry and free from lumps consisting of aggregations of fine
particles. Ground phosphate will not be allowed as a mineral filler.
Stone or slag screenings may also be used as filler material for asphalt concrete mixtures,
under the provisions specified in 917-3, below.
917-2 Gradation.
The mineral filler shall meet the following gradation requirements:
Total passing No. 30 sieve ........................................... 100%
Total passing No. 80 sieve .......................... 95% (minimum)
Total passing No. 200 sieve ........................ 65% (minimum)
917-3 Provision for Use of Coarser Filler Material.
Process screenings from stone or slag, having a coarser gradation than as specified above,
may also be used as filler material provided the particular product, and the source thereof, are
approved by the Engineer and that the material meets the following requirements.
(a) All of the material shall pass the No. 10 sieve, and not more than 35% shall
pass the No. 200 sieve.
(b) The material passing the No. 200 sieve shall be free from organic impurities,
and not more than 4.0% of such shall consist of clay minerals. The plasticity index of the
material passing the No. 200 sieve shall not exceed 4.
(c) For the stone or slag material from which the screenings are produced the loss,
when subjected to the Los Angeles Abrasion Test, shall not exceed 45%.
996
SECTION 919
GROUND TIRE RUBBER
FOR USE IN ASPHALT RUBBER BINDER
919-1 Description.
This Section governs ground tire rubber for use in asphalt rubber binders for use in a
variety of paving applications.
919-2 General Requirements.
The ground tire rubber shall be produced from tires by an ambient grinding method. The
entire process or a final separate grinding process shall be at or above ordinary room
temperature. The rubber shall be sufficiently dry so as to be free flowing and to prevent foaming
when mixed with asphalt cement. The rubber shall be substantially free from contaminants
including fabric, metal, mineral, and other non-rubber substances. Up to 4% (by weight of
rubber) of talc or other inert dusting agent, may be added to prevent sticking and caking of the
particles.
The ground tire rubber used shall be one of the products listed on the Departments
Qualified Products List (QPL). Manufacturers seeking evaluation of their product shall submit an
application in accordance with Section 6.
919-3 Physical Requirements.
The physical properties of the ground tire rubber shall be determined in accordance with
FM 5-559, and shall meet the following requirements:
Specific Gravity ................................................. 1.06 to 1.20
Moisture Content .......................................Maximum 0.75%
Metal Contaminants ...................................Maximum 0.01%
Gradation - The gradation shall meet the limits shown in Table 919-1 for the type
of rubber specified.
Sieve Size
% Passing
No. 16
No. 30
No. 50
No. 100
Type B
Type C
--100
40-60
---
100
70-100
20-40
---
919-4 Chemical Requirements.
The chemical composition of the ground tire rubber shall be determined in accordance
with ASTM D297 and shall meet the following requirements:
997
Acetone Extract .............................................Maximum 25%
Rubber Hydrocarbon Content ............................... 40 to 55%
Ash Content ....................................................Maximum 8%
Carbon Black Content ........................................... 20 to 40%
Natural Rubber ...................................................... 16 to 45%
919-5 Packaging and Identification Requirements.
The ground tire rubber shall be supplied in moisture resistant packaging such as either
disposable bags or other appropriate bulk containers. Each container or bag of ground tire rubber
shall be labeled with the manufacturers designation for the rubber and the specific type,
maximum nominal size, weight and manufacturers batch or LOT designation.
919-6 Certification Requirements.
The Contractor shall provide the Engineer a certification conforming to the requirements
of Section 6 from the manufacturer, confirming that the ground tire rubber meets the
requirements of this Section.
998
MATERIALS FOR PORTLAND CEMENT CONCRETE (STRUCTURAL
PAVEMENT AND MISCELLANEOUS)
SECTION 921
PORTLAND CEMENT AND BLENDED CEMENT
921-1 General.
Cement shall conform to the requirements of AASHTO M85 or AASHTO M240, as
applicable, except as defined below or as specifically restricted in Section 346.
921-1.1 Type of Cement: Cement may be Types I, II, II (MH), III, IV, V
(AASHTO M85), or IP, IP (MS), IS (AASHTO M240). Different brands of cement, cement of
the same brand from different facilities, or different types of cement shall be stored separately
and shall not be mixed.
921-1.2 Alkali Content: Only portland cement containing a maximum of 0.60%
alkali, or less, calculated as Na2O (% Na2O plus 0.658% K2O), may be used with no further
testing. When tests performed in accordance with ASTM C33 X1.3 on coarse and fine aggregate
indicate the aggregate to be non-reactive to alkalis, cements exceeding 0.60% alkali is allowed.
921-1.3 Heat of Hydration: The cement heat of hydration for Type II (MH) shall
be 88 cal/g or less at 7 days when tested in accordance with ASTM C186. For Type II (MH)
used in mass concrete, the cement heat of hydration shall be 80 cal/g or less at 7 days when
tested in accordance with ASTM C186.
921-2 Terminology.
The following definitions are applicable to the production and quality control of cement:
Source of Supply - indicates a cement supplier responsible for supplying the final
product. Where the supplier has more than one manufacturing facility, the source of supply may
be designated as the manufacturer/facility.
Approved Source - indicates a cement supplier, including but not limited to a
plant, a terminal, or a transfer facility, that has been qualified by the State Materials Office. A
list of Approved Cement Sources will be maintained by the State Materials Office.
Quality Control (QC) Plan Status - indicates quality control approval status, for
each cement supplier and will be maintained by the State Materials Office in conjunction with
the Approved Source List.
Purchaser - The term purchaser in the AASHTO Specifications shall be taken
as the Department.
Approved Laboratory - indicates a laboratory acceptable to the State Materials
Office which has been currently inspected by the Cement and Concrete Reference Laboratory
(CCRL), is actively participating in their proficiency program and which has all deficiencies
noted at the time of inspection corrected. The laboratory must also authorize CCRL to send
copies of final inspection reports to the State Materials Office.
Mill Test Report - indicates a certification from the cement supplier identifying
that the cement meets Section 921, the Type, the production period the sample represents and the
chemical and physical analyses of the cement, and the silo numbers where the cement is stored.
The mill test report must identify that there is limestone in the cement, if limestone is included.
An acceptable mill test report is found in the appendix of AASHTO M85.
999
921-3 Packing, Handling and Storing.
Cement may be delivered in bags or in bulk. The storage building, bin or silo shall be
weatherproof and shall be located convenient to the work. On small jobs, storage in the open
may be permitted by the Engineer in which case raised platforms and adequate waterproof
coverings shall be provided.
921-4 Rejection.
The entire contents of the sack or bulk container which contains cement that does not
meet the requirements of this Specification or has been damaged, is partially set, lumpy or caked
shall be rejected.
Bagged cement which varies more than 5% from the designated weight, or if the average
weight of 50 sacks, taken at random, is less than the designated weight, the cement shall be
rejected.
921-5 Quality Control Plan.
921-5.1 General: The Quality Control Program of a cement supplier shall conform to
Section 105. Cement suppliers shall submit a proposed QC Plan to the State Materials Office for
plan approval. In addition to the QC Plan, the supplier must submit test reports from an approved
laboratory which certifies that the cement in current production or supply conforms to these
Specifications. Upon initial QC Plan approval and receipt of the cement mill test report, the
suppliers will be placed in an approved source status with an approved quality control plan. An
approved laboratory shall perform one quality control test per day. Submit a copy of the monthly
mill test report to the State Materials Office. The mill test report shall indicate that the cement
meets the requirements of this Specification. Also, the corresponding samples along with mill
test reports shall be submitted to the Department, upon request.
Producers intending to use limestone as a component material in the production of
cement shall describe the type and source of the limestone. In addition, the producer shall supply
the Department with a sample of the limestone, a sample of the cement prior to the limestone
being added and a sample of the cement after the limestone has been added. The analysis of
these materials will be used as a baseline for information. In the event that the source of
limestone used by the cement producer changes, additional samples of both the limestone and the
cement with the limestone added shall be provided to the State Materials Office for evaluation.
Representatives from the Department may take samples from the cement
production facility at a minimum of once per year to verify compliance with the producers QC
Plan.
The suppliers QC Plan shall be sufficient to insure that more than 97% of all
cement delivered for FDOT work shall meet all Specification requirements. Upon request of the
Department, the supplier shall provide split samples of the cement collected for quality control
testing. Split samples shall be delivered to the State Materials Office and shall be identified as
representing a designated LOT of cement.
921-5.2 Acceptance of Portland Cement: Portland cement from an approved source
with a current QC Plan approval may be accepted on the basis of mill test reports meeting the
requirements of the applicable AASHTO and FDOT Specifications and a delivery ticket printed
on the producers letterhead and traceable to the mill test report. Mill test reports shall be
provided upon request to the State Materials Office and corresponding samples for verification
testing. Quality control testing shall be performed by an approved laboratory.
1000
921-5.3 Cement Ownership and Responsibility: For purposes of QC Plan approval
status, the cement supplier shall be responsible for cement quality until the cement is accepted by
the concrete producer. Where the cement has been accepted by a concrete producer and is
subsequently found deficient, the concrete plant QC Plan approval may be withdrawn with
respect to further use of that cement and reinstated only when the deficiency is adequately
resolved. Reinstatement is made by the State Materials Office.
921-5.4 Quality Control Plan Approval Control: The State Materials Office may
withdraw QC Plan approval and may require cement shipments to be individually tested prior to
incorporation into Department work. QC Plan approvals may be rescinded when the performance
of cement is in question, including problems with concrete quality, inconsistent quality control
data, or failure of quality control or verification test results. Discontinuance of approval may be
based on testing at the point of use, testing by the manufacturer or proven poor performance of
the cement in concrete.
In the specific instance of a failing cement sample taken by the Department at the
cement source, the failure shall initiate the Department to retest the sample. Failure of the retest
will be considered adequate evidence to withdraw the QC Plan of the cement supplier.
Notification of failing test results will be distributed to the cement supplier (and
concrete producers, if applicable) as designated in the approved QC Plan. Split samples of the
initial sample may be provided to the cement supplier and concrete producer upon request.
Reinstatement of the QC Plan will occur when the cement producer identifies and
corrects the specific cause of the failures or that a statistical analysis indicates that the current
cement production meets or exceeds the requirements of this Specification.
921-5.5 Sampling of Cement: The verification samples may be taken at the
manufacturers plant, distribution facility or at the concrete production facility. Samples shall be
obtained by one of the methods in FM 5-503. Samples shall be a minimum of 10 pounds in size.
At the concrete production facility, cement samples shall be jointly obtained by the Department
Inspector and the concrete producers representative.
1001
SECTION 923
WATER FOR CONCRETE
923-1 General Requirements.
Water for use with cement shall be clear and free from oil, and injurious amounts of acid,
alkali, chlorides, organic matter, and other deleterious substances. It shall not be salty or
brackish. If it contains quantities of substances which discolor it or make it smell or taste unusual
or objectionable or cause suspicion, it shall not be used unless approved by the Department.
Water sources permitted include potable water supplies that are approved by a public health
department, open bodies of water, well water, reclaimed water, and recycled water. Reclaimed
water shall be as defined in Chapter 62-610, F.A.C. Open bodies of water are defined as
naturally occurring rivers, lakes, and ponds. Recycled water includes wash water from mixer
washout operations (stored in a lined settling pond). All other sources of water not listed above
shall be considered recycled and reclaimed water. Recycled and reclaimed may be used only to
sprinkle the coarse aggregate stockpiles and for batching concrete meeting the requirements of
Section 347.
923-2 Evaluation of Water for Concrete.
923-2.1 General: Water from potable water supplies approved by a public health
department may be used without additional testing. The concrete producer shall provide test data
of water samples from other sources. To determine chemical properties, use a laboratory
accredited by the National Environmental Laboratory or Construction Materials Engineering
Council Accreditation Program. To determine physical properties, use a laboratory accredited by
the Construction Materials Engineering Council Accreditation Program or Cement and Concrete
Reference Laboratory.
923-2.2 Initial Sampling and Testing Frequency: Open bodies of water and
well water shall be initially sampled once prior to use. Recycled and reclaimed water shall be
tested once per week for four weeks initially, and thereafter once per month for four months
prior to its use, provided that the results of the test samples comply with all the applicable limits.
Failing test results will result in restarting initial sampling and testing.
923-2.3 Production Sampling and Testing Frequency: Open bodies of water and
recycled water shall be tested monthly. Well water and reclaimed water shall be tested once
every three months. If the last eight consecutive well water and reclaimed water samples meet
the requirements, then the sample frequency may be reduced to one sample every six months, as
approved by the Department. If a well water or reclaimed water sample fails once the frequency
has been reduced, then the sampling frequency shall revert back to once every three months.
923-3 Chemical Requirements.
923-3.1 Testing: All chemical analysis or tests shall be performed in accordance with the
test methods listed in Tables 1 and 2 or Standard Methods for the Examination of Water and
Wastewater.
923-3.2 Recycled and Reclaimed Water: Recycled and reclaimed water shall be tested
before use and shall not exceed the limits in Table 1:
Table 1
Chemical Test
Test Method
1002
Maximum (%)
Table 1
Chemical Test
Total Solids
Total Chlorides as ClTotal Sulfates as SO4
Test Method
AASHTO T 26
ASTM D 512
ASTM D 516
Maximum (%)
5.00
0.031
0.30
923-3.3 Open Bodies of Water and Well Water: Open bodies of water and well water
shall be tested before use and shall not exceed the limits of Table 2:
Table 2
Chemical Test
Acidity or Alkalinity Calculated in terms of Calcium
Carbonate
Total Organic Solids
Total Inorganic Solids
Total Chlorides as ClTotal Sulfates as SO4
Test Method
AASHTO T 26
AASHTO T 26
AASHTO T 26
ASTM D 512
ASTM D 516
Maximum (%)
0.05
0.05
0.08
0.031
0.30
923-4 Physical Requirements for Mortar.
Mortar shall be tested in accordance with ASTM C109 with the following exception: the
mortar shall not be tested for flow. The mortar, composed of the sampled water, shall have a
compressive strength of not less than 90% when compared to a mortar prepared using distilled
water and tested at seven days.
Water of a questionable quality, as determined by the Department, shall be subject to the
acceptance criteria for time of set as required by ASTM C1602, Table 1.
1003
SECTION 924
ADMIXTURES FOR CONCRETE
924-1 General.
This Section covers materials for use as admixtures for concrete. The use of admixtures is
restricted to those admixtures as may be allowed or required elsewhere in the specifications for
specific concrete applications. Admixtures shall comply with applicable AASHTO and ASTM
specifications as modified in 924-2.3 through 924-2.7. Admixtures that have been previously
qualified for Department use are listed on a Qualified Products List (QPL).
924-2 Acceptance of Admixtures.
924-2.1 Qualified Products List (QPL): The Department maintains a list of qualified
admixtures for air-entraining, water-reducing (Type A), accelerating (Type C), water-reducing
and retarding (Type D), water-reducer and accelerating (Type E), high range water reducing
(Type F) and high range water-reducing and retarding (Type G), high range water-reducing
(Type I - Plasticizing and Type II - Plasticizing and retarding) in producing flowing concrete,
and corrosion inhibitor, which have been determined as meeting requirements for use on
Department projects. Admixtures included on this list, will be permitted without further testing.
The inclusion of any specific product on the QPL, as specified in 6-1, indicates
that the product has been given contingent approval, as evidenced by previous tests and apparent
effectiveness under field conditions.
Except as specified in Sections 346 and 347, no further testing will be required
for any product on the QPL unless there is indication in actual field use of inadequate or
unreliable results.
924-2.2 Certification: Manufacturers of admixtures shall provide certified test results
from an independent laboratory inspected by the Cement and Concrete Reference Laboratory
(CCRL) on a regular basis for applicable tests, with all deficiencies corrected for QPL approval
and upon request of the Engineer.
924-2.3 For Air-Entraining: Air-entraining admixtures shall meet the requirements of
AASHTO M154, except for the flexural strengths, relative durability factor, and length change
requirements are waived.
924-2.4 For Type A (Water-Reducing) and Type D (Water-Reducing and
Retarding): Water-reducing and water-reducing and retarding admixtures shall meet the
requirements of AASHTO M194 for Type A and D, respectively, except for the compressive
strength at six months and one year, flexural strengths, and relative durability factor
requirements are waived.
924-2.5 For Type C (Accelerating) and Type E (Water Reducing and Accelerating):
Accelerating and water reducing and accelerating admixtures shall meet the requirements of
AASHTO M194 for Type C and Type E, respectively, except for the compressive strength at six
months and one year, flexural strengths and relative durability factor requirements are waived.
924-2.6 For High Range Water-Reducing: High range water reducing admixtures shall
meet the requirements of the applicable AASHTO or ASTM specifications as modified in 9242.6.1 and 924-2.6.2.
924-2.6.1 For Type F or Type G: High range water reducing (Type F) and high
range water reducing and retarding (Type G), shall meet the requirements of AASHTO M194,
1004
except for the compressive strengths, at one year, and relative durability factor requirements are
waived.
924-2.6.2 For Type I and Type II: High range water reducing (Type I) and high
range water reducing and retarding (Type II), for use in producing flowing concrete shall meet
the requirements of ASTM C1017, except for the compressive strength, at one year, and relative
durability factor requirements are waived.
924-2.7 For Corrosion Inhibitors: Corrosion inhibitors shall meet the requirements of
ASTM G109 and all requirements in this Section.
Calcium nitrite is a chemically reactive admixture used in concrete to inhibit the
corrosion of embedded reinforcing steel and other metallic components. The calcium nitrite
supplier shall furnish the Engineer with test certificates from an independent laboratory
indicating compliance with this Specification. The test certificate shall include corrosion
inhibiting properties per ASTM G109 and results of physical tests included in this section.
Calcium nitrite shall be supplied by the same manufacturing source throughout the project. If a
single primary source of calcium nitrite cannot be maintained throughout the project, new test
certificates shall be submitted. The Engineer will determine specification compliance of a new
suppliers product, and evaluate the effectiveness of the new calcium nitrite product before
approving the source.
The active ingredient shall be calcium nitrite Ca(NO2)2.
The calcium nitrite shall be furnished in solution containing not less than 29%
calcium nitrite solids. The concentration of the calcium nitrite solution shall be verified by
spectrophotometric analysis or other comparable methods. The nitrite concentration shall be
measured in accordance with Standard Methods for the Examination of Water and Waste Water,
18th Edition.
A volume of one gallon of calcium nitrite solution shall weigh within the range of
10.40 to 11.92 lb.
The calcium nitrite solution shall be added to the concrete mixture at a rate of
4.50 to 4.60 gal/yd3 of concrete.
The addition of calcium nitrite to the concrete mix shall not adversely affect the
properties of fresh and hardened concrete.
Calcium Nitrite concrete shall meet the following physical requirements when
mixed and tested in accordance with AASHTO M194:
Water Content, % of control
Time of setting, allowable deviation from control, h:min:
Initial: at least not more than
Final: at least not more than
Compressive Strength, min. % of control:
Flexural strength, min, % of control:
Length change, max Shrinkage (alternative Requirements):
% of control
Increase over control
Relative durability factor, min
1005
95 to 100
1:00 earlier nor 1:30 later
1:00 earlier nor 1:30 later
shall be 100 for all ages
shall be 100 for all ages
135
0.010
80
The following table lists the corrosion inhibiting test result limits for calcium
nitrite concrete tested in accordance with ASTM G109:
Maximum Allowable Test Results of Calcium Nitrite Concrete
Measured average macrocell current any time during the test
Average macrocell current at test completion
Average visible corrosion measured as percent corroded area of control
10 A
2 A
85%
924-3 Performance Test on Air-Entraining Admixtures, for Effect on Strength of Concrete.
924-3.1 Conditions under which Test is Required: For any air-entraining admixture
selected for use the Engineer may call for a performance test (either prior to or at any time
during construction) for determining its effect on the strength of the concrete. In general, this
check-test will be required only when there is indication that such admixture is giving erratic
results or is unduly reducing the strength of the concrete. Testing shall be in accordance with
924-3.2 and 924-3.3.
924-3.2 Permissible Reduction in Strength of the Concrete: For concrete composed of
the same cement and aggregates (and in the same proportions) to be used in the work, and
containing the admixture under test, in an amount sufficient to produce between 3 and 5%
entrained air in the plastic concrete, the compressive strength at seven days shall be at least 90%
of the strength of the same concrete without the admixture.
924-3.3 Method of Test for Strength Reduction: The percentage reduction in strength
shall be calculated from the average strength of at least three standard 6 inch by 12 inch
cylinders of each class of concrete. Specimens shall be made and cured in the laboratory in
accordance with ASTM C192, and shall be tested in accordance with ASTM C39. The
percentage of entrained air shall be determined in accordance with ASTM C173 or ASTM C231.
924-4 Retesting.
The approved admixtures are required to be tested for their uniformity and equivalence
whenever there is an indication of erratic results. The tests shall be performed in accordance with
the following procedure. The admixture shall be checked for comparison between infrared
spectrophotometry, pH value, specific gravity, and solids content. Any marked variation from
the original curve, pH value, specific gravity, or solids content will be considered sufficient
evidence that the chemistry of the original material has been changed and, therefore, the use of
this material will be rejected and the material will be removed from the QPL.
1006
SECTION 925
CURING MATERIALS FOR CONCRETE
925-1 Burlap.
Burlap for curing concrete shall consist either of two layers, each weighing 10 to
18 ounces/10 square feet, or of four layers, each weighing 6 to 7 ounces/10 square feet. Burlap
which has been used as a container for sugar shall not be used. Burlap that is being used for the
first time shall be thoroughly washed in order to remove starches used in sizing the material.
Burlap shall be furnished in strips of at least 3 feet wide and shall be at least 3 feet longer than
the width of surface to be covered.
925-2 Membrane Curing Compound.
925-2.1 General: Membrane curing compound shall conform to requirements of
AASHTO M148 (Type 1 for clear compound and Type 2 for white-pigmented compound), and
the following additional requirements:
The membrane curing compound shall be of a consistency suitable for spraying at
temperatures prevalent at the time of construction operations, and which forms a continuous,
uniform film. It shall be free from precipitated matter caused by conditions of storage or
temperature. The compound shall be relatively nontoxic. Thorough agitation shall be performed
prior to shipment from manufacturers plant and prior to use at job site.
Curing compound delivered to the job in drums shall be in the manufacturers
original container, labeled with the manufacturers name, plant location, grade designation of
compound, LOT number, and quantity.
Curing compound delivered in bulk shall be supplied from and delivered to
storage tanks designed to provide thorough agitation by means of compressed air.
925-2.2 Sampling: Samples shall be obtained as specified in AASHTO M148 with the
following exception. Take one sample for each lot, batch, or other unit of production
representing each 2,200 gallons or fraction there of. Filled containers, represented by the samples
shall be sealed and marked by the sampling agency for later identification and correlation. Each
sample shall be at least 1 quart. Allow fourteen days for completion of the tests after arrival of
the sample in the laboratory.
925-2.3 Storage: Curing compound that has been tested and stored for longer than six
months but less than one year shall be retested prior to use. Compound that has been stored
longer than one year shall not be incorporated into the work.
925-3 Sheet Materials.
925-3.1 General: Waterproof paper, polyethylene film and white burlap-polyethylene
sheet, for curing concrete shall meet the requirements of AASHTO M171, with the additional
requirements for waterproof paper and for polyethylene film as shown below.
925-3.2 Additional Requirements for Waterproof Paper: The paper as prepared for
use shall be in such dimensions that each unit as laid will extend at least 18 inches beyond the
edges of the slab. If laid longitudinally, paper not manufactured in sizes which will provide this
width shall be securely sewed or cemented together; the joints being sealed in such manner that
they do not open up or separate during the curing period.
1007
At the option of the Contractor, instead of the single longitudinal strip specified
above, the blanket may be furnished in three strips; one strip being the neat width of the
pavement, with two side strips.
925-3.3 Additional Requirements for Polyethylene Sheeting: The sheets, as prepared
for use, shall be of such dimensions that each unit as laid will extend beyond the edges of the
slab by at least twice the thickness dimension of the pavement edge, and the sheets shall overlap
by at least 18 inches.
No sheet may be reused except after individual inspection and approval by the
Engineer. Any sheets determined by the Engineer to be so damaged as to not afford the
protection to the concrete in preventing moisture loss during the curing period will be rejected.
925-4 Certification.
For burlap or white burlap-polyethylene, the Contractor shall provide the Engineer a
certification conforming to the requirements of Section 6 from the manufacturer confirming that
the requirements of this Section are met. Each certification shall cover only one type of burlap or
white burlap-polyethylene sheeting.
1008
SECTION 926
EPOXY COMPOUNDS
926-1 Types of Compounds.
Epoxy resin compounds for application to portland cement concrete, bituminous cement
concrete, metals and other type surfaces shall be two-component systems of the applicable of the
following types as designated.
Type
Description
A An epoxy resin, for bonding fresh concrete to hardened concrete.
B An epoxy resin adhesive, for bonding hardened concrete to hardened concrete and
constructing doweled splices in precast prestressed concrete piles.
E A fluid epoxy for crack injection in the repair of old structures.
F An epoxy for repairing spalled areas on concrete bridge structures with these subtypes:
F-1
A non sagging gel type for vertical surfaces.
F-2
A pourable type for repairs where forms are to be used.
G An epoxy for rebuilding expansion joints and associated wearing surfaces.
H An epoxy for structural bonding where asphalt overlays are to be in contact with the
hardened compound.
I An epoxy for filling small holes in concrete such as lifting bolt cut-outs on beams, etc.
J An epoxy for installing rebar and anchor bolts into hardened concrete.
K An epoxy for underwater sealing of the bottom of the jacket of an integral pile jacket
system.
L An epoxy for coating the interior of sewage disposal tanks.
M A coal tar epoxy coating for steel sheet piles and H piles (water immersion).
N An epoxy for preparing mortars and concrete for patching portland cement concrete
pavement.
Q An epoxy for use in post tensioning anchorage protection systems.
T Hot applied coal tar epoxy tape.
926-2 Epoxy Design Requirements.
926-2.1 General: All types of compounds except L, and M shall contain no volatile
solvent.
All types of compounds except F, J, L, M, and N shall be basically pure reactive
material with a maximum ash content of 2%.
All types shall have simple mix ratios of one to one or two to one or shall be
supplied in pre-measured containers in which all of the contents of both packages are to be
mixed.
Certain terms used in this specification shall have these meanings:
low modulus - the stress-strain property for which ultimate tensile strength
is attained at over 10% elongation.
high modulus - the stress-strain property for which ultimate tensile
strength is attained at under 6% elongation.
non-sagging gel - grades of mixed compounds which will not perceptibly
flow under their own weight on a vertical surface in the unhardened state.
1009
pourable - grades of mixed compound sufficiently fluid that they (either
neat or filled) can be cast into and will take the shape of a mold.
926-2.2 Qualified Products List (QPL): All epoxy materials shall be one of the
products listed on the Departments Qualified Products List (QPL). Manufacturers seeking
evaluation of their products shall submit product data sheets, performance test reports from an
independent laboratory showing the product meets the requirements of this section, an infrared
identification curve (2.5 to 15 m) and a QPL application in accordance with Section 6.
Information on the QPL application must identify the epoxy type.
Products may only be used for applications recommended by the manufacturer.
926-2.3 Certification: The Contractor shall provide the Engineer with certification from
the manufacturer of the epoxy, confirming that the requirements of this Section are met. The
certification shall conform to the requirements of Section 6. Each certification shall cover only
one batch of epoxy materials.
926-3 Specific Requirements for Types A and B Compounds.
926-3.1 Mixing and Application: Types A and B epoxy compounds (for bonding fresh
concrete to hardened concrete or bonding precast concrete parts) shall be mixed, applied, and
cured in accordance with the manufacturers directions, or as might be directed otherwise by the
Engineer.
Epoxy compounds shall be used only under conditions which are compatible with
the material being applied in accordance with the specific directions of the manufacturer.
926-3.2 Performance Tests:
(a) Epoxy Bonding Compounds: Epoxy Bonding Compounds shall be prepared
and tested in accordance with FM 3-C882. The ratio of the compressive strength of the
composite cylinder to the compressive strength of the weaker concrete shall not be less than 0.90
(b) Epoxy Mortars: Epoxy mortar shall be prepared and tested in accordance with
FM 3-C882. The average compressive strength of the three test specimens shall be at least
5,000 psi.
926-4 Specific Requirements for Type E Compounds.
Epoxies for crack injection shall meet the Specification for Type B compound with these
additional requirements:
Viscosity five minutes after mixing
Wet bond strength to concrete, minimum
300 to 600 cps at 77F by ASTM D 2393
250 psi at seven days by Florida Method FM 5-518
926-5 Specific Requirements for Type F Compounds.
Epoxies for repairing spalled areas shall meet these requirements:
Subtype F-1 for repairing vertical and other surfaces shall be a trowelable low
modulus, non-sagging gel epoxy compound capable of bonding to wet surfaces with these
properties:
1010
Color
Viscosity
Maximum sand loading
Elongation in tension
minimum
Wet bond to Steel and
Concrete minimum
Shall match gray color No. 36622 of Federal Standard No. 595a
Gel
2.25 parts sand to one part mixed epoxy by volume
10% by ASTM D 638, seven day cure
250 psi by Florida Test Method FM 5-518
Subtype F-2 for filling larger spalls where a form is required to build back to the
original surface shall be a pourable low modulus type compound capable of bonding to wet
surfaces with these properties:
Color
Maximum sand loading
Elongation in tension,
minimum
Exotherm
Wet bond strength
Shall match gray color No. 36622 of Federal Standard No. 595a
2.25 parts sand to one part mixed epoxy by volume
10% by ASTM D 638, seven day cure
110F by ASTM D 2471, 1 pint sample
250 psi at seven days by Florida Method FM 5-518
926-6 Specific Requirements for Type G Compounds.
Epoxies for rebuilding expansion joints shall be pourable types which may be mixed with
sand and with these requirements for the mix:
Compressive strength
at 24 hours, minimum
at seven days, minimum by the method of 926-3.2(b)
Bond to wet concrete at seven days by Florida Method FM 5-518
Maximum sand loading
Elongation in tension at seven days,
ASTM D 638,minimum
Color
Exotherm, maximum by test method
ASTM D 2471, 1 pint sample size
4,500 psi
7,500 psi
250 psi
2.25 parts to one part mixed
epoxy by volume
2%
Natural
110F
926-7 Specific Requirements for Type H Compounds.
Epoxies for structural bonding where bituminous pavement overlays will come in contact
with the hardened compound shall meet the requirements for Types A and B compounds above
and the manufacturer shall provide test data showing that cutback and emulsified asphalts,
asphalt cement, and bituminous mixes shall bond to but not soften or otherwise damage the
epoxy after a curing period of four days.
926-8 Specific Requirements for Type I Compounds.
Epoxies for cosmetic patching of small areas on new concrete structures and components
shall be of any non-sagging grade which has a gray color matching that of Shade 36622 of the
1011
Federal Standards and which has been demonstrated to the Engineer to bond satisfactorily to the
concrete.
926-9 Specific Requirements for Type J Compounds.
Epoxies for installing rebar and anchor bolts into the hardened concrete shall meet the
requirements of Section 937 and be installed in accordance with Section 416. When the Contract
Documents call for the use of Type J, Class I, II, III, IV, epoxy or a Class IV Adhesive Anchor
System, use materials meeting the requirements of Section 937, constructed in accordance with
Section 416.
926-10 Specific Requirements for Type K Compounds.
Epoxies for sealing the bottom of integral pile jackets in the repair of concrete piles shall
be a type which will harden underwater with these requirements for the sand-epoxy mix:
Compressive strength at seven days, minimum by the
method described in 926-3.2(b)
Bond
to wet concrete, minimum
to wet pile jacket, minimum
(by Florida Method FM 5-518)
4,500 psi
250 psi
150 psi
Maximum sand loading
2.25 parts to one part mixed epoxy
by volume
Viscosity of mixed epoxy component at 77F,
five minutes by ASTM D 2393
1,000-2,000 cps
The epoxy sand mix shall be capable of flowing through water in the void area of the
jacket so as to provide a water tight seal of the depth indicated in the Plans or approved shop
drawings and to maintain this seal during subsequent construction steps.
926-11 Specific Requirements for Type L Compounds.
Epoxies for coating the interior of sewage disposal system tanks shall be of an approved
type. Manufacturers shall submit data and a record of previous usage showing satisfactory
performance in the protection of concrete from the aggressive effect of sewage for a five year
minimum to the State Materials Office.
926-12 Specific Requirements for Type M Compounds.
Epoxy coatings for steel sheet and H piles used in bridges, fender systems and other
structures subject to immersion in water shall comply with the requirements of Corps of
Engineers Specification C-200. Products not meeting these requirements may be approved by the
State Materials Office on the basis of data furnished by the manufacturer documenting equal or
superior performance.
Application of the epoxy coating shall meet the requirements of Section 560 for a coal tar
epoxy coating.
1012
926-13 Specific Requirements for Type N Compounds.
Epoxy adhesives for making epoxy mortar or concrete for patching portland cement
concrete pavement shall be any of approved products listed at the time of the work. Mix designs
for mortar and concrete shall be submitted to the Engineer at the time of the preconstruction
conference. Approval shall be by a field demonstration made by the Contractor using the criteria
of bond to the pavement, matching color, durability, and absence of excessive surface slicking
under traffic flow for acceptance.
The basic approval of new adhesives shall be made by the State Materials Office using a
six months road test with mortar-concrete mix designs recommended by the epoxy manufacturer.
926-14 Specific Requirements for Type Q Compounds.
These epoxy materials are to be used to protect the anchorages of post-tensioning tendons
or bars and other uses indicated in the Plans. The material shall produce a low exothermic
reaction and have flow and fill characteristics suitable for machine base plate applications. The
material will be extended with the aggregate supplied by the manufacturer. Mix with the full
aggregate loading unless the use of less aggregate is approved by the Engineer.
The material shall be factory pre-proportioned including factory supplied aggregate.
Deliver products in original containers with manufacturers name, date of manufacture, product
identification label and batch numbers. Materials must be within the manufacturers
recommended shelf life. Store and condition the product in full compliance with manufacturers
recommendations.
The epoxy grout plus aggregate mix shall meet or exceed the specified physical
properties stated herein as determined by the following standard ASTM test methods.
Property
Compressive Strength Cubes 7
day Cure at 77F
Tensile Strength at 7 days
Flexural Strength at 7day Cure
at 77F
Modulus of Elasticity 7 day
Cure at 77F
Coefficient of Thermal
Expansion at 74 to 210F
Peak Exotherm, Specimen
12 x 12 x 3 in.
Slant Shear at 7 days
(Bond Strength to Concrete)
Thermal Compatibility
Linear Shrinkage at 7 days
Flowability and Bearing Area
Gel Time, Specimen
12 x 12 x 3 in.
Test Value
Test Method
10,000 psi
ASTM C 579B
2,100 psi
ASTM C 307
> 3,600 psi
ASTM C 580
< 2,100,000 psi
ASTM C 580
< 20 x 10 -6 in/in/F
ASTM C 531
< 150F
ASTM D 2471
> 3000 psi
ASTM C 882
5 Cycles Passed
0.025%
90% Contact area
ASTM C 884
ASTM C 531
ASTM C 1339
< 4:00 (hr.)
ASTM D 2471
1013
926-15 Specific Requirements for Type T Tape Compounds.
Hot applied coal tar epoxy tape used to protect tie back rods on sheet pile walls and
bulkheads shall comply with the requirements of American Water Works Association standard
C203. Application shall be according to the manufacturers published recommendations.
926-16 Packaging, Labeling, and Safety.
All containers shall be identified as Component A - contains epoxy resin or
Component B - contains hardener, and shall show the type, mixing directions, batch numbers,
manufacturers name, date of packaging, shelf life expiration date and quantity in pounds or
gallons. Mix ratios shall be prominently shown on labels. Potential hazards shall be stated on
each package in accordance with the Federal Hazardous Products Labeling Act.
926-17 Storage.
Epoxy materials, which have been in storage for more than twelve months, will not be
accepted for use.
926-18 Fillers.
Fillers for mixing mortars and grouts may be as recommended by the manufacturer of the
particular epoxy compound and may be supplied as packages accompanying the epoxy or
premixed in accordance with approved properties.
If a manufacturer recommends only the gradation of filler, it must be a silica sand
commercially available in Florida and shall be a gradation listed in Table I or a specified blend
of these gradations.
The silica sands specified in Table I shall be clean, kiln dried, packaged in strong
moisture proof bags, contain no more than 0.2% organic trash, and be chloride free.
Fillers shall not be used with these compounds: Types E, J, L, and M.
When the fillers specified in Table I are used, the maximum amount shall be
2.25 volumes to one volume of mixed compound.
TABLE I
GRADATION REQUIREMENTS FOR FILLERS FOR USE WITH
EPOXY COMPOUNDS
GRADE
A
B
C*
Sieve Opening Size
Required % Passing
No. 4
95-100
No. 6
90-100
No. 8
0-15
No. 16
No. 20
80-100
0-20
No. 30
0-40
No. 50
0-10
No. 100
*For use only in sections 1 1/2 inches or greater in thickness.
**Same as quartz sand fine aggregate for cement concrete (902-1.3.1).
1014
D**
95-100
85-100
65-97
25-70
5-35
0-7
SECTION 929
POZZOLANS AND SLAG
929-1 Basis for Source Approval.
929-1.1 General: The cementitious materials supplier shall submit the proposed Quality
Control (QC) Plan, certified test reports from an approved independent laboratory acceptable to
the State Materials Office, and a sample of the material for Department verification. The Quality
Control Program of a cementitious materials supplier shall conform to 105-3. Continuance of
Department qualifications is subject to satisfactory results from periodic verification evaluations.
A verification sample may be taken at the manufacturers plant, distribution facility or at the
concrete producers plant.
Upon review of the QC Plan and satisfactory verification of the test results, the
plant will be placed on the Departments list of Cementitious Materials Sources with accepted
Quality Control Programs. The cementitious materials supplier shall utilize a QC Plan accepted
by the State Materials Office. The Department reserves the right to withdraw QC Plan
acceptance and to require cementitious material shipments to be individually tested prior to
incorporation into Department work. QC Plans may be suspended when the performance of
cementitious material is in question, including problems with concrete quality, inconsistent QC
data, or failure of QC or verification test results.
Repulpable bags may be accepted by the Engineer, provided a successful
demonstration by the producer has indicated complete degradation of the repulpable bags during
the mixing operation and before the mix is discharged.
929-1.2 Approved Laboratory: The cementitious materials suppliers testing laboratory
must maintain Cement and Concrete Reference Laboratory (CCRL) accreditation, be currently
inspected by the CCRL, be actively participating in the CCRL proficiency program and have all
deficiencies noted at the time of inspection corrected. The laboratory must authorize the CCRL
to send a copy of the final inspection report to the State Materials Office.
929-2 Fly Ash.
929-2.1 General: Sampling and testing of fly ash shall follow the requirements of
ASTM C311. Fly ash shall not include the residue resulting from the burning of municipal
garbage or any other refuse with coal, or the burning of industrial or municipal garbage in
incinerators.
929-2.2 Fly Ash (Class F): Fly ash derived from the combustion of ground or powdered
coal shall meet the requirements of ASTM C618 Class F fly ash.
929-2.2.1 Petroleum Coke Class F: Fly ash resulting from the combustion of
coal and petroleum coke shall meet the physical and chemical requirements of ASTM C618
Class F fly ash. When petroleum coke Class F fly ash is used in concrete, the test results shall
verify improved or comparable strength, sulfate resistance, corrosion protective properties and
other durability requirements of concrete, as compared to ASTM C618 Class F fly ash concrete.
The strength and durability tests of concrete shall be performed in accordance with ASTM C39,
ASTM C157, ASTM C1012, ASTM C1202, ASTM G109, FM 5-516 and FM 5-522.
929-2.2.2 Bark Ash Class F: Fly ash resulting from the combustion of timber
bark ash and coal shall meet the physical and chemical requirements of ASTM C618 Class F fly
ash. When bark ash is used in concrete, the strength and durability of the bark ash concrete shall
1015
be improved or comparable to the strength and the durability properties of ASTM C618 Class F
fly ash concrete. The tests shall be performed as specified in 929-2.2.1.
929-2.3 Fly Ash (Class C): Fly ash derived from the combustion of ground or powdered
coal shall meet the requirements of ASTM C618 Class C fly ash. When Class C fly ash is used in
concrete, the test results shall verify improved sulfate resistance and improved or comparable
corrosion protective properties, as compared to ASTM C618 Class F fly ash concrete. The
durability tests of concrete shall be performed in accordance with FM 3-C-1012.
929-2.4 Exceptions: Fly ash shall not be used in conjunction with Type IP or Type IS
cements.
929-2.5 Acceptance Testing of Fly Ash: Acceptance of fly ash from sources operating
under an approved QC Plan shall be based on the monthly certified test report meeting the
chemical and physical requirements of ASTM C618. When the loss on ignition exceeds 5%, the
Supplementary Optional Physical Requirements shall be mandatory except that the Effectiveness
in Controlling Alkali-Silica Reaction will not be required. An approved laboratory shall perform
the monthly QC tests and a copy of their certified test reports shall be sent to the State Materials
Office when the material is in use on Department projects. The certification shall indicate that
the fly ash meets the requirements of this Specification. Also, the corresponding samples along
with certified test reports shall be submitted to the Department, upon request.
929-3 Silica Fume.
929-3.1 General: Silica Fume shall meet the requirements of ASTM C1240 using the
referenced test methods and frequencies.
929-3.2 Acceptance Testing of Silica Fume: Acceptance of silica fume from sources
operating under an approved QC Plan shall be based on certification that the material meets the
requirements of ASTM C1240 and this Specification.
929-4 Metakaolin.
929-4.1General: Metakaolin shall meet the requirements of ASTM C618 Class N with
the following modifications:
1. The sum of SiO2 + Al2O3 + Fe2O3 shall be at least 85%. The material safety
data sheet (MSDS) shall indicate that the amount of crystalline silica, as measured by National
Institute of Occupation Safety and Health (NIOSH) 7500 method, after removal of the mica
interference, is less than 1.0%.
2. The loss on ignition shall be less than 3.0%.
3. The available alkalies, as equivalent Na2O, shall not exceed 1.0%.
4. The amount of material retained on a No. 325 mesh sieve shall not exceed
1.0%.
5. The strength activity Index, at 7 days, shall be at least 85%.
6. When metakaolin is used in concrete, the test results shall verify improved or
comparable strength, sulfate resistance, corrosion protective properties and other durability
performance properties of concrete, as compared to the performance of silica fume concrete. The
comparison strength and durability tests shall be performed in accordance with ASTM C39,
ASTM C157, ASTM C1012, ASTM C1202, ASTM G109, FM 5-516 and FM 5-522, by an
approved independent testing laboratory. Sampling and testing of metakaolin shall follow the
requirements of ASTM C311.
1016
929-4.2 Acceptance Testing of Metakaolin: Acceptance of metakaolin from sources
operating under an approved QC Plan shall be based on the monthly certified test report meeting
the chemical and physical requirements of ASTM C618 Class N, as modified herein. An
approved laboratory shall perform the monthly QC tests and a copy of their certified test reports
shall be sent to the State Materials Office, when the material is in use on Department projects.
Also, the corresponding samples along with certified test reports shall be submitted to the
Department, upon request. The certification shall indicate that the metakaolin meets the
requirements of this Specification.
929-5 Slag.
929-5.1 General: Slag shall meet the requirements of ASTM C989. Sampling and testing
procedures shall follow the requirements of ASTM C989.
929-5.2 Special Requirements: Only ground granulated blast-furnace slag Grade 100
and 120 will be permitted.
929-5.3 Exceptions: Slag shall not be used in conjunction with Type IP or Type IS
cements.
929-5.4 Acceptance Testing: Acceptance of slag from sources operating under an
approved QC Plan shall be based on the monthly certified QC tests meeting the chemical and
physical requirements of ASTM C989. An approved laboratory shall perform the monthly QC
tests and a copy of their mill certificates shall be sent to the State Materials Office when the
material is in use on Department projects. Reference cement used for determination of slag
activity shall meet the requirements of ASTM C989. The certification shall indicate that the slag
meets the requirements of this Specification. Also, the corresponding samples along with mill
certificates shall be submitted to the Department, upon request.
929-6 Ultra Fine Fly Ash.
929-6.1 General: Sampling and testing of the ultra fine fly ash shall follow the
requirements of ASTM C311. Ultra fine fly ash derived from the combustion of ground or
powdered coal shall meet the requirements of ASTM C618 as a Class F fly ash with the
following modifications:
1. The pozzolanic activity index, at 7 days, shall be at least 85% of the control
and the pozzolanic activity index, at 28 days, shall be at least 95% of the control.
2. Particles less than 3.25 microns shall be at least 50% of the particle size
distribution, as measured by laser particle size analyzer. Particles less than 8.50 microns shall be
at least 90% of the particle size distribution, as measured by laser particle size analyzer.
3. The amount of material retained when wet-sieved on a 45-m sieve shall be
less than 6.0%.
4. The moisture content shall be less than 1.0%.
5. The loss on ignition shall be less than 2.0%.
929-6.2 Exceptions: Ultra fine fly ash shall not be used in conjunction with Type IP or
Type IS cements.
929-6.3 Acceptance Testing of Ultra Fine Fly Ash: Acceptance of fly ash from sources
operating under an approved QC Plan shall be based on the monthly certified test report meeting
the chemical and physical requirements of ASTM C618. When the loss on ignition exceeds
2.0%, the Uniformity Requirements in the Supplementary Optional Physical Requirements shall
be mandatory. An approved laboratory shall perform the monthly QC tests and a copy of their
1017
certified test reports shall be sent to the State Materials Office when the material is in use on
Department projects. The certification shall indicate that the fly ash meets the requirements of
this Specification. Also, the corresponding samples along with certified test reports shall be
submitted to the Department, upon request.
1018
SECTION 930
MATERIALS FOR CONCRETE REPAIR
930-1 Description.
This Section covers cementitious materials used to repair concrete including defects or
purposely placed openings in concrete elements. Materials containing organic compounds, such
as bitumens and epoxy resin as the principal binder are not included. The requirements for epoxy
resin materials are covered in Section 926. Any depth larger than the manufacturers
recommendation for the specific material shall be repaired with portland cement concrete
meeting the requirements of Section 346.
930-2 Product Acceptance on the Project.
930-2.1 Product Acceptance: Use only products listed on the Departments Qualified
Products List (QPL). Manufacturers seeking evaluation of products must submit an application
in accordance with Section 6 and include independently certified test reports that the material
meets the requirements of this Section. The application package must describe detailed quality
control requirements for installation including, but not limited to: maximum water to
cementitious material ratio, formulation for two or more component systems, special materials
and/or equipment, recommendations for all surface preparation, and curing requirements.
Provide the Engineer certification conforming to the requirements of Section 6
from the manufacturer confirming that the materials used meets the requirements of this Section
and is the appropriate product for the intended use.
When specified in the Contract Documents, furnish a report of test results from an
independent laboratory on samples taken from material shipped. Ensure the test was performed
within 45 days prior to the shipping date of the material.
930-2.2 Material Supply, Storage, and Marking: The material shall be preproportioned including aggregate. Deliver products in original, unopened containers with
manufacturers name, date of manufacture, and clearly marked with all information described
below. Store the material in an elevated dry and weather protected enclosure in full compliance
with the manufacturers recommendations. Material must be used within manufacturers
recommended shelf life.
The material from which the containers are made shall have water vapor
transmission not greater than 100 g/m2 in 24 hours as determined in accordance with
Procedure B of ASTM E96.
All containers shall be marked with the following information:
(a) LOT identification number and material expiration date
(b) Directions for use shall include but are not limited to the following:
(1) The type and kind of adhesive recommended (if any) to bond fresh
repair material to the concrete or mortar being repaired.
(2) The recommended amount of resin, other liquid component, or both, to
be mixed with the package contents.
(3) The recommended length of mixing time or sequence of mixing and
resting times in minutes.
(c) Date the material was packaged.
(d) The yield in cubic feet or yield in ft2/in thickness when mixed with the
recommended amount of liquid.
(e) The net weight in each container. The contents of any container shall not vary
by more than 2% from the weight stated in the declarations. The average weight of filled
containers in a LOT shall be not less than the individual weight stated in the declarations.
1019
(f) Instructions for the maximum and minimum water (or solutions) to
cementitious material ratio.
(g) State the approximate working time.
930-2.3 Sampling, Mixing, and Additional Testing: A LOT is the packaged repair
material normally placed on a pallet. A unit sample is a single container or package of material
randomly selected from the LOT. Mix and install the materials in accordance with the
manufacturers recommendations. Manufacturers will be required to provide field representation
upon request by the Engineer. The Department reserves the right to conduct further field testing
on any approved material.
930-2.4 Rejection: All broken containers will be rejected. Material that fails to meet any
of the requirements of this Specification will be rejected. Report all materials failing to meet this
specification and state the reasons for rejection in writing to the Engineer and the producer or
supplier. Material in local storage in the hands of a vendor for more than six months after testing
will be retested before use, except for the scaling resistance test and length change immersed in
sulfate solution test for magnesium ammonium phosphate concrete. Retested material will be
rejected if it fails to conform to any of the requirements of this Specification.
930-3 Laboratory Specimen Preparation:
930-3.1 Mixing and Fabrication: Mechanically mix the dry packaged materials with
liquid components in accordance with the manufacturers recommendations.
930-3.2 Length Change: Make and cure the test specimens in accordance with
ASTM C157, except omit the curing period in Section 10.3; however both 11.1.1 and 11.1.2
shall apply for 28 day curing period.
930-3.3 Manifestly Faulty Specimens: Visually examine each group of specimens
representing a given test or a given age of test, including tests of freshly mixed concrete, before
or during the test, or both, whichever is appropriate. Discard any specimen found to be
manifestly faulty by such examination without testing. Visually examine all specimens
representing a given test at a given age after testing, and should any specimen be found to be
manifestly faulty the test results thereof shall be disregarded. Should more than one specimen
representing a given test at a given age be found manifestly faulty either before or after testing,
the entire test shall be disregarded and repeated. The test result reported shall be the average of
the individual test results of the specimens tested or, in the event that one specimen or one result
has been discarded, it shall be the average of the test results of the remaining specimens.
930-4 Materials for Repair of Predominately Horizontal Surfaces.
930-4.1 General: This material is intended to be used to repair concrete where the area to
be treated will be on a horizontal surface. Examples of the type of locations for these materials
are bridge decks, portland cement concrete pavements and other locations required by the
Contract Documents. Follow the manufacturers recommendations for preparing the surfaces,
mixing, placing, and curing the repair material unless otherwise directed in the Contract
Documents.
930-4.2 Classification: The materials to be considered under this classification shall
meet the following requirements:
930-4.2.1 Rapid Hardening: Moderate compressive strength for repairing
concrete with an in-place compressive strength less than or equal to 4,000 psi.
930-4.2.2 Very Rapid Hardening: High compressive strength for repairing
concrete with an in-place compressive strength greater than 4,000 psi. This material may be used
in lieu of Rapid Hardening materials.
1020
930-4.3 Physical Properties: The repair material shall meet or exceed the physical
properties stated in Table 1 as determined by the specified test methods.
Table 1 - Physical Properties of Repair Materials for Horizontal Surfaces
Very Rapid
Requirement
Test Method
Rapid Hardening
Hardening
Minimum Compressive Strength, psi
3 hours
24 hours
7 days
ASTM C39* or
ASTM C109*
N/A
2,000
2,000
4,000
4,000
6,000
Greater than or equal to strength at 7
days.
28 days
Maximum Length Change, %
Allowable expansion at 28 days
when water cured compared to
length at one day
Allowable shrinkage at 28 days
ASTM C157**
when air cured compared to length
at one day
Allowable difference between
increase in water and decrease in air
Minimum Slump (Concrete), inches ASTM C143***
Minimum Flow (Mortar), %
ASTM C1437***
0.12
0.12
-0.12
-0.12
0.20
0.20
3
100
3
80
Time of Setting (Initial), minutes
ASTM C191* or
ASTM C403*
Minimum 30
10 to 29
Coefficient of Thermal Expansion,
in/in/F
ASTM C531* or
AASHTO T336
5.0 x 10-6 to 9.0 x
10-6
5.0 x 10-6 to
9.0 x 10-6
Minimum Bond Strength by Slant Shear, psi
24 hours
400
450
FM 5-587
Greater than or equal to strength at
7 days
24 hours.
Maximum Allowable Total
FM 5-516
0.40
Chlorides lbs/yd3
* as applicable
** Make and cure the test specimens in accordance with ASTM C-157, except omit the curing period in
Section 10.3; however both 11.1.1 and 11.1.2 shall apply for 28 day curing period.
*** Testing for flow/slump will be completed in 5 plus or minus 1/2 minutes after the start of mixing liquid with the
Rapid Hardening materials or 15 plus or minus 1/2 minutes after mixing the liquid with the Very Rapid Hardening
materials.
930-4.4 Specimen Preparation:
930-4.4.1 Flow/Slump: Testing for flow/slump will be completed in 5 minutes,
plus or minus 1/2 minutes, after the start of mixing liquid with the Rapid Hardening materials or
15 minutes, plus or minus 1/2 minutes, after mixing the liquid with the very rapid hardening
materials.
1021
930-5 Materials for Repair of Predominately Vertical Surfaces.
930-5.1 General: This material is intended to be used to repair concrete where the area
exposed in the field to be treated will be on a vertical surface. If an element has both horizontal
and vertical surfaces, then the repair used will be for vertical surfaces. If it is not apparent which
material is to be used, the vertical application will prevail. Examples of the type of locations for
these materials are columns, caps, beams, piles, incidental concrete products, drainage structures
and other locations required by the Contract Documents. Follow the manufacturers
recommendations for preparing the surfaces and for mixing, placing and curing the repair
material.
930-5.2 Classification: The materials to be considered under this classification shall
meet the following requirements:
930-5.2.1 High Performance: Moderate compressive strength for repairing
concrete with a designed compressive strength greater than or equal to 5,000 psi.
930-5.2.2 Ultra-high Performance: High compressive strength for repairing
concrete with a designed compressive strength greater than 5,000 psi. These materials may be
used in lieu of high performance vertical materials.
930-5.3 Physical Properties: The repair material shall meet or exceed the physical
properties stated in Table 2 as determined by the specified test methods.
Table 2 - Physical Properties of Repair Materials for Vertical Surfaces*
High
Ultra-high
Requirement
Test Method
Performance
Performance
Minimum Compressive Strength, psi
24 hours
1,000
2,000
7 days
N/A
5,000
ASTM C39** or
Greater than or
ASTM C109**
28 days
5,000
equal to strength at
7 days
Maximum Length Change, %
Allowable expansion at 28 days
when water cured compared to
0.12
0.12
length at one day
ASTM C157**
Allowable shrinkage at 28 days when
air cured compared to length at one
-0.08
-0.08
day
Maximum Slump (Concrete), inches
ASTM C143
3****
3****
Maximum Flow (Mortar), %
ASTM C1437
100****
100****
Time of Setting (Initial), minutes
ASTM C191** or
ASTM C403**
10 to 180****
10 to 180****
Coefficient of Thermal Expansion, ASTM C531*** or
5.0 x 10-6 to 9.0 x 10-6
in/in/F
AASHTO T336***
Minimum Bond Strength by Slant Shear, psi,
24 hours
450
750
FM 5-587
7 days
750.
750
Minimum Flexural Strength (at
ASTM C580
1022
500
700
7 days), psi
Maximum Absorption (Mortar at
7 days), %
Minimum Surface Resistivity
(Concrete at 28 days), KOhm-cm
Maximum Allowable Total
Chlorides lbs/yd3
ASTM C413
FM 5-578
N/A
22
FM 5-516
0.40
* Use cement based materials modified with polymers and silica fume for extremely aggressive environments
** Make and cure the test specimens in accordance with ASTM C157, except omit the curing period in Section 10.3;
however both 11.1.1 and 11.1.2 shall apply for 28 day curing period.
*** As applicable
**** For pump and pour applications, the maximum flow, slump and time of setting can be adjusted according to
the manufacturers recommendation.
930-6 Material for Repair of Concrete in High Stress Concentration Areas.
930-6.1 General: This material is intended to be used to repair block-outs and voids in
post-tensioned elements, load bearing area of a beam, and other locations required by the
Contract Documents. This material may be used for the repair of horizontal or vertical surfaces.
Follow the manufacturers recommendations for preparing the surfaces and for mixing, placing
and curing the concrete. This material shall be a magnesium ammonium phosphate based
concrete (MAPC).
930-6.2 Physical Properties: The MAPC material shall meet or exceed physical
properties stated in Table 3 as determined by the specified standard test methods.
Table 3 - Physical Properties of Repair Material in High Stress Areas
Requirement
Test Method
Test Value
Minimum Compressive Strength (at 28 days),
ASTM C109*
8,500
psi
Minimum Flexural Strength (at 28 days), psi
Minimum Slant Shear Bond (at 14 days), psi
ASTM C348*
600
FM 5-587*
2,500
Time of Setting (Initial), minutes
ASTM C191**
Maximum Scaling Resistance
ASTM C672
Maximum Length Change, %
Allowable expansion at 28 days when water
cured compared to length at one day
ASTM C157***
Allowable shrinkage at 28 days when air
cured compared to length at one day
Maximum Allowable Total Chlorides lbs/yd3
FM 5-516
15 to 60
No scaling
0.03
-0.03
0.40
* The test methods for compressive strength (ASTM C109), flexural strength (ASTM C348), and Slant Shear
Bond (FM 5-587) shall be modified so that the specimens are air cured instead of moist cured. All of these
samples shall be air cured until the time of testing..
** Initial time of set for MAPC will be tested in accordance with ASTM C191 with the following modification.
The initial time of set shall be tested at 95 plus or minus 5F.
*** Make and cure the test specimens in accordance with ASTM C-157, except omit the curing period in
Section 10.3; however both 11.1.1 and 11.1.2 shall apply for 28 day curing period.
1023
930-6.3 Specimen Requirements:
930-6.3.1 Curing of Compressive Strength, Flexural Strength and Slant
Shear Bond Specimens: The test methods for compressive strength (ASTM C109), flexural
strength (ASTM C348), and Slant Shear Bond (FM 5-587) shall be modified so that the
specimens are air cured instead of moist cured. All of these samples shall be air cured until the
time of testing.
930-6.3.2 Time of Setting: Initial time of set for MAPC will be tested in
accordance with ASTM C191 with the following modification. The initial time of set shall be
tested at 95F, plus or minus 5F.
930-7 Special Fillers.
930-7.1 General: This material is intended to be used as filler material and for rapid
repairs to pile jacket structures and other locations specified in the Plans when no design mix
concrete is available or a special filler is specified in the Contract Documents. Meet the
requirements of Section 457 for preparing the surfaces, placing, testing and curing the concrete.
Mix the material in accordance with the manufacturers recommendations.
930-7.2 Classification: The materials to be considered under this classification shall
meet the following requirements:
930-7.2.1 Cathodic Protection (CP) Filler: Provide cementitious based materials
with a minimum cement content of 900 pounds of cement per cubic yard of mix. Material
formulation must not contain fly ash, slag, silica fume or other mineral admixtures which may
produce increased electrical resistance. The material shall not contain any substances corrosive
to metals.
930-7.2.2 Non-Cathodic Protection (Non-CP) Filler: Provide cementitious
based materials with a minimum cement content of 650 pounds of cement per cubic yard of mix.
The material shall not contain any substances corrosive to metals.
930-7.2.3 Extended Materials: Where concrete filler materials are specified,
approved mortar materials may be extended using size number 89 gradation aggregates from a
certified FDOT approved source.
930-7.3 Physical Properties: The repair material shall meet or exceed the physical
properties stated in Table 4 as determined by the specified standard test methods. If extended,
materials shall meet the minimum requirements of Table 4.
Table 4 - Physical Properties of Special Fillers
Requirement
Test Method
Cathodic
Protection
NonCathodic
Protection
1,500
2,000
5,000
5,000
0.12
0.12
Minimum Compressive Strength, psi
24 hours
ASTM C39* or
ASTM C109*
28 days
Maximum Length Change, %
Allowable expansion at 28 days when water cured
ASTM C157**
compared to length at one day
1024
Allowable shrinkage at 28 days when air cured
compared to length at one day
-0.12
-0.12
Allowable difference between increase in water and
decrease in air
0.20
0.20
Slump (Concrete), inches
ASTM C143
7-9
7-9
Minimum Flow (Mortar), %
ASTM C1437
100
100
ASTM C191*
or
200 to 400 200 to 400
ASTM C403*
Time of Setting (Initial), minutes
Minimum Bond Strength by Slant Shear (at 7 days),
psi
FM 5-587
450
450
Minimum Flexural Strength (at 7 days), psi
ASTM C580
700
700
Minimum Tensile Strength (at 7 days), psi
ASTM C307
200
200
Surface Resistivity (at 28 days), KOhm-cm
Maximum Allowable Total Chlorides lbs/yd3
FM 5-578
FM 5-516
15 or less 22 or greater
0.40
* as applicable
** Make and cure the test specimens in accordance with ASTM C157, except omit the curing period in Section 10.3;
however both 11.1.1 and 11.1.2 shall apply for 28 day curing period.
930-7.4 Constructability: Furnish to the Engineer for approval shop drawing as may be
required to complete repairs in compliance with the design shown in the Plans and the
manufacturers recommended repair system.
1025
ACCESSORY MATERIALS FOR
CONCRETE PAVEMENT AND CONCRETE STRUCTURES
SECTION 931
METAL ACCESSORY MATERIALS FOR CONCRETE
PAVEMENT AND CONCRETE STRUCTURES
931-1 Reinforcement Steel (for Pavement and Structures).
931-1.1 Steel Bars: Unless otherwise shown in the Plans, billet steel bars for concrete
reinforcement shall conform to the requirements of ASTM A615 Grade 60 except that the
process of manufacture will not be restricted. For processes not included in ASTM A615 the
phosphorus content will be limited to 0.08%.
The following special requirements shall apply:
(1) Unless otherwise specified or shown in the Plans all reinforcement
bars No. 3 and larger shall be deformed bars.
(2) All billet-steel bars shall be of the grade called for in the Plans.
(3) Twisted bars shall not be used.
(4) Wherever in the Specifications the word purchaser appears it shall
be taken to mean the Department.
Acceptance of reinforcing steel shall be based on samples taken by the
Department and manufacturers certified mill analysis certifying that the test results meet the
specification limits of the ASTM or AASHTO designation for the particular size, grade and any
additional requirements. The manufacturers certified mill analysis for each heat, size, and grade
per shipment of reinforcing steel shall be provided to the Engineer prior to use.
The Engineer will select samples representing each LOT of reinforcing steel. A sample is
defined as the reinforcing steel and a copy of the certified mill analysis corresponding to the
sample. A LOT is defined as the weight of all bars, regardless of size, grade or pay item in
consecutive shipments of 80 tons or less. Samples shall be cut from bundled steel that is shipped
to the jobsite.
931-1.2 Welded Wire Reinforcing Steel:
931-1.2.1 Plain Welded Wire Reinforcing Steel: Unless otherwise shown in the
Plans, plain welded wire reinforcing steel shall meet the requirements of AASHTO M55 or
ASTM A1064.
Acceptance of plain welded wire reinforcement shall be based on the
manufacturers certified mill analysis certifying that the test results meet the specification limits
of the ASTM or AASHTO designation for the particular sizes and any additional requirements.
Prior to use, submit to the Engineer the manufacturers certified mill analysis for each heat and
size per shipment.
931-1.2.2 Deformed Welded Wire Reinforcing Steel: Unless otherwise shown
in the Plans, deformed welded wire reinforcement shall meet the requirements of
AASHTO M221 or ASTM A1064.
Acceptance of deformed welded wire reinforcement shall be based on the
manufacturers certified mill analysis certifying that the test results meet the specification limits
of the ASTM or AASHTO designation for the particular sizes and any additional requirements.
1026
Prior to use, submit to the Engineer the manufacturers certified mill analysis for each heat and
size per shipment.
931-2 Metal Materials for Joints in Concrete Pavement.
931-2.1 Sheet Metal Bottom Strips: The sheet metal strip for protecting the bottom and
side edges of transverse expansion joints shall be composed of galvanized sheet metal of
0.0157 inches minimum thickness and shall conform to the requirements of ASTM A653.
The sheets shall be furnished in accordance with the dimensions shown in the Plans. They may
be in one continuous piece, or spliced. When splicing is used the metal shall be lapped not less
than 3 inches and securely fastened, by welding or otherwise, in such manner as to leave the
spelter undamaged and produce a smooth sliding surface in contact with the pavement slab. The
splices shall be spaced not less than 10 feet apart and not less than 5 feet from either end. The
complete sheet shall not vary from a straight line by more than 1 inch from end to end.
The Contractor shall provide the Engineer a certified mill analysis from the
manufacturer of the sheet metal bottom strips including test results for thickness, dimension,
grade, length, size, and spacing. Each certified mill analysis shall cover only one type of metal
material for joints.
931-2.2 Bars and Chairs for Longitudinal Joints: Transverse reinforcing steel across
the joint shall be deformed steel bars conforming to the requirements of 931-1.1 except that the
bars may be any grade shown in ASTM A615.
These bars, and the chairs to hold them in place, shall be of the type and spacing
as indicated in the Plans.
931-2.3 Dowel Bars: Dowel bars shall be plain steel bars conforming to the requirements
of ASTM A615 for any grade of steel shown. They shall be of the length, size and spacing as
shown in the Plans.
The Contractor shall provide the Engineer a certified test report from the
manufacturer of the dowel bars confirming that the requirements of this Section are met. The
certified test report shall conform to the requirements of Section 6 and include metallurgical mill
analysis, grade, length and size. Each certification shall cover only one LOT for dowel bars.
931-2.4 Chairs and Metal Expansion Caps: The chairs and metal expansion caps shall
be of an approved type as shown in the Plans.
Dowel bars for expansion joints shall have a metal cap on one end so placed to
provide ample space for movement of the slab. Continuous sleeves covering one half of the
length of the bar will not be permitted. Other fasteners may be approved. Dowel bars shall be
coated with an approved material to break the bond.
931-3 Metal Dowel Bar Assemblies for Joints in Concrete Pavement.
931-3.1 Qualified Products List (QPL): The dowel bar assembly used shall be a
product included on the Departments Qualified Products List (QPL).
Manufacturers or distributors seeking approval of their material in accordance
with this specification shall demonstrate the performance of their products in accordance with
the requirements in 931-3.2 thru 931-3.6.
931-3.2 Rigidity: The dowel bars shall be supported by an approved welded assembly
possessing sufficient rigidity to hold the dowel bars in position to such accuracy that error or
deviation from its required position in any bar in the entire installation after the pavement has
been finished shall be no greater than 1/2 inch.
1027
The assembly shall have continuous parallel spacer bars and two continuous
parallel bearing members of no less than 1/4 inch diameter wire. One spacer bar shall be located
at or near each end of the dowel. Alternate ends of dowels shall be welded to a spacer bar in such
a manner as to maintain the dowels parallel to each other and permit sliding movement in the
joint.
The free ends of each dowel shall be retained securely in place by means of wire
loops or metal tubes welded to the other spacer bar. An expansion cap shall be installed on one
end of each bar if the dowels are being used in an expansion joint.
Suitable struts or ties shall be provided to hold the assembly in correct position
during installation.
The assembly shall have an upright support welded to the spacer bar and
continuous bearing member at the end of each dowel and a continuous bearing member.
If the upright support consists of a single vertical wire, the support shall be no less
than 5/16 inch diameter wire. Otherwise, the support shall be no less than 1/4 inches in diameter.
931-3.3 Sand Plates: Sand plates, if required, shall be made from no less than 3/8 inch
sheet steel. Each plate shall have no less than 0.1 square feet of bearing area. The plates shall be
furnished in sufficient number to provide uniform support for the complete assembly. They may
be furnished separate from the assembly units or attached thereto by welding, suitable clips, or
other approved means.
931-3.4 Welds: The welds of the assembly shall be made securely. A broken weld will
be cause for rejection of the length of section of the assembly where it occurs.
931-3.5 Assembly Placement: When the dowel bar assembly is in place, it shall act as a
rigid unit with each component part securely held in position relative to the other member of the
assembly.
The entire assembly shall be held securely in place during placing, consolidating,
and finishing the concrete by means of metal pins. Pins used on granular subbase or cold mixed
bituminous stabilized subbase shall penetrate at least 12 inches below the dowel bar assembly.
The pins shall be of no less than 1/4 inch diameter wire and shall be provided with a hook or arm
welded to the pin in such a manner that it shall secure the assembly in place.
Nail securing systems may be used as an anchoring device on hot bituminous
stabilized subbase. The nail shall be no less than 1/8 inch in diameter, no less than 2 inches in
length and the nail head or attached washer shall be not less than 1/2 inch outside diameter. The
nail shall be driven through both ends of a metal strap after it has been placed around one of the
lower transverse bars on the dowel bar assembly.
At least eight pins or nails shall be used for each 12 foot section (a lane width) of
assembly. Sand plates, if required, shall be drilled to receive the pins.
The Contractor shall provide the equipment and personnel necessary to verify
dowel bar location after the concrete is placed and has received the initial screeding.
931-3.6 Materials: The wire for the welded assembly shall be in accordance with all
applicable requirements of ASTM A82.
Apply one coat of alkyd primer meeting the material requirements of SSPC
Paint 25. Apply the primer in accordance with the manufacturers recommendations.
1028
SECTION 932
NONMETALLIC ACCESSORY MATERIALS
FOR CONCRETE PAVEMENT AND CONCRETE STRUCTURES
932-1 Joint Materials.
932-1.1 Preformed Joint Filler for Pavement and Structures: Preformed joint
filler shall meet the requirements of AASHTO M153 or AASHTO M213, or cellulose
fiber types meeting all the requirements of AASHTO M213 (except for the asphalt
content) is acceptable provided they contain minimums of 0.2% zinc borate as a
preservative and 1.5% waterproofing wax. For AASHTO M153, unless a particular type
is specified, either Type I, Type II or Type III may be used.
Preformed joint fillers shall have a thickness equal to the width of the joint
required, and shall be furnished in lengths equal to the widths of the slabs in which they
are to be installed, except that strips which are of a length not less than the distance
between longitudinal joints, or between longitudinal joint and edge, may be used if laced
or clipped together in a manner approved by the Engineer. The depth and shape of the
joint filler shall conform to the dimensions shown in the Plans. For doweled joints, proper
provision shall be made for the installation of the dowels.
932-1.1.1 Certification: The Contractor shall provide the Engineer a
certification conforming to the requirements of Section 6 from the manufacturer,
confirming that the preformed joint filler meets the requirements of this Section.
932-1.2 Joint Sealer for Pavement and Structures:
932-1.2.1 General: This Specification covers joint sealer intended for use
in sealing joints in asphaltic concrete pavement and portland cement concrete pavement.
These materials may also be used to seal joints in portland cement concrete bridges and
other structures.
932-1.2.2 Material: The joint sealant shall be composed of a mixture of
materials, typically but not limited to bituminous based, that will melt when heated for
application and then solidify to form a resilient and adhesive compound capable of
sealing joints in portland cement concrete and/or asphaltic concrete against the
infiltration of moisture and foreign materials throughout normal pavement conditions and
at ambient temperatures. The manufacturer shall have the option of formulating the
material according to their Specifications. However, the requirements delineated in this
Specification shall apply regardless of the type of formulation used. The material shall
cure sufficiently to not flow from the joint or be picked up by vehicle tires after 3 hours at
77F. The material shall be capable of a uniform application consistency suitable for
filling joints without the inclusion of large air holes or discontinuities and without
damage to the material.
Materials for pavement joints shall be tested according to
ASTM D5329.
932-1.2.2.1 Physical Requirements of Joint Sealants for
Portland Cement Concrete Only:
Parameter
Pour Point
Limits
At least 20F lower than the safe heating temperature as
stated by the manufacturer.
1029
Cone-Penetration, NonLess than or equal to 90 mm
immersed at 77F, 150 g, 5 s
Flow at 140F, 5 h
Less than or equal to 5.0 mm
Bond, Non-immersed, 0F No cracking, separation, or opening that at any point is over
for 5 cycles*
1/4 inch deep, in the sealant or between the sealant and the
substrate.
*The depth of a crack, separation or opening shall be measured perpendicular to the side of the sealant showing the
defect. At least two test samples in a group of three representing a given sample of sealant shall meet this requirement.
932-1.2.2.2 Physical Requirements of Joint Sealants for
Portland Cement Concrete and/or Asphaltic Concrete:
Parameters
Pour Point
Limits
At least 20 lower than the safe heating temperature as stated
by the manufacturer.
Cone-Penetration, Nonimmersed at 77F, 150 g,
Less than or equal to 90 mm
5s
Flow at 140F, 5 h
Less than or equal to 3.0 mm
Bond, Non-immersed, - No cracking, separation, or opening that at any point is over
20F for 3 cycles, 50%
1/4 inch deep, in the sealant or between the sealant and the
extension*
substrate.
Resilience at 77F
Recovery greater than or equal to 60%
No failure in adhesion, formation of an oily exudates at the
Asphaltic Concrete
interface between the sealant and the asphaltic concrete, or
Compatibility at 140F softening or other deleterious effects on the asphaltic concrete
or sealant.
*The depth of a crack, separation or opening shall be measured perpendicular to the side of the sealant showing the
defect. At least two test samples in a group of three representing a given sample of sealant shall meet this requirement.
932-1.2.3 Qualified Products List (QPL): The joint sealant materials
used shall be one of the products listed on the Departments Qualified Products List
(QPL). Manufacturers seeking evaluation of their products shall submit product
datasheets, performance test reports from an independent laboratory showing the product
meets the requirements of this section, and a QPL application in accordance with
Section 6. Information on the QPL application must identify the sealant type.
932-1.2.4 Shipment: The material shall be delivered in containers plainly
marked with the manufacturers name or trademark product name, LOT number and date
of expiration.
932-1.2.5 Bond Breaker Rod: The bond breaker rod shall be a closed
cell, expanded polyethylene foam rod of the size and dimensions shown in the Plans. It
shall be compatible with the joint sealant and no bond or reaction shall occur between the
rod and the sealant.
All bond breaker rods installed shall be covered by a sealant at the
end of each work day.
Bond breaker tape approved by the sealant manufacturer may be
used in lieu of bond breaker rod when sealing random cracks.
1030
932-1.3 Low Modulus Silicone Sealant Materials:
932-1.3.1 Low Modulus Silicone Sealants: Silicone sealant shall be
furnished in a one part or pre-measured two part formulation meeting the requirements
specified herein.
Acetic acid cure sealants are not acceptable. A primer as specified
in 932-1.4 for bonding sealant to concrete shall be used if required by the manufacturer.
When a manufacturers product is tested and approved by the Department using a primer,
primer will be required for project installation.
Do not use Low Modulus Silicone Sealants Types A, B or C for
bridge expansion joints.
Silicones shall be identified in the following manner:
Type A - A low modulus, non-sag (non-self-leveling)
silicone formulation, used in sealing horizontal and vertical joints in cement concrete
pavements and bridges (i.e., concrete-concrete joints). Tooling is required.
Type B - A very low modulus, self-leveling silicone
formulation, used in sealing horizontal joints (including joints on moderate slopes) in
cement concrete pavements and bridges (i.e., concrete-concrete joints). Tooling is not
normally required.
Type C - An ultra-low modulus, self-leveling silicone
formulation, used in sealing horizontal joints (including joints on moderate slopes) in
cement concrete pavements and bridges (i.e., concrete-concrete joints). It can also be
used to seal the joints between cement concrete pavements and asphalt concrete shoulders
(including asphalt-asphalt joints). Tooling is not normally required.
Type D - An ultra-low modulus, self-leveling silicone
formulation, cold-applied, rapid-cure, used to seal expansion joints that experience both
thermal and/or vertical movements. The material must cure by chemical reaction and not
by evaporation of solvent or fluxing of harder particles. Tooling shall not be required.
Use according to Design Standards, Index No. 21110.
932-1.3.2 Physical Requirements:
Silicone
Sealant
Type
Flow
Slump
(maximum)
Extrusion
rate
(minimum)
Tack-free
time at 77
3F and
45 to 55%
Relative
Humidity
Specific
Test Method
Type A
ASTM D5893
No Flow
ASTM D2202
0.3 inches
ASTM C1183,
Procedure A
20 ml/min
Type B
Type C
Type D
20 ml/min
20 ml/min
20 ml/min
ASTM C679
90 minutes 180 minutes, 60 minutes,
maximum
maximum
maximum
ASTM D792,
1.1 to 1.515 1.10 to 1.40 1.26 to 1.34 1.26 to 1.34
1031
30 60
minutes
Silicone
Sealant
Test Method
Type A
Type B
Type C
Type D
Type
gravity
Method A
Durometer
hardness,
Shore A
(Cured
seven days
ASTM D2240
10-25
at 77 3F
and 50
5%
Relative
Humidity)
Durometer
hardness,
Shore 00
(Cured 21
days at 77
ASTM D2240
40-80
20-80
3F and
50 5%
Relative
Humidity)
Tensile
stress
(maximum) ASTM D412 (Die C)
45 psi
40 psi
15 psi
at 150%
elongation
Elongation
(Cured
seven days
at 77 3F
800%
600%
ASTM D412 (Die C)
and 50
minimum
minimum
5%
Relative
Humidity)
Elongation
(Cured 21
days at 77
800%
1400%
3F and ASTM D412 (Die C)
minimum
minimum
50 5%
Relative
Humidity)
Ozone and
No chalking, cracking or bond loss after 5,000 hours,
Ultraviolet
ASTM C793
minimum.
Resistance
1032
Silicone
Sealant
Type
Bond to
concrete
mortar
briquets
(primed if
required)
(Cured
seven days
at 77 3F
and 50
5%
Relative
Humidity)
Bond to
concrete
briquets
(Cured 21
days at 77
3F and
50 5%
Relative
Humidity)
Movement
Capability
Test Method
Type A
AASHTO T132
50 psi
minimum
AASHTO T132
ASTM C719
Type B
Type C
40 psi
minimum
35 psi
minimum
(includes
bond to
asphalt)
No adhesive or cohesive failure and
adhesion, 10 cycles at -50 to +100%
Type D
No adhesive
or cohesive
failure and
adhesion,
10 cycles at
+100/-50 %
(joints
2 wide)
Portland Cement Mortar: Briquettes shall be molded and cured
28 days minimum in accordance with AASHTO T132. Cured briquettes shall be dried at
230, plus or minus 5F, sawed in half and bonded together with a thin section of sealant.
After cure of sealant, briquettes shall be tested in accordance with AASHTO T132.
932-1.3.3 Field Cure: Six-inch samples of the sealant shall be taken by
the Engineer from the joint at the end of a two week curing period and tested for
durometer hardness (by Florida Method ANSI/ASTM D2240), except that the
requirements of a 1 inch sample width shall not apply. A minimum hardness of 7.0 is
required as evidence of adequate cure.
932-1.3.4 Qualified Products List: The low modulus silicone sealant
used shall be one of the products listed on the QPL. Manufacturers seeking evaluation of
their products shall submit product datasheets, performance test reports from an
1033
independent laboratory showing the product meets the requirements of this section, an
infrared identification curve (2.5 to 15 m) and a QPL application in accordance with
Section 6. Information on the QPL application must identify the sealant type.
932-1.3.5 Shipment: The material shall be delivered in containers plainly
marked with the manufacturers name or trademark product name, LOT number and date
of expiration.
932-1.3.6 Primer: When required by the manufacturers product, a primer
shall be used.
The manufacturer shall perform quality control tests on each LOT
of sealant primer material furnished to each project and furnish a certified report that each
LOT of primer material furnished to a project meets his companys specifications for that
product and the primer is suitable for its intended use.
Sealant primer material shall be delivered in containers plainly
marked with the manufacturers name or trademark and product name, LOT number and
date of expiration.
932-1.3.7 Backer Rod and Tape Bond Breakers: Backer rods and tape
shall be compatible with the joint sealant and approved by the sealant manufacturer. No
bond or reaction shall occur between the rod and the sealant.
932-1.3.8 Installation: Installation, material selection, joint dimensions,
bond breaker suitability (by type and project) shall be in agreement with the requirements
of the Design Standards, Index Nos. 305 and 21110. Any modifications or exceptions to
these requirements shall be shown in the Plans.
For new construction projects or general use where the joints to be
sealed have uniform width, a closed cell, expanded polyethylene foam backer rod bond
breaker shall be required. For rehabilitation projects and similar joint seals where the
joints to be sealed have irregular width, an open cell, expanded polyethylene foam backer
rod bond breaker with an impervious skin shall be required.
The backer rod shall be compatible with the joint sealant. No bond
or reaction shall occur between the rod and the sealant.
Tape bond breaker approved by the sealant manufacturer may be
used in lieu of backer rod bond breaker when sealing joints and/or random cracks, as
required.
Type D Silicone sealant shall be placed when the ambient
temperature is rising and is between 55F and 85F and the temperature is expected to
rise for the next three hours minimum to provide to adequate joint opening and
compression of the sealant during curing.
All installed bond breakers shall be covered by sealant at the end
of each work day.
A tolerance in cross-sectional height at midpoint of minus
1/16 inches to plus 3/16 inches will be allowed to the nominal values shown for each
joint width on the plan sheet. The Engineer shall check one joint for each 1,000 feet of
roadway by cutting out specimens. If the cross section of the cut specimen is out of the
allowable range, additional specimens shall be taken as follows:
One joint every 100 feet of pavement, not to exceed 500 feet.
1034
If the average of the specimens is out of tolerance, the Contractor
shall remove and replace the entire 500 foot section at no additional expense to the
Department.
Installation tolerance shall be verified at 1,000 foot intervals.
932-1.4 Pre-cured Silicone Sealant:
932-1.4.1 General: Pre-cured silicone sealants are intended for sealing
vertical joints on concrete surfaces. Type V1 sealant is intended for contraction joints or
joints with movements less than 1/4 inches. Type V2 sealant is intended for expansion
joints not exceeding 200% of the nominal joint opening. Type V2 sealant may be
substituted for Type V1 sealant. The joint sealant must be listed on the QPL.
932-1.4.2 Physical Requirements: Sealant material shall be a nominal
1/16 inches thick, available in standard widths from 1 inch to 6 inches, colored to match
the finish surface coating of the concrete, and meet the following minimum testing
requirements:
TEST PROPERTY DESCRIPTION TEST METHOD
Minimum Movement,
ASTM C1523
Cohesion/Adhesion
Dry/Room Temperature Loss of
ASTM C1523
Adhesion/Cohesion
Water Immersion Loss of
ASTM C1523
Adhesion/Cohesion
TYPE V1
TYPE V2
100%
200%
None
None
None
None
Frozen Loss of Adhesion/Cohesion
ASTM C1523
None
None
Heat Loss of Adhesion/Cohesion
ASTM C1523
None
None
Artificial Weathering Loss of
Adhesion/Cohesion
ASTM C1523
None
None
Tear Propagation
ASTM C1523
Ultimate Elongation
ASTM D412
NT or PT (No
NT or PT
Tear or
(No Tear or
Partial/Knotty Partial/Knotty
Tear)
Tear)
250%
500%
932-1.4.3 Qualified Products List: The pre-cured silicone sealant used
shall be one of the products listed on the QPL. Manufacturers seeking evaluation of their
product shall submit an application in accordance with Section 6. Applications must
include test results, an infrared identification curve (2.5 to 15 m), and a product data
sheet with the recommended adhesive and installation requirements.
932-1.5 Compression Seals and Adhesive Lubricant
932-1.5.1 Preformed Elastomeric Compression Seals: Preformed
Elastomeric Compression Seals shall meet the requirements of ASTM D2628 except that
immersion oil IRM 903 may be substituted for Oil No. 3 in the Oil Swell test procedure.
1035
932-1.5.2 Compression Seal Adhesive Lubricant: Compression seal
adhesive lubricant shall meet the requirements of ASTM D4070. The material shall be
fluid from 5F to 120F (-15C to 49C).
932-1.5.3 Certification: The manufacturer shall provide a certified test
report for each lot of material furnished to each project along with a statement certifying
that the material conforms to this specification and identifying the project number and
manufacturers lot number.
932-1.5.4 Verification Samples: Provide verification samples in
accordance with Section 6.
8-13.1 932-2 Structure Bearing Pads.
932-2.1 General: Furnish elastomeric structure bearing pads as shown in the
Contract Documents. Elastomeric bearings as defined herein shall include plain pads
(elastomer only) and laminated bearings with steel or fabric laminates. Flash tolerance,
finish and appearance of bearings shall meet the requirements of the latest edition of the
Rubber Handbook as published by the Rubber Manufacturers Association, Inc. RMAF3-T.063 for molded bearings, and RMA-F2 for extruded bearings.
932-2.2 Materials: Use elastomer that is Grade 2 or higher, as defined in the
AASHTO LRFD Bridge Design Specifications, crystallization resistant, 100% virgin
polychloroprene (neoprene). Use only new materials; reclaimed material is not allowed in
the finished product. No wax, anti-ozonants, or other foreign material may accumulate or
be applied to the surfaces of the bearing. The steel layers of the laminated pads shall
utilize 10 gauge steel sheet (0.1345 inches thick). The steel utilized for the steel layers
and for external load bearing plates (if specified) shall meet the requirements of
ASTM A36 or ASTM A1011 Grade 36 Type I steel sheet. External load bearing plates
shall be finished or machined flat to within 0.01 inches. The bottom surfaces of external
load plates (masonry plates) designed to rest on bearing pads shall not exceed an out of
flatness value of 0.0625 inches. External load bearing plates shall be protected from rust
until all exposed surfaces can be field painted. Any rust inhibitor shall be removed from
all surfaces prior to welding.
932-2.3 Sampling: A sampling LOT shall consist of a maximum of 100 bearing
pads of a single type of bearing, of the same design, materials, and thickness, delivered to
the project site.
932-2.3.1 Ancillary Structure Pads: Sampling is not required and
acceptance is by certification.
932-2.3.2 Bridge Structure Pads: A minimum of two bridge bearing pads
per LOT will be selected by the Engineer at the project site- one for testing and one for
confirmation in the event of a failing test result. Samples shall consist of complete pads
as detailed in the Plans. Furnish additional complete bridge bearing pads to replace those
selected for testing. Bridge bearing pads shall be available for sampling a minimum of
three weeks prior to their installation. The sample bridge bearing pads shall be tested by
an independent laboratory approved by the Department.
932-2.4 Dimensional Tolerances: Fabricate elastomeric bearings within the
dimensional tolerances specified below or as designated in the Plans. If any of the
dimensions are outside the limits specified, the bearing pad shall be rejected.
Measurement
1036
Tolerance
Design thickness 1.25 inches
Design thickness 1.25 inches
measurements 36 inches
2. Overall horizontal dimensions
measurements 36 inches
3. Thickness of individual layers of elastomer (laminated bearings
only) at any point within the bearing
4. Variation from a plane parallel to Top (slope relative to bottom)
the theoretical surface (as
determined by measurements at the
Sides
edge of the bearings)
1. Overall vertical dimensions
(inches)
-0, +0.125
-0, +0.25
-0, +0.25
-0, +0.50
0.125
0.005 radians
0.25
5. Position of exposed connection members
0.125
6. Edge cover of embedded laminates of connection members
-0, +0.125
7. Position and size of holes, slots, or inserts
0.125
Note: If the variation in thickness of individual layers of elastomer is greater than that allowed in the tolerance for
Measurement (3) (0.125 in.), use the following equation to determine compliance: 7.5 + v/hr <0.35 provided 0.02
where (radians) and v (in) are absolute values of steel laminate rotation and vertical displacement. If the specified
layer elastomeric layer thickness is hr, the bearing length is L, and H1 and H2 are the measured maximum and minimum
thicknesses at the edges of the layer, then v=|hr-1/2(H1+H2)| and =|(H1-H2)/2L| for interior layers and =|(H1-H2)/L| for
top and bottom layers provided that the minimum elastomer layer thickness H20.2 in.
932-2.5 Ancillary Structures - Plain, Fiber Reinforced, or Fabric Laminated
Bearing Pads:
932-2.5.1 Plain Pads: Plain pads shall be either molded, extruded, or
vulcanized in large sheets and cut to size. Cutting shall not heat the material and shall
produce a smooth finish conforming to ANSI B46.1, 6.3 m (0.248 mils). Plain pads
shall be molded or extruded to the finished thickness. Plying pads of lesser thickness
together shall not be permitted. External load plates, when used, shall be protected from
rusting and shall be hot bonded by vulcanization during the primary molding process.The
finished pads shall withstand a minimum uniform compressive load of 1200 psi when
tested in accordance with FM 5-598.
932-2.5.2 Fiber Reinforced or Fabric Laminated Pads: Fiber reinforced
pads shall be constructed with a homogeneous blend of elastomer and random-oriented
high strength synthetic fiber cords. Bearing pads may be molded and vulcanized in large
sheets and cut to size. Cutting shall be performed so as to prevent heating and must
produce a smooth finish conforming to ANSI B46.1.
Fabric laminated bearings shall be constructed of multiple layers of
fabric and elastomer. The fabric shall be composed of 8 ounce cotton duck and the pads
manufactured in accordance with Military Specification MIL-C-882. Ensure the fabric is
free of folds or ripples and parallel to the top and bottom surfaces.
Fiber reinforced and fabric pads shall withstand a minimum
uniform compressive load of 2,400 psi when tested in accordance with FM 5-598.
932-2.5.3 Certification: The Contractor shall provide the Engineer a
certification conforming to the requirements of Section 6 stating that the ancillary
1037
structure pads meet the requirements of this Section and the physical and heat resistance
properties of Section 6 of FM 5-598.
932-2.6 Bridge Structures - Elastomeric Bearing Pads: Bearings with steel
laminates shall be cast as a unit in a mold and bonded and vulcanized under heat and
pressure. Bearings with steel laminates which are designed to act as a single unit with a
given shape factor must be manufactured as a single unit. The mold shall have a standard
shop practice mold finish. The internal steel laminates shall be blast cleaned to a
cleanliness that conforms to SSPC-SP6 at the time of bonding. Plates shall be free of
sharp edges and burrs and shall have a minimum edge cover of 0.25 inches. External load
plates (sole plates) shall be hot bonded to the bearing during vulcanization.
Edges of the embedded steel laminates, including the laminate restraining
devices and around holes and slots shall be covered with not less than 3/16 inches of
elastomer or the minimum edge cover specified in the Plans. All exposed laminations or
imperfections that result in less than the specified elastomer cover of any surface of the
steel laminations shall be repaired by the manufacturer at the point of manufacture. The
repair shall consist of sealing the imperfections flush on the finished pads with a bonded
vulcanized patch material compatible with the elastomeric bearing pad. Repairs
employing caulking type material or repairing the bearings in the field will not be
permitted.
932-2.6.1 Testing: Test bridge bearing pads in accordance with FM 5598. Laminated bridge bearings must meet a minimum compressive load of 2,400 psi and
non-laminated (plain) pads must meet a minimum compressive load of 1,200 psi. If any
properties are identified as non compliant with the criteria specified, the bearing shall be
rejected and the confirmation sample tested. If the confirmation sample test results are
also non compliant, the LOT shall be rejected.
932-2.6.2 Marking: Each elastomeric bearing pad shall be permanently
marked. The marking shall consist of the order number, LOT number, pad identification
number, elastomer type, and shear modulus or hardness (when shear modulus is not
specified). Where possible, the marking shall be on a face of the bridge bearing pad that
will be visible after erection of the structure.
932-2.6.3 Certified Test Results: For bridge bearing pads, provide a
certified copy of the independent laboratorys complete test results for all tests specified,
properly identified by LOT and project number, to the Engineer.
932-2.6.4 Certification: The Contractor shall provide the Engineer a
certification conforming to the requirements of Section 6 stating that the bearing pads,
(plain, fiber reinforced or elastomeric) meet the requirements of this Section. The
certification shall designate the bearings in each LOT and state that each of the bearings
in the LOT was manufactured in a reasonably continuous manner from the same batch of
elastomer and cured under the same conditions.
1038
SECTION 933
PRESTRESSING STEEL
933-1 Strands for Prestressing.
The strands for prestressing concrete members shall be Grade 270, low-relaxation strand
and shall conform to the requirements of ASTM A416.
933-2 Bars for Prestressing.
The bars for prestressing concrete members shall conform to the requirements of
ASTM A722, Type II.
933-3 Parallel Wire Assemblies for Prestressing.
The wire assemblies for prestressing concrete members shall consist of parallel wires of
the number and size shown in the Plans and shall conform to the requirements of ASTM A421.
933-4 Anchorages for Prestressing.
933-4.1 For Strands and Bars: Meet the requirements of Section 960.
933-4.2 For Parallel Wire Assemblies: Anchorage for parallel wire assemblies may be
provided by Type BA (Button Anchorages) cold-end deformation of the wires bearing against
suitable anchorage plates, or by Type WA (Wedge-type Anchorages) without cold end
deformations, of the sandwich-plate or conical type. The anchorage device shall be capable of
developing at least 90% of the specified ultimate strength of the total number of wires anchored.
Conical type anchorages shall be embedded within the ends of the concrete
members unless otherwise specified. Anchorages shall generally bear against embedded grids of
reinforcing steel of approved type.
Alternate type anchorages will be considered if proposed by the Contractor. Any
alternate anchorage will be required to develop the full specified ultimate strength for bars or at
least 90% of the specified ultimate strength for parallel wire assemblies.
933-5 Required Tests for Prestressing Steel.
933-5.1 General: Tests shall be performed to determine the physical characteristics of
prestressing reinforcement. For tests specified to be made by the manufacturer, certified copies
of all test results shall be submitted to the Engineer prior to use.
933-5.2 Strands: Acceptance of prestressing strands shall be based on samples taken by
the Department and the manufacturers certified mill analysis certifying that the test results meet
the specification limits of ASTM or AASHTO as specifically designated. Prior to use, submit to
the Engineer the manufacturers certified mill analysis for each heat or production LOT per
shipment of strand.
Certifications for prestressing strand shall contain, for each heat number or
production LOT, all test results required by ASTM A416 and the modulus of elasticity expressed
in psi or the stress-strain curve with units identified.
The Engineer will select samples and certified mill analysis representing each
shipment at a frequency of one sample per manufacturer, per size of strand, per shipment.
933-5.3 Bars: Acceptance of prestressing bar shall be based on samples taken by the
Department and the manufacturers certified mill analysis certifying that the test results meet
specification limits of the ASTM or AASHTO as specifically designated. Prior to use, submit to
the Engineer the manufacturers certified mill analysis for each heat or production LOT and size
1039
9330000
All Jobs
per shipment of bars. Certifications of prestressing bar shall contain, for each heat number or
production LOT, all test results required by ASTM A722 and the modulus of elasticity expressed
in psi or the stress-strain curve with units identified.
The Engineer will select samples and certified mill analysis representing each
shipment at a frequency of one sample per heat or production LOT, per size of bar, per shipment.
933-5.4 Wires: Acceptance of wires shall be based on the manufacturers certified mill
analysis of test results meeting the specification limits of the ASTM or AASHTO as specifically
designated. Prior to use, submit to the Engineer the manufacturers certified mill analysis for
each heat or production LOT per shipment of wire. Certifications of prestressing wire shall
contain, for each heat number or production LOT, all test results required by ASTM A421.
1040
SECTION 934
NON-SHRINK GROUT
934-1 Scope.
This Section covers only prepackaged non-shrink cementitious grout for structural
use.
934-2 Type Permitted.
Only non-metallic formulations of grouts are allowed. Gas producing, metal
oxidizing and expansive aggregate grouts are not allowed.
934-3 Sampling and Testing Methods.
Perform concrete sampling and testing in accordance with the following methods:
Making and Curing Concrete Test Specimens
in the Laboratory ............................................... ASTM C192
Time of Setting Concrete Mixtures by
Penetration Resistance ...................................... ASTM C403
Determining Low-Levels of Chloride in Concrete and
Raw Materials ....................................................... FM 5-516
Compressive Strength of Hydraulic Cement
Mortars .............................................................. ASTM C109
Flow of Grout for Preplaced Aggregate Concrete
(Flow Cone Method) ......................................... ASTM C939
Measuring Changes in Height of Cylindrical Specimens from
Hydraulic Cement Grout ................................. ASTM C1090
Expansion and Bleeding of Freshly Mixed Grout for Preplaced
Aggregate Concrete in the Laboratory .............. ASTM C940
934-4 Requirements.
When tested as provided in 934-3, the grout shall meet the following
requirements:
Property
Test Value
Compressive strength
one day
3 days
Time of set, final
Chloride Content
Hardened Height Change at 1, 3, 14,
and 28 Days
Hardened Height Change at 1, 3, and 14 Days
Expansion
Bleeding, Final
1041
2,500 psi minimum
5,000 psi minimum
8 hours maximum
0.40lb/yd3 maximum
0.0% to 0.3%
Height Change @ 28 Days
2.0% @ 3 Hours
0.0% @ 3 Hours
934-5 Product Acceptance on the Project.
Non-shrink grout used shall be one of the products listed on the Qualified
Products List (QPL). Manufacturers seeking evaluation of their product shall submit an
application in accordance with Section 6.
Acceptance will be made in accordance with the products listed on the QPL.
934-6 Rejection.
Materials shall be rejected at the point of use if the materials are caked, lumpy, or
show any signs of deterioration. Materials shall be rejected if the grout does not achieve
the design fluidity or consistency when mixed according to the manufacturers
recommendations.
All broken or open packages shall be rejected.
934-7 Packaging.
Cementitious materials for grouts must be packaged in suitable moisture resistant
containers and clearly labeled. Where applicable, manufacturers recommendations,
limitations and cautions shall be clearly visible on each label.
1042
SECTION 937
POST-INSTALLED ANCHOR SYSTEMS FOR
STRUCTURAL APPLICATIONS IN CONCRETE ELEMENTS
937-1 General.
Post-installed anchor systems intended for structural applications in concrete elements
consist of adhesive-bonded anchor systems.
937-2 Qualified Products List (QPL).
Manufacturers of post-installed anchor systems may apply for inclusion of individual
products on the Departments Qualified Products List (QPL). The application shall be made in
accordance with Section 6 and shall include certified test reports from an independent testing
laboratory which shows the material system meets all the requirements of this Section.
937-3 Certification.
The Contractor shall provide the Engineer with certification from the manufacturer of the
anchor system, confirming that the requirements of this Section are met. The certification shall
conform to the requirements of Section 6. Each certification shall cover only one LOT of
anchoring materials.
937-4 Adhesive Bonding Material Systems.
937-4.1 General: Adhesive bonding material systems for structural applications shall
consist of pre-packaged, 2-part chemical components. The material systems shall be specifically
intended for use in structural applications for bonding anchors and dowels to hardened concrete.
Applications are limited to anchors and dowels installed in positions ranging from vertically
downward to horizontal.
Do not use material from containers which are damaged or have been previously
opened. Use only full packages of components. Combining of adhesive bonding components
from bulk supplies is not permitted.
Material systems shall be pre-packaged to automatically proportion and mix the
materials for use. Manual proportioning of the components will not be permitted.
937-4.2 Minimum Performance Requirements (FM 5-568): When tested in
accordance with FM 5-568, the adhesive bonding material system, for general use, shall meet the
following requirements:
Uniform Bond Stress
Type HV
Confined Tension
2,290 psi
Damp-Hole Installation
1,680 psi
Elevated Temperature
2,290 psi
Horizontal Orientation
2,060 psi
Short Term Cure
1,710 psi
Specified Bond Strength
1,080 psi
Maximum Coefficient of Variation for Uniform Bond Stress: 20%.
Long Term Load (Creep):
1043
Type HSHV
3,060 psi
1,830 psi
3,060 psi
2,060 psi
1,710 psi
1,830 psi
(1) The rate of displacement shall decrease during the 42 day application
of load.
(2) At 42 days, the total displacement due to creep (with load still applied)
shall be less than 0.03 inches and during the last 14 days of the 42 day load duration, the total
displacement due to creep shall be less than 0.003 inches.
(3) After removal of the 42 day load, the uniform bond Stress from a
subsequent Confined Tension Test shall not be less than 1,826 psi.
937-4.3 Product Identification (Fingerprint) Properties (FM 5-569): References for
comparison including infrared absorption, density or average weight, gel time or setting time,
and bond strength shall be determined in accordance with FM 5-569.
937-4.4 Packaging and Marking: The adhesive bonding material system shall be
delivered to the project site in original unopened containers with the manufacturers label
identifying the product. Each package shall be clearly marked with the following information:
Manufacturers name and address
Product Name
Date of Manufacture
Expiration Date
LOT Identification Number
Storage and Handling Requirements
Each package shall include the manufacturers instructions for anchor and dowel
installation. The instructions shall include the following information:
Diameters of drilled holes for applicable anchor and dowel sizes.
Cleaning procedure for drilled holes, including a description of permitted
and prohibited equipment and techniques.
Allowable temperature ranges for storage, installation and curing.
Identification of acceptable mixing/dispensing nozzles.
Fabrication requirements for anchors and dowels.
Description of tools permitted or required for installation.
Method of identifying properly proportioned and mixed adhesive
materials.
Time and temperature schedule for initial set and full-strength cure.
Special requirements for special installation conditions such as damp
holes, or horizontal or near horizontal orientation of the anchor or dowel.
1044
SECTION 938
POST-TENSIONING GROUT
938-1 General Requirements.
This Section covers grouts to be used to protect post-tensioning steel. Grout applications
are differentiated into three applications: horizontal, vertical and repair.
Grouts shall be prepackaged in moisture proof containers. Grout bags shall indicate
application, date of manufacture, LOT number and mixing instructions. Any change of materials
or material sources requires new testing and certification of the conformance of the grout with
this Specification. A copy of the Quality Control Data Sheet for each lot number and shipment
sent to the job site shall be provided to the Contractor by the grout supplier and furnished to the
Engineer. Materials with a total time from manufacture to usage in excess of six months shall be
tested and certified by the supplier that the product meets the quality control specifications
before use or the material shall be removed and replaced.
938-2 Qualified Products List.
Only post-tensioning grouts listed on the Departments Qualified Products List (QPL)
shall be used. Manufacturers of post-tensioning grout seeking evaluation of their product shall
submit an application in accordance with Section 6 and include certified test reports from an
independent laboratory, audited by the Cement Concrete Reference Laboratory (CCRL) which
shows the material meets all the requirements specified herein. A written certification from the
manufacturer that the product meets the requirements of this Section must be provided. Grout
products will be qualified by application (horizontal, vertical or repair).
938-3 Mixing.
The material shall be mixed in accordance with the manufacturers recommendations.
938-4 Grout Physical Properties.
938-4.1 Gas Generation: The grout shall not contain aluminum or other components
which produce hydrogen, carbon dioxide or oxygen gas.
938-4.2 Laboratory Test: The grout shall meet or exceed the specified physical
properties stated herein as determined by the following standard and modified ASTM and FM
test methods conducted at normal laboratory temperature (65F-78F) and conditions. Conduct
all grout tests with grout mixed to produce the minimum time of efflux. Establish the water
content to produce the minimum and maximum time of efflux.
Property
Total Chloride Ions
Fine Aggregate (if utilized)
Test Value
Test Method
3
Max. 0.4 lbs/yd
99% passing the No. 50
Sieve (300 micron)
FM 5-516
ASTM C136*
Hardened Height Change @ 24
hours and 28 days
0.0% to + 0.2%
ASTM C1090**
Expansion
2.0% for up to 3 hours
ASTM C940
Wet Density - Laboratory
Report maximum and minimum
obtained test value lb/ft3
ASTM C185
1045
Property
Test Value
Test Method
Wet Density - Field
Report maximum and minimum
obtained test value lb/ft3
ASTM C138
Compressive Strength
28 day (Average of 3 cubes)
7,000psi
ASTM C942
Initial Set of Grout
Time of Efflux
(a) Immediately after mixing
Min. 3 hours
Max. 12 hours
***
Min. 20 Sec.
Max. 30 Sec.
or
Min. 9 Sec.
Max. 20 Sec.
ASTM C953
***
ASTM C939
ASTM C939****
Max. 30 Sec.
ASTM C939
or
Max. 30 Sec.
ASTM C939****
Bleeding @ 3 hours
Max. 0.0 percent
ASTM C940*****
Permeability @ 28 days
Max. 2,500 coulombs
at 30 V for 6 hours
ASTM C1202
(b) 30 minutes after mixing
with remixing for 30 sec
*Use ASTM C117 procedure modified to use a #50 sieve. Determine the percent passing the #50 sieve after washing the sieve.
**Modify ASTM C1090 to include verification at both 24 hours and 28 days.
***Adjustments to flow rates will be achieved by strict compliance with the manufacturers recommendations. The time of
efflux is the time to fill a one liter container placed directly under the flow cone.
****Modify the ASTM C939 test by filling the cone to the top instead of to the standard level.
*****Modify ASTM C940 to conform with the wick induced bleed test as follows:
(a) Use a wick made of a 20 inch length of ASTM A416 seven wire 0.5 inch diameter strand. Wrap the strand with
2 inch wide duct or electrical tape at each end prior to cutting to avoid splaying of the wires when it is cut. Degrease (with
acetone or hexane solvent) and wire brush to remove any surface rust on the strand before temperature conditioning.
(b) Condition the dry ingredients, mixing water, prestressing strand and test apparatus overnight at 65 Fto 75F.
(c) Mix the conditioned dry ingredients with the conditioned mixing water and place 800 ml of the resulting grout
into the 1,000 ml graduate cylinder. Measure and record the level of the top of the grout.
(d) Completely insert the strand into the graduated cylinder. Center and fasten the strand so it remains essentially
parallel to the vertical axis of the cylinder. Measure and record the level of the top of the grout.
(e) Store the mixed grout at the temperature range listed above in (b).
(f) Measure the level of the bleed water every 15 minutes for the first hour and hourly for two successive readings
thereafter.
(g) Calculate the bleed water, if any, at the end of the 3 hour test period and the resulting expansion per the
procedures outlined in ASTM C940, with the quantity of bleed water expressed as a percent of the initial grout volume. Note if
the bleed water remains above or below the top of the original grout height. Note if any bleed water is absorbed into the
specimen during the test.
938-5 Accelerated Corrosion Test Method (ACTM).
Perform the ACTM as outlined in Appendix B of the Specification for Grouting of PostTensioning Structures published by the Post-Tensioning Institute. Report the time to corrosion
for both the grout being tested and the control sample using a 0.45 water-cement ratio neat grout.
A grout that shows a longer average time to corrosion in the ACTM than the control
sample and the time to corrosion exceed 1,000 hours is considered satisfactory.
1046
938-6 Variation in Testing for Specific Applications.
938-6.1 Horizontal Applications: Horizontal grout applications are defined as grouting
of all superstructure tendons and transverse substructure tendons in caps, struts, etc. All physical
requirements defined in 938-4 and 938-5 are applicable for grouts used in horizontal
applications.
938-6.2 Vertical Applications: Vertical grout applications are defined as grouting of
substructure column tendons. All physical requirements defined in 938-4 and 938-5 are
applicable for grouts used in vertical applications. In addition, perform the Schupack Pressure
Bleed Test Procedure for Cement Grouts for Post-Tensioned Structures as outlined in
Appendix C of the Specification for Grouting of Post-Tensioned Structures published by the
Post-Tensioning Institute. Report the percent bleed for the grout tested. Test grout at the
specified pressure of 100 psi. An acceptable test will result in no bleed water (0.0 percent).
938-6.3 Repair Applications: Repair applications are used to augment grouting
operations which did not completely fill the duct or anchorage. For new construction, repairs
may be made with the same grout approved for use in the tendon as long as the volume of the
void is less 0.5 gal. In all other cases, use a non-sanded grout meeting the requirements of 938-4
and 938-5 with a modified maximum permeability of 2,800 coulombs (ASTM C1202 at
30 volts). Non-sanded grouts shall have 95% passing on the #100 sieve and 90% passing the
#170 sieve as determined by ASTM C33. Each sieve may be washed and dried before weighing
in accordance with the procedure in ASTM C117 modified for sieve size.
1047
DRAINAGE MATERIALS
SECTION 942
PIPE GASKETS
942-1 Round Rubber Gaskets for Pipe Joints.
Except where O-ring type gaskets are specified for special cases and for special type
pipe, round rubber gaskets for use in concrete pipe joints shall meet the requirements of
ASTM C443, with the additional requirements that the gasket used shall be of such cross
sectional area and perimeter as to properly fit the space provided in the pipe joint in which it is to
be used.
Prior to use, the gasket shall be stored in as cool a place as practicable.
942-2 Cold Adhesive Preformed Plastic Gaskets (For Sealing Elliptical Concrete Pipe
Joints).
942-2.1 General: Cold adhesive preformed plastic gaskets shall be of a material, shape
and size so as to effect a permanent water tight seal in joints of elliptical concrete pipe. A
minimum of two pieces of gasket material shall be used in each joint.
The gasket material shall be protected by a 2-piece removable wrapper. To
facilitate application, the 2-piece wrapper shall be so designed that one-half may be removed
longitudinally without disturbing the other half.
The size of the gasket shall be in accordance with the manufacturers
recommendation for the particular joint in which it is to be used. However, the minimum size for
each of the gaskets used in a joint shall be in accordance with the following:
Pipe Size
(Inches)
Up to 19 by 30
19 by 30 to 53 by 83
Over 53 by 83
Nominal Gasket Size
(Inches)
1-1/2
1-3/4
2
Minimum Cross-Section
(In2)
1.75
2.5
3.25
The above minimum size requirements are based on a joint designed with a
maximum taper of 10 degrees and an in-place annular space of approximately 1/4 inch.
942-2.2 Composition: The gasket sealing the joints shall be produced from blends of
refined hydrocarbon resins and plasticizing compounds reinforced with inert mineral filler. The
material shall contain no solvents and shall not produce irritating fumes or obnoxious odors. The
gasket shall not depend on oxidizing, evaporation or chemical action for its adhesive or cohesive
strength.
The chemical composition of the gasket material shall meet the following
requirements:
Bitumen (petroleum plastic content) (% by weight)
Ash-Inert Mineral Matter (% by weight)
1048
Minimum
50
30
Maximum
70
50
Minimum
Volatile Matter (@ 325F)
(% by weight)
Maximum
2.0
The gasket joint sealing compound when immersed for 30 days at ambient room
temperature separately in 5% solution of caustic potash, a mixture of 5% hydrochloric acid, a 5%
solution of sulfuric acid, and a saturated hydrogen sulfide solution shall show no visible
deterioration.
The physical properties of the gasket joint sealing compound as shipped shall
meet the following requirements:
Specific Gravity @ 77F
Ductility @ 77F
Softening Point @ 77F
Penetration (0.1 mm) 77F @ (150 gms)
five seconds
Minimum
1.2
50 mm
320F
Maximum
1.35
50
120
942-2.3 Certification: The manufacturer of the gasket material shall furnish the Engineer
certified test results covering each shipment of material to each project.
942-3 Resilient Connectors for Sealing Precast Structures to Pipe Joints.
942-3.1 General: Resilient connectors shall meet the requirements of ASTM C1478. The
connectors shall also be compatible with the precast structure and pipe.
942-3.2 Qualified Products List (QPL): All resilient connectors shall be listed on the
Departments Qualified Products List (QPL). Manufacturers seeking evaluation of their product
shall submit an application in accordance with Section 6.
942-4 Profile Rubber Gaskets for Concrete Pipe Joints.
(a) Round Pipe: The gaskets shall meet the requirements of ASTM C443.
(b) Elliptical Pipe: The gaskets shall meet the requirements of ASTM C443.
Additionally, the gaskets used shall be of such cross sectional area and perimeter as to
properly fit the space provided in the pipe joint in which it is to be used.
The gaskets shall be stored in as cool a place as practicable prior to use.
1049
SECTION 943
CORRUGATED STEEL PIPE AND PIPE ARCH
(INCLUDING UNDERDRAIN)
943-1 General Requirements.
Corrugated steel pipe, including round culvert pipe, pipe arch and underdrain and
coupling bands for each type shall conform to AASHTO M36. Provide certification of the actual
mean diameter of pipe shipped to the project. Include in the certification the minimum and
maximum diameters used to certify the actual mean diameter. The certification shall be attested
to by a person having legal authority to bind the manufacturing company.
In addition, except for underdrain corrugated steel pipe including pipe arch shall be
fabricated with helical corrugations with a minimum of two annular corrugations formed on each
end of each pipe to accommodate a coupling band. Annular fabrication is not permitted unless
specifically called for in the Plans or Specifications.
Ensure that the pipe joints have been tested at the plant hydrostatically at the specified
pressure using test methods in ASTM D3212 with the exceptions of Sections 7.3 and 7.4. In lieu
of Section 7.4, deflect one side of the pipe to a 5% reduction in internal diameter using the
parallel plate testing methodology of ASTM D2412. Load the deflected pipe to within 1/2 the
actual pipe diameter from the centerline of the gasket or just beyond the end of the hugger band,
whichever is greater. Ensure that the loading mechanism does not contact the hugger band or
associated hardware. Testing shall be witnessed by the Engineer.
943-2 Round Culvert Pipe.
For round culvert pipe used as sidedrain, unless shown otherwise in the Plans, the
minimum thickness of the metal (including galvanizing - AASHTO M218, or aluminum coating
- AASHTO M274), shall be as specified below.
TABLE I
THICKNESS OF METAL FOR SIDEDRAIN PIPE
Nominal Diameter
Metal Sheet
Mean Thickness Metal
(Inches)
Gauge No.
(Inches)
6
18
0.0516
8
16
0.0635
10
16
0.0635
12
16
0.0635
15
16
0.0635
18
16
0.0635
21
16
0.0635
24
16
0.0635
30
14
0.0785
36
14
0.0785
42
12
0.1084
48
12
0.1084
54
12
0.1084
1050
TABLE I
THICKNESS OF METAL FOR SIDEDRAIN PIPE
Nominal Diameter
Metal Sheet
Mean Thickness Metal
(Inches)
Gauge No.
(Inches)
60
10
0.1382
66
10
0.1382
72
10
0.1382
78
8
0.1681
84
8
0.1681
90
8
0.1681
96 and over
8
0.1681
TABLE II
PERMISSIBLE VARIATION IN THICKNESS
OF METAL FOR PIPE AND CONNECTING BANDS
Mean Thickness of Metal
Metal Sheet Gauge No
Permissible Variation (Inches)
(Inches)
18
0.0516
0.007
16
0.0635
0.007
14
0.0785
0.008
12
0.1084
0.009
10
0.1382
0.009
8
0.1681
0.009
943-3 Pipe Arch.
For corrugated metal pipe arch, in addition to the requirements shown in AASHTO M36,
thickness of the metal shall be as shown for the equivalent size round pipe in Tables I and II,
above, and the fabrication of the pipe arch sections shall be such as to insure a substantially flat
invert.
943-4 Alternate Connecting Bands.
In addition to the connecting bands as specified in AASHTO M36, alternate types of
connecting bands are specified in 430-8.1.3, for use with the types of installations as shown.
943-5 Bituminous Coating and Paved Invert.
When bituminous coating is specified, the pipe, or pipe arch, shall be coated in
accordance with the requirements of AASHTO M190, for Type A (Fully Bituminous Coated).
When bituminous coated and paved invert are specified the pipe or pipe arch shall be
coated and paved in accordance with AASHTO M190, for Type C (Fully Bituminous Coated and
Paved). The temperature of the asphalt at the time of coating and the duration of the pipe
submerged time shall be optimized such that excess coating does not adhere to the pipe.
1051
943-6 Paved Interior.
When bituminous coated and paved interior are called for, the coating and paving shall
meet the requirements specified above for bituminous and paved invert (Type C), with the
following additions and exceptions:
(a) The smooth pavement formed by the asphalt cement shall extend over the
entire interior of the pipe.
(b) The exterior coating and the interior paving shall be applied.
(c) No markings will be required on the outside of the pipe to designate the center
line of the top of the pipe.
(d) Lifting lugs shall be attached to the pipe, and shall be suitably placed to
facilitate moving the pipe without damage to the exterior or interior bituminous material.
943-7 Basis of Acceptance of Bituminous Coating and Paving.
The acceptance of the bituminous coating, paved invert, and paved interior will be based
on the manufacturers certified mill tests.
943-8 Underdrain Pipe.
Corrugated metal pipe for underdrain shall conform to the requirements of
AASHTO M36 except that Class IV pipe, as specified in Section 18.1.1.4 therein, shall not be
used.
1052
SECTION 944
STRUCTURAL PLATE STEEL PIPE AND PIPE ARCH
944-1 Description.
This Section covers the materials for corrugated galvanized steel structural plate pipe and
pipe arch, including the necessary bolts and nuts for connecting plates and for assembling the
pipe or pipe arch at the point of destination when so specified. The sizes of the pipe or pipe arch
shall be as shown in the Plans.
944-2 Materials.
Structural plate pipe and pipe arch shall be of galvanized steel, complying with the
requirements of AASHTO M167, with the additional requirement that the minimum thickness of
the plates shall be as shown in the Plans.
944-3 Tolerance in Span and Height.
A tolerance of plus or minus 4% will be allowed in the specified span and height of pipe
arches. A tolerance of minus 2 inches to plus 4 inches will be allowed in the specified diameter
of round pipe.
944-4 Bituminous Coating.
When bituminous coating is specified, all plates shall be fully coated on both sides with
asphalt cement. The bituminous coating shall conform to the requirements of AASHTO M190,
for Type A.
944-5 Mill Analysis and Guarantee.
Six certified copies of Mill Analysis and Guarantee shall be furnished to the Engineer,
and acceptance of the pipe will be based on such reports.
944-6 Assembly Diagrams.
Diagrams for assembling shall be furnished unless the pipe or pipe arch is furnished
completely assembled.
944-7 Fabrication.
The fabrication of the pipe and pipe arch shall comply with the applicable requirements
of Section 23, of the AASHTO LRFD Bridge Construction Specifications. Unless otherwise
specified, the pipe and pipe arch shall be of full section for the entire length.
944-8 Assembly.
When purchase contracts stipulate that the pipe be assembled, the dealer shall furnish the
pipe and pipe arch completely assembled at the point of destination, or at the site, as specified,
and in lengths as specified.
944-9 Direct Purchases by the Department.
When the Department purchases the pipe or pipe arch direct from the dealer, the quantity
to be paid for shall be the number of feet of pipe and of pipe arch, as ordered, provided that
sufficient materials meeting the requirements of these specifications shall be furnished to
construct the pipe and pipe arch of the length and sizes shown.
1053
The quantity shall be the net length as ordered, with no allowance for length in excess
thereof.
The price per foot for direct purchases shall be full compensation for furnishing the
complete materials for the pipe or pipe arch, including all bolts and nuts required for connecting
the plates. When assembling of the pipe or pipe arch is specified, such price shall also include all
labor, equipment, tools and incidentals required for completely assembling the pipe or pipe arch.
1054
SECTION 945
ALUMINUM PIPE, INCLUDING UNDERDRAIN, PIPE
ARCH AND STRUCTURAL PLATE PIPE AND PIPE ARCH
945-1 Corrugated Aluminum-Alloy Culverts and Underdrains.
Aluminum-alloy culvert pipe and underdrains shall meet the requirements of
AASHTO M196 and the additional provisions contained herein. Except for underdrain,
corrugated aluminum pipe including pipe arch shall be fabricated with helical corrugations with
a minimum of two annular corrugations formed into each end of each pipe to accommodate a
coupling band. Annular fabrication is not permitted unless specifically called for in the Plans or
specifications. Provide certification of the actual mean diameter of pipe shipped to the project.
Include in the certification the minimum and maximum diameters used to certify the actual mean
diameter. The certification shall be attested to by a person having legal authority to bind the
manufacturing company.
For sidedrains, unless shown otherwise in the Plans the minimum thickness of the metal
shall be as specified below.
NON SI UNITS
TABLE I THICKNESS OF METAL FOR SIDEDRAIN PIPE
Nominal Diameter or
Equivalent (inches)
6
8
10
12
15
18
21
24
30
36
42
48
54
60
66
72 and over
Sheet Gauge No.
18
16
16
16
16
16
16
16
14
14
12
12
12
10
10
8
Mean Thickness of Metal
(inches)
0.048
0.060
0.060
0.060
0.060
0.060
0.060
0.060
0.075
0.075
0.105
0.105
0.105
0.135
0.135
0.164
Where bituminous coated aluminum pipe is specified the bituminous coating shall meet
the requirements as specified for corrugated steel pipe in 943-5. Bituminous coated and paved
aluminum pipe shall meet the additional requirements specified in 943-6 and 943-7, as
applicable.
Class IV pipe shall not be used.
1055
Ensure that the pipe joints have been tested at the plant hydrostatically at the specified
pressure using test methods in ASTM D3212 with the exceptions of Sections 7.3 and 7.4. In lieu
of Section 7.4, deflect one side of the pipe to a 5% reduction in internal diameter using the
parallel plate testing methodology of ASTM D2412. Load the deflected pipe to within 1/2 the
actual pipe diameter from the centerline of the gasket or just beyond the end of the hugger band,
whichever is greater. Ensure that the loading mechanism does not contact the hugger band or
associated hardware. Testing shall be witnessed by the Engineer.
945-2 Aluminum Alloy Structural Plate Pipe, Pipe Arch and Arches.
945-2.1 General Requirements: Aluminum alloy structural plate pipe, pipe arch, and
arches shall conform to AASHTO M219, with the exceptions and additions specified herein. The
nominal thickness of the plate shall be as shown in the Plans.
945-2.2 Bolts and Nuts: In lieu of shaped bolts and nuts, standard type bolts and nuts,
with special shaped washers, may be used. For aluminum bolts and nuts the material shall
conform to the chemical requirements shown in Table I of ASTM B211, for Alloy 6061. Nuts
shall be lubricated at the factory, with a suitable wax compound. The bolts may be sampled and
tested before erection or may be accepted on the basis of the manufacturers certification.
For steel bolts and nuts, the material shall meet the requirements of either
ASTM A307 or ASTM A325, as appropriate, and shall be hot double-dipped galvanized.
Aluminized steel bolts, or other equally suitable devices for connecting the plates, may be used if
approved by the Engineer.
945-2.3 Certification of Tests: For all aluminum materials, test certifications as
specified in 965-2, shall be furnished.
945-2.4 Direct Purchases by the Department: The provisions of 944-9, for the
conditions of direct purchase of structural plate steel pipe and pipe arches, shall also apply to
Departmental purchases of aluminum alloy structural plate pipe, pipe arches and arches.
945-2.5 Pipe Markings: In lieu of the coined markings required by AASHTO M196,
Section 14, information may be ink stamped on the pipe at the time of manufacture. The pipe
fabricators identity, date of corrugating or forming into pipe may be stamped onto the pipe
using indelible ink and a suitably fashioned stamping device. The pipe markings must be clearly
legible upon arrival at the jobsite and at the time of installation. Pipe with illegible or incomplete
markings may be rejected.
1056
SECTION 946
CAST IRON PIPE
946-1 Cast Iron Culvert Pipe.
Cast iron culvert pipe of diameter 12 inches and over shall conform with the
requirements of AASHTO M64, including the requirements for the coating as specified in
Article 7.1. Cast iron culvert pipe smaller than 12 inches in diameter shall meet ANSI A21.51
and the joints shall meet ANSI A21.11.
Unless a particular type or class of pipe is designated in the plans the Contractor may
furnish any class included in the above specifications. Only one class or type shall be furnished
for any one Contract. The pipe shall be smooth bore pipe.
946-2 Cast Iron Soil Pipe.
Cast iron soil pipe, for roof drains or for other purposes where such pipe is designated,
shall meet the requirements of either of the following:
(1) ASTM A74, for service-type pipe.
(2) The building code of the municipality or other governmental authority having
jurisdiction within the area of the installation.
1057
SECTION 948
MISCELLANEOUS TYPES OF PIPE
948-1 Polyvinyl-Chloride (PVC) Pipe, or Acrylonitrite-Butadiene-Styrene (ABS) Plastics
Pipe.
948-1.1 For Bridge Drains: PVC pipe shall conform to the requirements of
ASTM D1785, for Type I, Grade 1, Schedule 80 PVC pipe with a minimum polymer cell
classification of 12454 per ASTM D1784 and a minimum of 1.5% by weight of titanium dioxide
for UV protection.
948-1.2 Pressure Pipe: Pressure pipe for direct burial under pavement shall conform to
the requirements of ASTM D1785, for Type I, Grade I, Schedule 40, for sizes up to and
including 2-1/2 inches, and Schedule 80 for sizes up to 4 inches. Pressure pipe 4 inches in
diameter and larger shall conform to the requirements of AWWA C900-75, DR18, and
ASTM D1785, Type I, Grade I or other types as may be specifically called for in the Plans or
Special Provisions.
948-1.3 Pipe Marking: All PVC pipe shall be marked as required by Article 8 of
ASTM D1785, and acceptance of the pipe may be based on this data.
948-1.4 Nonpressure Pipe: PVC pipe and ABS pipe intended for direct-burial or
concrete encasement, shall meet the following requirements:
(a) PVC Pipe: ASTM D3034, SDR-35, or ASTM F949, profile wall without
perforations.
(b) ABS Pipe: ASTM D2680.
The manufacturer of the PVC or ABS pipe shall furnish to the Engineer six copies
of mill analysis covering chemical and physical test results.
948-1.5 Underdrain: PVC pipe for use as underdrain shall conform to the requirements
of ASTM F758 or ASTM F949. Also, PVC underdrain manufactured from PVC pipe meeting
ASTM D3034, perforated in accordance with the perforation requirements given in
AASHTO M36 or AASHTO M196 will be permitted.
948-1.6 Edgedrain: PVC pipe for use as edgedrain shall conform to the requirements of
ASTM F758, ASTM F949 or ASTM D3034 pipe shall be perforated in accordance with the
perforation requirements given in AASHTO M36 or AASHTO M196. Additional perforations
will be required as indicated in the Design Standards, Index No. 286 for pipes designated under
ASTM F758 and ASTM D3034. PVC pipe intended for direct burial in asphalt shall meet the
following requirements:
(a) ASTM D3034, SDR-35, or ASTM F949
(b) NEMA TC-2 (pipe material and compounds) and NEMA TC-3 (pipe fittings)
for PVC (90C electrical conduit pipe) NEMA ECP-40 and NEMA ECP-80. Underwriter
Laboratory Specifications referenced under NEMA specifications for electrical conductivity are
not required.
(c) Pipe shall withstand asphalt placement temperatures specified without
permanent deformation.
(d) Perforations shall be in accordance with AASHTO M36 or AASHTO M196.
948-1.7 PVC Pipe (12 Inches to 48 Inches): PVC pipe for side drain, cross drain, storm
drain and other specified applications shall conform to AASHTO M278 for smooth wall PVC
pipe or ASTM F949 for PVC ribbed pipe. Resin shall contain a minimum of 1.5% by weight of
1058
titanium dioxide for UV protection. Mitered end sections are not to be constructed of PVC. Use
only concrete or metal mitered end sections as indicated in the Design Standards.
All pipe produced and shipped to the job site shall meet the requirements of 1053.2.
948-2 Corrugated Polyethylene Tubing and Pipe.
948-2.1 General: For underdrain, corrugated polyethylene tubing and fittings shall meet
the requirements of AASHTO M252. For edgedrain, corrugated polyethylene tubing and fittings
shall meet the requirements of AASHTO M252, except as modified in 948-2.2. For storm drain
side drain, french drain and cross drain corrugated polyethylene pipe shall meet the requirements
of AASHTO Mp-294 and 948-2.3.2.
The tubing or pipe shall not be left exposed to sunlight for periods exceeding the
manufacturers recommendation.
948-2.2 Edgedrain (4 Inches to 10 inches): The requirements for edgedrain as specified
in AASHTO Mp-252 are modified as follows:
(a) Coiling of tubing 6 inches in diameter or greater is not permitted. Tubing shall
have a minimum pipe stiffness of 46 psi at 5% deflection.
948-2.3 Corrugated High Density Polyethylene Pipe (HDPE) (12 Inches to
60 inches):
948-2.3.1 General: Class I (50 year) corrugated polyethylene pipe used for side
drain, storm and cross drain or french drain shall meet the requirements of AASHTO M294.
Class II corrugated pipe shall meet the requirements of AASHTO M294 and the additional
requirements as specified herein. Corrugations may only be annular. Ensure that pipe resin
conforms to ASTM D3350 minimum cell classification 435400C except that cell class 435400E
may be used if the combination of color and UV stabilizer provides the same or better UV
protection than that of resin cell class 435400C. Mitered end sections are not to be constructed of
polyethylene. Use only concrete or metal mitered end sections as indicated in the Design
Standards.
All pipe produced and shipped to the job site shall meet the requirements
of 105-3.2.
948-2.3.2 Additional Requirements for Class II (100 Year), Type S
Polyethylene Pipe Meet the following requirements:
Pipe Location
Table 1
Stress Crack Resistance of Pipes
Test Method
Test Conditions
Pipe Liner
FM 5-572,
Procedure A
Pipe
Corrugation(1),
(molded plaque)
ASTM F2136
Requirement
Average failure time of the
10% Igepal solution at 122F
pipe liner shall be
and 600 psi applied stress,
18.0 hours, no single value
5 replicates
shall be less than 13.0 hours.
Average failure time shall
10% Igepal solution at 122F
be 24.0 hours, no single
and 600 psi applied stress,
value shall be less than
5 replicates
17.0 hours.
1059
Table 1
Determine failure time at
500 psi at 73.4F
Full Test(2)(3)
100 years (95% lower
Test at 3 temperature/stress confidence) using 15 failure
combinations:
time values(4)
176F at 650 psi
The tests for each condition
176F at 450 psi
can be terminated at
FM 5-572,
158F at 650 psi;
duration equal to or greater
Junction
Procedure B and
5 replicates at each test
than the following criteria:
FM 5-573
condition
110.0 hr at 176F 650 psi
430.0 hr at 176F 450 psi
500.0 hr at 158F 650 psi
(5)
Single Test :
The average failure time
Test temperature 176F and
must be equal to or greater
applied stress of 650 psi.;
than 110.0 hr
5 replicates
Determine failure time at
500psi at 73.4F 100 years
Full Test(2)(3):
(95% lower confidence)
Test at 3 temperature/stress
using 15 failure time
combinations:
values(4).
176F at 650 psi
The tests for each condition
176F at 450 psi
can be terminated at
FM 5-572,
158F at 650 psi;
duration equal to or greater
Longitudinal
Procedure C, and
5 replicates at each test
than the following criteria:
Profiles(6)
FM 5-573
condition
110.0 hr at 176F 650 psi
430.0 hr at 176F 450 psi
500.0 hr at 158F 650 psi
Single Test(5):
The average failure time
Test temperature 176F and
must be equal to or greater
applied stress of 650 psi.;
than 110.0 hr
5 replicates
Oxidation Resistance of Pipes
Pipe Location
Test Method
Test Conditions
Requirement
2 replicates (to determine
Liner and/or
OIT Test
initial OIT value) on the as
25.0 minutes, minimum
Crown(7)
(ASTM D3895) manufactured (not incubated)
pipe.
Three samples for incubation
Average of 3.0 minutes(9)
Incubation test
(8)
Liner and/or
of 265 days at 176F and
(no values shall be less than
FM 5-574 and OIT
Crown(7)
applied stress of 250 psi. One
2.0 minutes)
test (ASTM D3895)
OIT test per each sample
MI test
2 replicates on the as
Liner and/or
(ASTM D1238 at manufactured (not incubated)
< 0.4 g/10 minutes
Crown(7)
190oC/2.16Kg)
pipe.
1060
Table 1
Liner and/or
Crown(7)
Incubation test
2 replicates on the three aged
FM 5-574 and MI
MI Retained Value(9)(10)
sampled after incubation of
test
shall be greater than 80%
265 days at 176F(8) and
(ASTM D1238
and less than 120%.
applied stress of 250 psi
at 190C/2.16Kg)
Note: FM = Florida Method of Test.
(1) Required only when the resin used in the corrugation is different than that of the liner.
(2) A higher test temperature (194F) may be used if supporting test data acceptable to the State Materials Engineer is submitted
and approved in writing.
(3) Full test shall be performed on alternative pipe diameter of pipe based on wall profile design, raw material cell classification,
and manufacturing process. Full test must be performed on maximum and minimum pipe diameters within a manufacturing
process.
(4) Computer program to predict the 100 year SCR with 95% lower confidence can be obtained from FDOT.
(5) Single test for the junction and longitudinal profile may be used on alternating pipe sizes within a manufacturing process.
Single point tests may not be used on maximum and minimum pipe sizes within a manufacturing process except by approval of
the Engineer. Single point tests may be used for quality assurance testing purposes.
(6) Longitudinal profiles include vent holes and molded lines.
(7) OIT and MI tests on the crown are required when resin used in the corrugation is different than that of the liner.
(8) The incubation temperature and duration can also be 196 days at 185F.
(9) The tests for incubated and as-manufactured pipe samples shall be performed by the same lab, same operator, the same
testing device, and in the same day.
(10) The MI retained value is determined using the average MI value of incubated sample divided by the average MI value of asmanufactured pipe sample.
Manufacturer may use ground Class II, but not Class I, pipe for reworked
plastic.
948-2.3.3 Certification: Furnish to the Engineer certification from the
manufacturer for each pipe diameter manufacturers LOT to be incorporated into the project that
the pipe meets the requirements of these Specifications.
Manufacturers seeking evaluation of a product in accordance with Departmental
procedures must submit test reports conducted by a laboratory qualified by the Geosynthetic
Accreditation Institute-Laboratory Accreditation Program (GAI-LAP) or qualified by ISO 17025
accreditation agency using personnel with actual experience running the test methods for
Class II HDPE pipe. Submit the test reports to the State Materials Office.
948-2.3.4 Verification Samples: Furnish verification samples as directed by the
Engineer.
948-3 Fiberglass Reinforced Polymer Pipe.
948-3.1 For Bridge Drains: Fiberglass pipe shall conform to the requirements of
ASTM D2996 or ASTM D2310, for Type I, Grade 2, Class E, using polyvinyl ester as the only
resin. The minimum designation shall be RTRP-11EA. The resin shall contain UV stabilizers or
a two-part 100% solids polyurethane coating.
948-4 Ductile Iron Pipe.
948-4.1 For Bridge Drains: Ductile iron pipe shall conform to the requirements of
AWWA C151.
948-5 Hot Dip Galvanized Steel Pipe.
948-5.1 For Bridge Drains: Hot dip galvanized steel pipe shall conform to the
requirements of ASTM A53.
1061
948-6 Flexible Transition Couplings and Pipe.
948-6.1 For Bridge Drains: Flexible transition couplers and pipe shall conform to the
requirements of ASTM C1173.
948-7 Profile Wall Polypropylene (PP) Pipe.
PP pipe (12 inches to 60 inches) for side drain, cross drain, storm drain, and other
specified applications shall meet the requirements of AASHTO MP21-11. Mitered end sections
are not to be constructed of polypropylene. Use only concrete or metal mitered end sections as
indicated in the Design Standards.
All pipe produced and shipped to the job site shall meet the requirements of 105-3.2. The
manufacturer shall demonstrate that resin oxidation resistance will last using accelerated aging
by use of incubation tests in accordance with FM 5-574. Tests shall demonstrate that
stabilization package is present and that no degradation has occurred.
948-8 Filter Fabric Sock for Use with Underdrain.
For Type I underdrain specified in the Design Standards, Index No. 286, filter sock shall
be an approved strong rough porous, polyester or other approved knitted fabric which completely
covers and is secured to the perforated plastic tubing underdrain in such a way as to prevent
infiltration of trench backfill material.
The knitted fabric sock shall be a continuous one piece material that fits over the tubing
like a sleeve. It shall be knitted of continuous 150 denier yarn and shall be free from any
chemical treatment or coating that might significantly reduce porosity and permeability.
The knitted fabric sock shall comply with the following physical properties:
Weight, applied (oz/sq. yd.)
Grab tensile strength (lbs.)
3.5 min
50 min.*
Equivalent opening size (EOS No.)
25 min.**
Burst strength (psi)
100 min.**
ASTM D3887
ASTM D5034
Corps of Engineers
CW-02215-77
ASTM D3887
*Tested wet.
**Manufacturers certification to meet test requirement.
The knitted fabric sock shall be applied to the tubing in the shop so as to maintain a
uniform applied weight. The tubing with knitted fabric sock shall be delivered to the job site in
such manner as to facilitate handling and incorporation into the work without damage. The
knitted fabric sock shall be stored in UV resistant bags until just prior to installation. Torn or
punctured knitted fabric sock shall not be used.
948-9 Pipe Liner.
948-9.1 Cured-In-Place Pipe Liner: Cured-in-place pipe liner shall be continuous, resin
impregnated, flexible tubing that meets the requirements of ASTM D5813 and ASTM F1216.
948-9.2 Deformed Pipe Liner: Deformed pipe liner shall be manufactured in an out of
round state, usually collapsed circumferentially and folded on the long axis. After installation in
a host pipe, the liner is rounded by means of heat and pressure to fit the host pipe. Deformed pipe
liner, when installed, shall extend from one structure to the next in one continuous length with no
intermediate joints.
1062
(1) Polyethylene: Deformed polyethylene pipe liner shall meet the requirements
of ASTM F714 with a minimum cell classification of 335420c.
(2) PVC: Deformed PVC pipe liner shall meet the requirements of ASTM F1504.
948-9.3 Discrete Pipe Liner: Discrete pipe liner shall be round, flexible or semi-rigid
liner, manufactured in lengths that may be joined in a manhole or access pit before insertion in a
host pipe.
(1) High Density Polyethylene Solid Wall: Discrete high density polyethylene
pipe liner shall meet the requirements of ASTM F714 or AASHTO M326 and shall have a
minimum of cell classification of 345464c.
(2) High Density Polyethylene Profile Wall: Discrete high density polyethylene
pipe liner shall meet the requirements of AASHTO M294 and shall have a minimum cell
classification of 435400c.
(3) PVC: Discrete PVC pipe liner shall meet the requirements of ASTM F794,
ASTM F949, or AASHTO M304 and shall have a minimum cell classification of 12454.
(4) Fiberglass: Discrete fiberglass pipe liner shall meet the requirements of
ASTM D3262.
948-9.4 Spiral Wound Pipe Liner: Spiral wound pipe liner shall consist of coils of
profile strips that are wound into a host pipe helically, after which a cementious grout is injected
into the annular space between the liner and the host pipe, forming a rigid composite structure.
(1) PVC: PVC spiral wound pipe liner shall meet the requirements of
ASTM F1697 or ASTM F1735 and shall have a minimum cell classification of 12454.
948-9.4.1 Machine Spiral Wound Pipe Liner: Machine spiral wound pipe liner
shall consist of a continuous one piece profile strip wound directly into the deteriorated
pipelines. The liner can be installed in close fit to the host pipe, or alternatively installed at a
fixed diameter. Where the liner is installed at a fixed diameter, the annular space between the
spiral wound liner pipe and the existing pipe is grouted.
(1) PVC: PVC machine spiral wound pipe liner shall meet the
requirements of ASTM F1697 and shall have a minimum cell classification of 12454.
948-9.5 Paneled Pipe Liner: Paneled pipe liner consists of custom-cut flat or curved
panels that are formed to the inside circumference of a host pipe.
(1) PVC: PVC paneled pipe liner shall meet the requirements of ASTM F1735
and shall have a minimum cell classification of 12454.
948-9.6 Point Pipe Liner: Point pipe liner may consist of any materials covered by this
specification when used to repair and rehabilitate an isolated portion of an existing storm drain
pipe. Materials which are restricted (as primary components) to point repair are; steel, which
shall meet the requirements of AASHTO M167M, ASTM A167, or ASTM A240; aluminum,
which shall meet the requirements of AASHTO M196, and rubber; which shall meet the
requirements of ASTM C923.
948-9.7 Coated Pipe Liner: Coated pipe liner consists of liquid, slurry, foam or gel that
is spread or sprayed over the interior surface of an existing pipe to rehabilitate it. Materials that
may be used for coating are hydrophilic urethane gel, epoxy resin, polyester resin, gunite,
shotcrete, low density cellular concrete, and cementious grout.
1063
SECTION 949
BRICK AND CONCRETE MASONRY UNITS FOR
MANHOLES, INLETS AND OTHER STRUCTURES
949-1 Clay Brick and Shale Brick.
This brick shall meet the requirements of AASHTO M114, for Grade MW.
949-2 Concrete Brick.
Concrete brick shall meet the requirements of ASTM C55 for Grade S-II.
949-3 Concrete Masonry Units.
Concrete masonry units for use in manholes, inlets and similar structures shall meet the
requirements of ASTM C139.
When the masonry units are produced by a manufacturer exercising quality control
procedures acceptable to the Department, such units may be accepted on the basis of six test
certificates furnished to the Department. Such certificates shall be signed by an authorized agent
of the manufacturer, and identified by project number.
1064
TIMBER PRODUCTS AND MATERIALS
SECTION 951
INSPECTION OF TIMBER PRODUCTS
951-1 Control of Quality.
All timber products manufactured for incorporation into the work shall be produced by a
producer/treater approved by the Department for such production. If approval is withdrawn by
the Department during production for a construction project, it is the Contractors responsibility
to (a) obtain another approved producer/treater to produce the timber products, or (b) await
reestablishment of approval of the disapproved producer/treater. Cost or delays associated with
producer/treater approval or disapproval shall be borne by the Contractor.
The producer/treater of timber products shall exercise quality control through an
approved Quality Control Plan conforming to Section 6-8. Products produced under this Quality
Control Plan will not relieve the Contractor of his responsibility for unsuitable materials or
workmanship, which might become apparent at the job site, nor of the necessity of his replacing
any material which might be determined upon subsequent inspection to be unsuitable.
951-2 Preparations Prior to Requesting Inspection.
Prior to the requested time of inspection for approval of a producer/treater, the authorities
of the treating plant shall become knowledgeable with the most current requirements of the
Departments Specifications as appropriate to his production/treatment. The producer/treater
shall make his facility totally accessible to appropriate Department's inspection personnel. Such
access for inspection shall include, but not be limited to, all physical artifacts and processes,
materials records and copies of certified shipping documents (such as a treatment certification, a
treating report, and an assay report). All calls for inspections shall be made at least two weeks in
advance.
Upon approval of a producer/treater facility, the Department will inspect the facility
periodically for continued approval.
951-3 Certification.
Each order/shipment to the job site must be accompanied with a notarized certification
indicating compliance to the appropriate specifications. The certification shall include: the
project/order number, charge numbers, and assay retention results. The producer/treater shall
maintain all pertinent documents for a period of three years. Each timber product must also have
a preapproved producer/treater identification mark on every item delivered to the job site.
1065
SECTION 952
STRUCTURAL TIMBER
952-1 General Specifications for All Structural Timber.
This Section specifies the requirements for pine timber to be used as structural members
in the Departments work, including untreated timber as well as timber to be treated. All such
timber shall be manufactured and graded in accordance with the current edition of the Standard
Grading Rules for Southern Pine Timber, of the Southern Pine Inspection Bureau. The
requirements of No. 1 dense shall apply to this timber.
952-2 Timber for Other Specific Uses.
952-2.1 Specification Grade: For timber to be used for columns, sills, wheelguards,
bulkhead, sheeting, bracing, fender wales, or any other purpose for which the grade is not
specified otherwise, the specification grade shall be as follows:
Nominal Thickness
1 to 1.5 inches
2 to 4 inches
5 inches and larger
Nominal Width
2 inches and wider
2 inches and wider
5 inches and larger
Grade
No. 1 Boards
No. 1 Dimension
No. 2 Timbers
952-2.2 Permissible Knot Sizes for Fender Wales: For timber used as fender wales, the
maximum permissible size of knot (at any point on any face) shall be as follows:
For nominal width of face of 10 - 3-3/4 inches.
For nominal width of face of 12 - 4-1/2 inches.
952-3 Untreated Pine Timber - Specific Requirement for Heartwood.
In addition to meeting all of the requirements of 952-1 and 952-2, pine timber which is to
be used as untreated timber will be required to show at least 85% of heartwood on any girth.
1066
SECTION 953
TIMBER PILING
(INCLUDING TIMBER SHEET PILING)
953-1 General.
Piles shall be of timber which will stand the driving for which they are intended. They
shall be sound and solid. Piling cut from southern pine shall contain at least 30% of summer
wood.
Cypress piles used for purposes other than as foundation piling shall have, at the butt, a
diameter of red or black heart of at least 12 inches.
Douglas fir used for timber piling shall be Pacific Coast Douglas Fir.
Piles shall be cut above the ground swell, shall have a form taper, and shall not vary more
than plus or minus 6 inches from the specified length.
Specific requirements for timber sheet piles are contained in 953-6.
953-2 Diameter of Butt and Tip.
For round piles the minimum butt diameter shall be 12 inches, measured at a section
3 feet from the end.
For piles up to 50 feet in length, the minimum tip diameter shall be 8 inches. For lengths
in excess of 50 feet, a graduated reduction in tip diameter at the rate of 1 inch for each 10 feet of
length in excess of 50 feet will be permitted. This reduction will correspond to 7 inch tips for
60 foot piles and 6 inch tips for 70 foot pile; at which length these allowable reductions shall
cease. As an exception to the above, when so shown in the Plans, 7 inch diameter tips on timber
piles less than 60 feet in length will be accepted. No piles shall have tips less than 6 inches in
diameter. The maximum diameter at the cut-offs shall be 20 inches.
953-3 Straightness Requirements.
A straight line drawn from the center of the butt to the center of the tip shall not, at any
point, fall further away from the center of the pile than a distance equal to 1% of the length of
the pile.
The surface of the pile shall not contain kinks greater than 1 inch in 5 feet, as measured
by a straightedge.
953-4 Peeling and Trimming.
The pile shall be peeled soon after cutting. In the operation of removing the bark from the
pile, not more than three annual rings of the solid wood shall be removed. All knots shall be
trimmed close to the body of the pile.
953-5 Permissible Knots and Other Defects.
The diameter of sound knots shall not exceed one-third of the diameter of the pile at the
point where the knot occurs.
In these Specifications, a sound knot shall be defined as a knot which is solid across its
face, is as hard as the surrounding wood and shows no indication of decay. It may vary in color
from red to black and may contain a pith hole not more than 1/4 inch in diameter.
An unsound knot may or may not be as hard as the surrounding wood, but contains
decay, and will be allowed only in accordance with the restrictions in ASTM D25.
1067
Any defect, or combination of defects, which would be more injurious than the maximum
allowable knot will not be acceptable.
Turpentine cuts will be allowed on all timber piles provided that no single cut shall
exceed one-half of the circumference of the pile, and that the length of the cut shall not be more
than 15% of the length of the pile. Piles to be used as outside piles in timber bents shall not have
more than one turpentine cut.
953-6 Timber Sheet Piles.
Unless a particular species of timber is called for in the Plans, timber sheet piles may
consist of any species which will satisfactorily stand driving. They shall be sawn with square
corners and shall be free from worm holes, loose knots, wind shakes, decayed or unsound
portions, and other defects which might impair the strength or tightness.
The piles shall be of the dimensions shown in the Plans and shall be treated in accordance
with Section 955.
1068
SECTION 954
TIMBER FENCE POSTS AND BRACES
954-1 Types of Timber, and Treating Requirements.
Timber fence posts and braces shall be of southern yellow pine and shall be treated in
accordance with Section 955.
Prior to the treatment, all knots on the posts shall be trimmed close to the body of the
post.
954-2 Requirements for Cutting.
Round or square posts will be permitted but all posts on a single project shall be the
same. The posts shall be cut from sound and solid trees and shall contain no unsound knots. The
butt shall be cut at a sufficient distance above the ground swell of the tree that there will be no
abrupt change in cross-section of the post.
The butts shall be sawn square. The post tops shall be sawn neatly and at right angles to
the vertical axis of the post.
954-3 Knots, etc.
Sound knots will be permitted provided the diameter of the knot does not exceed onethird of the diameter of the piece at the point where it occurs.
Peck (in cypress posts) shall be limited as provided for knots; the area of permissible
peck not exceeding the area occupied by permissible knots, and a combination of peck and knots
not exceeding the aggregate of knots allowed.
The posts shall be free from decayed wood, rot, and red heart, and of ring shake or season
checks which penetrate at any point more than one fourth the diameter of the piece, or are greater
than 1/4 inch wide.
954-4 Peeling.
All posts shall be peeled for their full length, and all inner and outer bark removed,
except that isolated strips of inner bark which do not exceed 1/2 inch in width or 3 inches in
length will be permitted.
954-5 Straightness.
The straightness of the post shall be such that for any 8 foot post (or for any 8 feet of
length, for longer posts) a straight line from the center of the tip to the center of the butt (or from
center of the cross sections at the extremes of the 8 foot lengths) shall not fall outside the center
of the mid-section of the 8 foot length by more than 2 inches.
954-6 Dimensions.
954-6.1 Minimum Lengths Allowable:
Line posts - 8 feet.
Corner and pull posts - 8 feet, 6 inches.
Braces - As required by the Plans.
(A tolerance of minus 1 inch to plus 2 inches will be allowed in the lengths shown
for the posts.)
954-6.2 Minimum Allowable Cross Section:
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Round line posts - 4 inch diameter.
Round braces, corner and pull posts - 5 inch diameter.
Square line posts - 4 inches by 4 inches.
Square braces, corner and pull posts - 5 inches by 5 inches.
The minimum diameters specified for round posts are applicable before
preservative treatment. When the treated post is inspected at the job site a tolerance of 3/8 inch
under such diameters will be allowed, to compensate for shrinkage resulting from treatment and
storage.
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SECTION 955
TIMBER TREATMENT
(INCLUDING TREATING MATERIALS)
955-1 General.
The work specified in this Section is the treating of structural timber, timber piling and
timber posts. The method of treatment for all such timber materials shall be in accordance with
the American Wood Preservers Association (AWPA) Use Category Standard (USC) - U1, with
the exceptions and additions as specified herein.
955-2 Preservative.
955-2.1 Salt or Brackish Water Use: The treating of Southern Yellow Pine (SYP)
lumber or timber for use in salt or brackish water environments shall be done with Chromated
Copper Arsenate (CCA).
955-2.2 Above Ground or Ground Contact and Fresh Water Immersion Use: The
treating of SYP lumber and timber for above ground or ground contact and fresh water
immersion applications, shall be done with Copper Azole-Type B (CA-B), Copper Azole-Type C
(CA-C), Amine Copper Quat-Type D (ACQ-D), or CCA, with the following exceptions:
Treatment of the wood products of the pedestrian bridges, wood rails at buildings
or rest areas, and fence posts shall be done either with Copper Azole-Type B (CA-B), Copper
Azole-Type C (CA-C), or Amine Copper Quat-Type D (ACQ-D).
955-3 Process.
All timber and lumber items shall be treated in accordance with Standard T1 of the
AWPA manual.
955-4 Requirements for Preservative Materials.
Amine Copper Quat-Type D (ACQ-D), Chromated Copper Arsenate (CCA), Copper
Azole-Type B (CA-B), Copper Azole-Type C (CA-C), Ammoniacal Copper Zinc Arsenate
(ACZA) shall be in accordance with AWPA P5.
955-5 Requirements for Retainment.
955-5.1 Piling: A minimum of 2.50 lb/ft3 of CCA oxides shall be retained in zone 1,
outer 0.50 inch, and 1.5 lb/ft3 in zone 2, outer 0.50 inches to 2 inches.
If ACZA is used, a minimum of 2.50 lb/ft3 shall be retained in zone 1, outer
0.50 inch, and 1.5 lb/ft3 in zone 2, outer 0.50 inches to 2 inches.
955-5.2 Structural Timber and Sheet Piles: When installation is not in a salt (or
brackish) water environment, the minimum retention shall be 0.60 lb/ft3 of CCA or ACQ-D or
0.31 lb/ft3 of CA-B or CA-C, as determined by cores from the outer 0.60 inch. When installation
is in a salt (or brackish) water environment, a minimum of 2.50 lb/ft3 of CCA oxides shall be
retained in the outer 0.60 inch.
All guardrail material (timber posts, blocks, wedges, etc.) shall retain a minimum
of 0.40 lb/ft3 of CCA or ACQ-D; 0.21 lb/ft3 of CA-B; or 0.15 lb/ft3 of CA-C in the outer 1 inch
zone.
955-5.3 Posts: Round/sawn timber fence posts shall retain a minimum of 0.40 lb/ft3 of
ACQ-D or 0.21 lb/f3of CA-B or 0.15 lb/ft3 of CA-C in the outer 1 inch zone.
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955-5.4 Determination of Retention: Retention shall be determined by assay performed
and certified by the treating company in accordance with the applicable AWPA standards.
955-6 Penetration Requirements.
955-6.1 For Structural Timber: The penetration of the treatment shall be in accordance
with the applicable AWPA standards, with the exceptions as specified herein.
955-6.2 For Round Piles and Fence Posts: Any round pile or post, which does not show
complete sapwood penetration will be rejected or shall be retreated to meet such penetration
requirement.
955-6.3 Retreatment: The necessity for retreatment of structural timber, piling and posts
shall be avoided as far as practicable and if it becomes apparent that due measures are not being
taken to prevent such necessity, the acceptance of retreated materials may be withdrawn.
When retreatment is necessary the maximum limits for temperature of steam or
preservative, and for preservative pressure, which apply to the original treatment shall not be
exceeded during the retreatment.
955-6.4 Determination of Penetration: Sapwood penetration shall be determined by
taking at least one increment boring core from each pile and cap, and other pieces of similar
dimensions and, for other sizes of material, at least one boring from the charge for each
1,000 FBM in the charge. All bored holes shall be immediately plugged, with tight fitting treated
plugs.
955-7 Handling Salt Treated Piling.
In handling of piles that have been treated with chromated copper arsenate or
ammoniacal copper arsenate, cable slings shall be used. Mechanical grabbers or pointed tools
shall not be permitted. Rough or careless handing shall be avoided at all times.
955-8 Identification of Treating Plants for Round Piling.
The treating plant shall brand, or place a distinctive permanent mark, on each round pile,
approximately 6 feet from the butt end, such that the plant responsible for the treatment can be
readily determined at any time during the service life of the piling.
1072
METAL MATERIALS AND FABRICATION DETAILS FOR METAL ITEMS
SECTION 960
POST-TENSIONING COMPONENTS
960-1 Description.
This Section covers all post-tensioning (PT) components remaining in a completed
structure, including temporary erection PT left in-place and permanent PT for design capacity.
Manufacturers seeking approval of PT systems for inclusion on the Structures Design
Office (SDO) list of Approved Post-Tensioning Systems must use materials and components
meeting requirements of this Section and Section 462. Submit a complete PT System Application
Package including component drawings, system drawings, and test reports from a certified
laboratory (or laboratories), as defined in 960-3.1, to the SDO for review, acceptance and
inclusion on the list of Approved Post-Tensioning Systems.
Any marked variations from original test values or any evidence of inadequate field
performance of a PT system, will result in the PT System being removed from the list of
Approved Post-Tensioning Systems.
960-1.1 Material References:
Meet the requirements of this Section and the following:
Epoxy Compounds .....................................................Section 926*
Bar (post-tensioning) .................................................Section 933
Post Tensioning Grout ...............................................Section 938*
Reinforcing Steel (mild) ............................................Section 415
Wire/Strand (post-tensioning) ....................................Section 933
*Use products listed on the Departments Qualified Products List (QPL).
960-2 Component Standards.
Substitution, modification, or deletion of components of PT systems as shown on the
SDO website for Approved Post-Tensioning Systems, excluding local zone reinforcement, is not
permitted. Inclusion of all possible subcomponents is required for PT system and component
testing; however, subcomponents of approved systems may be eliminated from final installations
based on project specific requirements, provided all component-to-component interface hardware
are included as necessary to maintain connections and PT system integrity.
Provide only PT systems utilizing tendons completely encapsulated in grout-filled
anchorages and ducts. Do not use systems transferring prestress force by bonding prestress steel
strand directly to concrete. Embedded anchors for bars are permitted. Systems utilizing formed,
un-grouted voids, or Diabolos, are not permitted. Strand or strand-tendon couplers are not
permitted.
Stamp all components of a PT system with the suppliers name, trademark, model number,
and size corresponding to catalog designation.
All miscellaneous hardware components, including but not limited to splices, joints, duct
couplers, connections, inlets, outlets, valves, and plugs, are part of approved PT systems.
960-2.1 Anchorage Assembly:
(a) Construct anchorages from ferrous metal per ASTM A536 Grade 65-45-12
minimum.
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(b) Anchorage shall develop at least 95% of PT steel guaranteed ultimate tensile
strength (GUTS) when tested in an unbonded state, without exceeding anticipated anchor set.
(c) Average concrete bearing stress shall be in compliance with AASHTO LRFD
Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications.
(d) Test anchorage with typical local zone reinforcement shown in system
drawings.
(e) Anchorages with grout outlets shall be suitable for inspection from either top
or front of anchorage. Anchorage may be fabricated to facilitate both inspection locations or may
be two separate anchorages of the same type, each providing singular inspection entry locations.
(f) Geometry of grout outlets must facilitate access for endoscope inspection
directly behind wedge plate using a straight 3/8 inch diameter drill bit.
(g) Ferrous metal components of an anchorage that are to be embedded in
concrete shall be galvanized in accordance with Section 962. Other anchorage assembly
components, including wedges, wedge plates, and local zone reinforcement need not be
galvanized.
(h) All anchorages shall have a permanent vented anchorage cap bolted to
anchorage.
960-2.1.1 Trumpets:
(a) Trumpets associated with anchorages shall be constructed from ferrous
metal galvanized per ASTM A123, polypropylene plastic, or polyolefin.
(b) Trumpet thickness at transition location shall be the thickness of the
duct or greater.
960-2.1.2 Wedges and Wedge Plates:
(a) Wedge plate shall be ferrous metal.
(b) Wedge plates must have centering lugs or shoulders to facilitate
alignment with bearing plate.
(c) For longitudinal tendons greater than four strands, design system with
separate wedge plate and anchorage plate.
960-2.2 Grout Containment Assembly:
960-2.2.1 Duct and Pipe:
(a) Use plastic duct, steel pipe, or a combination of plastic duct and steel
pipe in accordance with this Section.
(b) Ducts shall be manufactured by a seamless fabrication method.
Fabricate all duct splices to prevent kinks during all phases of construction.
(c) Do not alter the natural duct color that results from UV protected
polymer.
(d) Corrugated ferrous metal ducts are prohibited.
960-2.2.1.1 Internal Duct (Corrugated Plastic):
(a) PT systems used for tendons internal to concrete shall use
corrugated polypropylene plastic material except where steel pipe is required.
(b) Furnish ducts with minimum wall thickness as follows:
Table 2.2.1.1-1: Corrugated Plastic Duct Minimum Wall Thicknesses
Table 2.2.1.1-1: Corrugated Plastic Duct Minimum Wall Thicknesses
Duct Shape
Duct Diameter
Duct Thickness
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Flat
Round
Round
Round
Round
Round
Round
Round
Round
Any Size
0.9 inch
2.375 inch
3.0 inch
3.35 inch
4.0 inch
4.5 inch
5.125 inch
5.71 inch
0.08 inch
0.08 inch
0.08 inch
0.10 inch
0.10 inch
0.12 inch
0.14 inch
0.16 inch
0.16 inch
960-2.2.1.2 External Duct (Smooth Plastic):
(a) PT systems for tendons external to concrete shall use smooth
plastic duct.
(b) External PT system duct shall be polyethylene resin material.
(c) Duct shall have a maximum dimension ratio (DR) of 17 as
established by either ASTM D3035 or ASTM F714, as appropriate for manufacturing process
used.
(d) Smooth duct shall have a minimum pressure rating of 100 psi.
960-2.2.1.3 Steel Pipe:
Where specified in the Contract Documents and in all deviation
blocks, steel pipes shall be Schedule 40 and galvanized in accordance with Section 962.
960-2.2.1.4 Minimum Internal Diameter:
(a) For prestressing bars, duct shall have a minimum internal
diameter of 1/2 inches larger than bar outside diameter, measured across deformations.
(b) For prestressing bars with couplers, duct shall have a minimum
internal diameter of 1/2 inches larger than largest dimension of the largest enclosed element.
(c) For multi-strand tendons, ducts must have a minimum crosssectional area 2-1/2 times PT steel cross-sectional area.
960-2.2.1.5 Connections, Fittings, and Tolerance:
(a) Corrugated plastic duct connections shall be from polyolefin or
polypropylene material.
(b) Devices or methods (e.g., mechanical duct couplers, plastic
heat shrink sleeves) for all duct connections (e.g., splices, joints, couplings, connection to
anchorage), shall produce smooth interior alignment with no lips or kinks.
(c) Use of tape is not permitted to join or repair duct, connections,
or for any other purpose.
(d) Heat welding techniques to make splices between sections of
smooth plastic duct or to make connections with electrofusion duct couplers or other mechanical
duct couplers is permitted.
(e) For external tendons, mechanical duct coupler or a circular
sleeve made of Ethylene Propylene Diene Monomer (EPDM) material shall be used to make all
connections between plastic duct and steel pipe.
(f) Use a reducer when adjacent sections of duct are directly
connected to each other and the outside diameters vary more than plus or minus 0.08 inch.
(g) Provide all connections with a minimum pressure rating of
100 psi.
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(h) Provide EPDM sleeves with a minimum wall thickness of
3/8 inches and reinforced with a minimum of four ply polyester reinforcement.
(i) To connect EPDM duct couplers, use a 3/8 inch wide stainless
steel power seated band and clamps on each end of the EPDM duct couplers and circular sleeves.
Band capacity at installation must withstand 120 pounds seating force.
960-2.2.1.6 Segmental Duct Couplers:
(a) Include segmental duct couplers at joints of permanent internal
PT systems.
(b) Mechanical internal duct couplers shall be stainless steel,
plastic, or a combination of these materials.
(c) Plastic duct couplers shall be polyolefin or polypropylene
material.
(d) Metallic components must be stainless steel per 960-2.4.3.
(e) Segmental duct couplers shall mount perpendicular to the
bulkhead at segment joints.
(f) Segmental duct couplers shall be able to receive duct at an
angle of 6 degree deviation from perpendicular.
(g) Segmental duct couplers must be able to accommodate angular
deviation of duct without tendon strands touching duct or coupler on either side of segment joint.
(h) Ducts for prestressing, used exclusively for temporary erection
PT that is to be removed from structure, are not required to be coupled across segment joints.
960-2.2.1.7 O-Rings:
(a) O-ring duct coupler assemblies and segment seal mounting
assemblies shall be polyolefin material or polypropylene material.
(b) Standard O-ring material, for diameters less than or equal to
0.25 inches, shall conform to the requirements of the following table:
Table 2.2.1.7-1 "O"-Ring Material Properties (diameter 0.25 in)
Mechanical Properties
Shore hardness, ASTM D2240
Ultimate elongation %, ASTM D412
Tensile strength, ASTM D412
Accelerated Testing
Thermal Deterioration 70 hours @ 257 F, ASTM D573
Change in tensile strength
Change of elongation
Change of hardness
Compression Set Method B 22 hours @ 257 F, ASTM D395
Volume change due to absorption of H2O,
Method D, for 70 hours @ 212F, ASTM D 471
Environmental Resistance
Ozone Resistance Exposure Method B,
ASTM D1171
Low Temp. Non-brittle after 3 Min. @ -40F,
ASTM D2137
1076
50-75
250% min.
1400 psi min.
30%
-50%
15 points
50%
+ 10%
Pass
Pass
(c) Segment seal assemblies for compression seals with diameters
greater than .25 inches, used to couple ducts at segment joints shall conform to the requirements
in Table 2.2.1.7-1 with the additions and modifications in the following table:
Table 2.2.1.7-2 Large Diameter Compression Seals (diameter > 0.25 in)
Mechanical Properties
Shore hardness, ASTM D2240
Tensile strength, ASTM D412
Compression Set Method B 22 hours @ 257 F, ASTM D395
30-60
600 psi min.
60%
(d) Compression Force - Maximum force to compress O-ring to
its final compressed position shall not be greater than 25 psi, times the area encircled by Oring.
(e) Voided Area - Seal must accommodate material flow within its
own cross sectional area by using a hollow or voided design.
(f) Mounting Assemblies - Assemblies holding O-ring must
mount to form bulkhead and provide for duct alignment.
960-2.2.1.8 Heat Shrink Sleeves:
(a) Heat shrink sleeves shall have unidirectional circumferential
recovery and be sized specifically for duct size being coupled.
(b) Use irradiated and cross linked high density polyethylene
backing for external applications and linear-density polyethylene for internal applications.
(c) Use adhesive with the same bond value to steel and polyolefin
plastic materials.
(d) Heat shrink sleeves shall have an adhesive layer that meets the
requirements of the following table:
Table 2.2.1.8-1 Heat Shrink Sleeve Adhesive Layer Minimum Requirements
Property
Minimum Fully
Recovered Thickness
Peel Strength
Softening Point
Lap Shear
Tensile Strength
Hardness
Water Absorption
Color
Minimum Recovery
Operating Temperature
Minimum Requirements
Internal Application
External Application
Test Method
ASTM D 1000
ASTM E 28
DIN 30 672M
ASTM D 638
ASTM D 2240
ASTM D 570
Heat Recovery Test
1077
92 to 126 mils
111 mils
29 pli
162oF
87 psi
2,900 to 3,480 psi
46 to 48 Shore D
Less than 0.05%
Yellow or Black
33% to 58%
125F
46 pli
216F
58 psi
3,480 psi
52 Shore D
Less than 0.05%
Black
23%
150F
(e) Install heat shrink sleeves using procedures and methods
specified in the manufacturers instructions.
960-2.2.2 Attachments:
960-2.2.2.1 Anchorage Caps:
(a) Provide permanent anchorage caps made of stainless steel,
nylon, polyester, or Acrylonitrile Butadiene Styrene (ABS).
(b) Seal Anchorage cap with O-ring seals or precision fitted flat
gaskets placed against the bearing plate.
(c) Place a vent suitable for grout venting and inspection of the
content inside the anchorage cap from the top or front of the anchorage cap as appropriate (e.g.
anchorage caps not accessible after grouting must have a vent at the top of the cap). Anchorage
caps may be fabricated to facilitate both inspection locations.
(d) Anchorage caps shall have a minimum pressure rating of
150 psi.
(e) Stainless steel bolts shall be used to attach cap to anchorage.
(f) Certified test reports documenting steel chemical analysis shall
be provided when stainless steel anchorage caps are used.
960-2.2.2.2 Inlets, Outlets, Valves, and Plugs:
(a) Provide permanent grout inlets, outlets, valves, and threaded
plugs made of nylon, polyolefin materials, or stainless steel.
(b) All inlets and outlets shall have pressure rated mechanical
shut-off valves or plugs.
(c) Inlets, outlets, valves, and plugs shall have a minimum pressure
rating of 150 psi.
(d) Inlets and outlets shall have a minimum inside diameter of
3/4 inches for strand and 3/8 inches for single bar tendons and four-strand ducts.
(e) Dual in-line mechanical shutoff valves are required for vertical
grouting systems.
(f) Specifically designate temporary items, not part of the
permanent structure, on PT system drawings.
960-2.3 Steel Reinforcing:
960-2.3.1 Mild:
(a) Reinforcing steel shall conform to Section 415 and Section 462.
(b) Test typical local zone reinforcement for compliance with AASHTO
LRFD Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications, as
applicable. Include reinforcement details in system drawings submitted for system approval.
960-2.3.2 Prestressing:
960-2.3.2.1 Strand:
Prestressing strands shall be in accordance with Section 933.
960-2.3.2.2 Bar:
(a) Prestressing bars shall be in accordance with Section 933.
(b) Bar couplers shall be in compliance with AASHTO LRFD
Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications.
(c) Use only spherical nuts to anchor bars at bearing plates.
960-2.4 PT System Materials:
1078
(a) Use material specifications in this Section for all PT system components and
subcomponents.
(b) Use only virgin material for all non-ferrous components. Do not use any
components manufactured from recycled material unless the manufacture provides data
supporting the material performance and oxidation properties meet or exceed that of virgin
material.
(c) Test only samples taken from finished product as applicable.
960-2.4.1 Nylon:
Use one of the following cell classes according to ASTM D5989:
(a) S-PA0141 weather resistant.
(b) S-PA0231 heat stabilized.
(c) S-PA0401 ultimate strength not less than 10,000 psi with UV
stabilizer added.
960-2.4.2 Polyolefin:
Conforms to both of the following:
(a) Contains antioxidants with a minimum Oxidation Induction
Time (OIT) according to ASTM D3895 of not less than 20 minutes.
(b) Remolded finished material has a minimum failure time of
three hours when tested for stress crack resistance using ASTM F2136 at an applied stress of
348 psi.
960-2.4.3 Stainless Steel:
Conforms to the following:
(a) ASTM A240 Type 316 - for metallic components other than
bolts.
(b) ASTM A193 Grade B8M Type 316 - for bolts.
960-2.4.4 Polypropylene:
Conforms to all of the following:
(a) Non-colored, unfilled polypropylene according to
ASTM D4101 with a cell class range of PP0340B44541 to PP0340B67884.
(b) Contains antioxidants with a minimum Oxidation Induction
Time (OIT) according to ASTM D3895 of not less than 20 minutes.
(c) Contains a non-yellowing light stabilizer.
960-2.4.5 Polyethylene Resin:
Conforms to all of the following:
(a) Meets requirements of ASTM D3350 with a minimum cell
class of 344464C.
(b) Contains antioxidants with a minimum Oxidation Induction
Time (OIT) according to ASTM D3895 of 40 minutes.
960-2.4.6 Ethylene Propylene Diene Monomer (EPDM):
Meets requirements of ASTM D1171 using Ozone Chamber Exposure
Method B (no cracks permitted under 2X magnification).
960-3 System Pre-Approval Requirements.
960-3.1 Independent Testing:
Use independent laboratories meeting the credentials described in this Section to
perform all testing and to provide certified test reports for materials and components.
1079
Certification may be performed by a qualified independent laboratory outside of the United
States, only if the facility is pre-approved by the State Materials Office.
Conform all testing procedures used for materials or components to applicable
American Society of Testing and Materials (ASTM) and International Federation of Structural
Concrete (fib) Specifications or as modified in this Section.
960-3.1.1 Material Laboratory:
Test plastic components in a certified independent laboratory accredited
through the laboratory accreditation program of the Geosynthetic Accreditation Institute (GAI)
or the American Association for Laboratory Accreditation (A2LA).
960-3.1.2 Component and System Laboratory:
Test individual components and the PT system as a whole witnessed by
and/or in a certified independent laboratory audited by the AASHTO Materials Reference
Laboratory (AMRL).
960-3.2 Testing Requirements:
960-3.2.1 System Pressure Test:
(a) For each Family of PT systems, assemble system as detailed on the
system drawings and perform pressure tests defined in this Article. A family of PT systems is a
group of PT tendon/bar assemblies of various sizes using common anchorage devices and design.
(b) Perform tests on the largest assembly and the smallest assembly for
each family of PT systems.
(c) Include in system test at least one of each component required to install
a tendon from anchorage cap to anchorage cap.
(d) Include plastic duct to steel pipe connections and segment duct
couplers, if applicable.
960-3.2.1.1 Grout Containment Assembly Pressure Test:
(a) Assemble anchorage and anchorage cap with all required
grouting attachments (e.g., grout tube, valves, plugs, etc.).
(b) Seal opening in anchorage where duct connects.
(c) Condition assembly by maintaining a pressure of 150 psi in
system for three hours.
(d) After conditioning, assembly must sustain 150 psi internal
pressure for five minutes with no more than 15 psi, or 10%, reduction in pressure.
(e) Grout Containment Assembly Pressure Test requirement will
be considered satisfied for systems using same anchorages, anchorage caps, and grouting
attachments as a previously approved system as long as appropriate documentation from the
previous submittal and written certification is provided by system Supplier stating that identical
components are used in both assemblies.
960-3.2.1.2 External (Smooth) Duct Systems:
System testing for external (smooth) duct assemblies requires two
additional tests beyond the Grout Containment Assembly Pressure Test requirements:
(a) Anchorage and its connection to duct/pipe assembly must be
tested in accordance with and satisfy requirements for the Internal (Corrugated) Duct Systems,
where duct/pipe assembly consists of all components internal to concrete. Test assembly at
1.5 psi.
1080
(b) Duct/pipe assembly consisting of all external duct connections
(e.g., welded duct splices, duct-to-pipe connections, etc.) and grout vent must meet the
following:
(1) Use 15 feet of pipe length for test pipe assembly.
(2) Condition assembly by maintaining a pressure of
150 psi in system for three hours.
(3) After conditioning, assembly must sustain 150 psi
internal pressure for five minutes with no more than 15 psi, or 10%, reduction in pressure.
960-3.2.1.3 Internal (Corrugated) Duct Systems:
(a) Perform system test of assembly for compliance with
requirements of Chapter 4, Article 4.2, Stage 1 and Stage 2 Testing contained in fib Technical
Report, Bulletin 7 titled, Corrugated Plastic Duct for Internal Bonded Post-Tensioning.
(b) For bar systems, modify system test length to 15 feet.
(c) For systems being tested for use in precast segmental
construction, modify this test to include one duct coupler or O-ring assembly intended for use
at segment joint:
(1) Test duct coupler for proper function by casting it into a
two part concrete test block using match cast techniques. Use blocks that are at least 12 inches x
12 inches x 12 inches.
(2) After concrete has hardened, pull blocks apart and clean
surface of any bond breaker materials.
(3) Using an external apparatus, clamp blocks together and
maintain 40 psi pressure on block cross-section during pressure test. Do not apply epoxy
compound between blocks.
(4) Pressurize duct within test block to 5 psi and lock off
outside air source.
(5) Assembly must sustain a 5 psi internal pressure for five
minutes with no more than a 0.5 psi, or 10%, reduction in pressure.
(d) Remove clamping device, separate duct coupler blocks from
duct system, and place a 1/16 inch layer of epoxy compound (Type B per Section 926) on face of
both blocks, clamp blocks together, and maintain a pressure of 40 psi on block cross-section for
24 hours. Upon removal of clamping force, demolish blocks. Duct coupler and attached ducts
should be intact and free of epoxy compound and properly attached without crushing, tearing, or
other signs of failure.
960-3.2.2 Minimum Bending Radius:
Establish bending radius for duct through testing. Test consists of a
modified duct wear test as described in Chapter 4, Article 4.1.7 of fib Technical Report,
Bulletin 7 titled, Corrugated Plastic Duct for Internal Bonded Post-Tensioning. Use identical
test apparatus as that used for wear test with same clamping force as a function of number of
strands in a duct.
(a) Modify procedure as follows: After the specimen has reached
its final position, remove the specimen and confirm that the residual thickness is adequate. With
confirmation that the residual thickness is acceptable, immediately (within 30 minutes) reapply
the original clamping force for 14 days.
1081
(b) Upon completion of test, remove duct and measure wall
thickness along strand path. Wall thickness must not be less than 0.03 inches for duct up to
3.35 inches diameter and not less than 0.04 inches for duct greater than 3.35 inches diameter.
960-3.2.3 Additional Material Tests:
Ensure internal duct system components and accessories meet
requirements of Chapter 4, Articles 4.1.1 through 4.1.8 of International Federation of Structural
Concrete (fib) Technical Report, Bulletin 7 titled, Corrugated Plastic Duct for Internal Bonded
Post-Tensioning as modified below:
(a) Conduct lateral load resistance test (fib 4.1.4) without use of a
duct stiffener plate using a 150 pound load for all sizes.
(b) Wear resistance of duct (fib 4.1.7) as modified above.
(c) Bond length test (fib 4.1.8) must achieve 40% of GUTS in a
maximum length of 16 duct diameters.
960-3.3 Required Sizes:
Develop and test PT systems for both internal (corrugated duct) and external
(smooth duct) applications for the following:
(a) Department standard tendon sizes for designing and detailing consist of
0.6 inch diameter strand in anchorages containing 4, 7, 12, 15, 19, 27, and 31 strands.
(b) Standard bar sizes range from 5/8 inches to 2-1/2 inches diameter.
(c) Systems using alternate anchorage sizes and/or strands utilizing
1/2 inch strand and providing equivalent force to these standard sizes may be submitted for
approval.
960-3.4 System Modifications:
Contact the SDO for direction before attempting to change pre-approved PT
system materials or components. Repeat all appropriate material, component, and entire system
tests if any component of a pre-approved PT system is modified or replaced, excluding local
zone reinforcement. Submit an updated application to the SDO containing test reports and
revised system drawings for proposed modified systems.
960-3.5 Component Samples:
Furnish all required material samples to laboratory for testing and to the
Department as requested, at no cost to the Department.
960-3.6 Calculations, Drawings, and Certification:
Show fully detailed drawings of all component configurations, connections,
anchorages, inlets, outlets, high point outlet inspection details, anchorage inspection details,
permanent anchorage caps and application limits of the PT system for approval and posting on
the SDOs website for Approved Post-Tensioning Systems. Submit details of typical local zone
reinforcement in system drawings signed and sealed by a Specialty Engineer. Indicate that all PT
system components are stamped with (1) manufacturers name, (2) trademark model number,
and (3) size corresponding to catalog description on PT system drawings.
Provide an application package cover letter signed by an officer of the PT system
vendor certifying that the submitted PT system, as a whole and all of its individual components,
meet or exceed all material and component/system requirements of this Section, as demonstrated
by the submittal. Indicate in this certification that all testing required by this Section was
performed by a certified independent laboratory (or laboratories), as defined in 960-3.1, and that
all tests were performed to applicable ASTM and fib Specifications. Provide proof of current
1082
laboratory accreditation specifically indicating applicable accreditation categories related to PT
systems. Provide all material and component certifications required throughout this Section.
1083
SECTION 962
STRUCTURAL STEEL AND MISCELLANEOUS
METAL ITEMS (OTHER THAN ALUMINUM)
962-1 Structural Steel.
962-1.1 Structural Steel Materials: Unless otherwise specified in the Contract
Documents, provide structural steel for bolted or welded construction in accordance with
Structural Steel for Bridges, ASTM A709. If the grade is not shown in elsewhere in the Contract
Documents, provide the grade as directed by the Engineer. All grades, as specified in the
Contract Documents, are to conform to ASTM A709, as shown in Table 962-2.1 below:
Table 962-2.1 Structural Steel Materials
Product
Yield Strength
ASTM A709 Grade
Form*
(ksi)
36
P, S, B
36 min
50
P, S, B
50 min
50W
P, S, B
50 min
50S
S
50-65
HPS 50W
P, S
50 min
HPS 70W
P
70 min
100 [690](to 2-1/2 in)
100 min
P
(over 2-1/2 in)
90 min
100W [690W](to 2-1/2 in)
100 min
P
(over 2-1/2 in)
90 min
* P = plates, S = structural shapes, B = bars
Tensile Strength
(ksi)
58-80
65 min
70 min
65 min
70 min
85-110
130 min
130 min
130 min
130 min
962-1.2 Testing: For structural steel subjected to tensile stress used for main loadcarrying members or components (as defined in Section 460), meet the ASTM A709 impact test
requirements for non-fracture and fracture critical tension components as specified in the
Contract Documents. Meet the requirements for Zone 1 (Minimum Service Temperature 0F).
If not specified elsewhere in the Contract Documents, provide structural steel in
accordance with ASTM A709 requirements for non-fracture and fracture critical tension
components as directed by the Engineer.
962-2 Steel Castings.
962-2.1 Carbon Steel Castings: Provide carbon steel castings that conform to the
requirements of ASTM A27. Unless otherwise specified in the Contract Documents, all castings
are to be Grade 65-35 or Grade 70-36.
962-2.2 Corrosion Resistant Steel Castings: Provide corrosion resistant Iron-Chromium
or Iron-Chromium-Nickel castings that conform to the requirements of ASTM A743. Unless
otherwise specified in the Contract Documents, all castings are to be Grade CA 15M.
962-3 Steel Forgings.
Provide steel forgings from which pins, rollers, trunnions, shafts, gears, or other forged
parts are fabricated that conform to ASTM A668. Unless otherwise specified in the Contract
Documents, all forgings are to be Class C, D, F, or G.
1084
962-4 Iron Castings.
962-4.1 Gray Iron Castings: Provide gray iron castings that conform to the
requirements of ASTM A48. Unless otherwise specified in the Contract Documents, provide
gratings, manhole covers and frames to Class 35B and machinery parts to Class 30. For
manholes constructed within the area of vehicular traffic, the frames and gratings shall be
machine ground so the irregularity of contact will be minimized and the grates will be rattleproof.
962-4.2 Ductile Iron Castings: Provide ductile iron castings that conform to the
requirements of ASTM A536. Unless otherwise specified in the Contract Documents, provide
castings to Grade 414-276-18. In addition to the specified test coupons, test specimens from parts
integral with the castings, such as risers, are to be tested for castings with a mass more than
1,000 pounds to determine that the required quality is obtained in the castings in the finished
condition.
962-4.3 Malleable Iron Castings: Provide malleable iron castings that conform to the
requirements of ASTM A47. Unless otherwise specified in the Contract Documents, provide
castings to Grade 24118.
962-5 Bolts, Nuts and Washers Not Designated as High-Strength.
Provide bolts that conform to the requirements of ASTM A307 or ASTM A449. Provide
nuts that conform to the requirements of ASTM A563 and washers that conform to ASTM F436,
unless specified as ordinary rough or machine bolts as approved by the Engineer. Washers
provided to ASTM F844 and nuts to ASTM A194 may be used with the Engineers approval.
Use double nuts, when ordinary rough or machine bolts are specified in the Contract
Documents.
962-6 High-Strength Bolts, Nuts, Washers and Direct-Tension-Indicator (DTI) Devices.
Use high strength bolts, nuts, washers and DTI devices meeting the following
requirements:
Bolts: ASTM A325 or A 490, Heavy Hex. Only use ASTM A490 high strength
bolts with the approval of the Engineer.
Nuts: ASTM A-563, Heavy Hex. Select nuts in accordance with ASTM A325
(Subsection 3.2). If grade C, D or C3 nuts are selected, provide with a minimum Rockwell
hardness of 89 HRB or a minimum Brinell hardness of 180 HB. Use nuts meeting the
requirements of ASTM A194 only when approved by the Engineer.
Washers: ASTM F436 and ASTM A325 (Subsection 3.3). Use washers meeting
the requirements of ASTM F844 only when approved by the Engineer.
Identifying Marks: in accordance with ASTM A325, ASTM A490 and
ASTM A563.
DTI devices: meeting the requirements of ASTM F959. Furnish plain DTI devices
for use with plain bolts if the finish coat of paint is applied after installation and testing of the
DTI device and will cover the remaining gap. Otherwise, coat the DTI device in accordance with
the manufacturers recommendations.
When the Contract Documents call for uncoated weathering steel in any
component of the connected part, provide Type 3 bolts and washers, and nuts with weathering
characteristics. If one side of the assembly is coated and the other exposed weathering steel, coat
the fastener assembly on the coated side similarly (Such as the case for weathering steel tub
girders coated on the inside only).
1085
Ensure that fastener assemblies are properly lubricated in accordance with
ASTM A563 Supplementary Requirements S1 and S2.
962-7 Anchor Rods and Bridge Bearing Materials.
Provide anchor rods, washers, masonry plates, bearings and other miscellaneous metal
components that conform to the following requirements:
Provide anchor rods that conform to the requirements of ASTM F1554 unless the
Engineer approves the use of anchor rods meeting the requirements of ASTM A307, with nuts
that meet the requirements of ASTM A563, Hex Nuts, Heavy and with a finish consistent with
the rod. Nuts meeting the requirements of ASTM A194 may be used only with the Engineers
approval.
Use washers meeting the requirements of ASTM F436, with a finish consistent with the
rod. Washers meeting the requirements of ASTM A844 may be used only with the Engineers
approval.
962-8 Miscellaneous Metal Items.
Unless otherwise specified in the Contract Documents, provide the following specific
materials.
962-8.1 Pipe Railings: Provide steel pipe conforming to the requirements of ASTM A53
for Standard Weight Pipe.
962-8.2 Steel Sheet Piling: Provide steel sheet piles conforming to the requirements of
ASTM A328, ASTM A572 or ASTM A690.
962-8.3 Steel Sign Supports and Accessories: Provide steel members for sign supports
that meet the material requirements specified in the Contract Documents.
962-8.4 Structural Tubing:
962-8.4.1 Materials: Provide steel structural tubing as one of the following:
Cold-formed, welded or seamless conforming to the requirements of ASTM A500, Grade B or
C, coated in accordance with the Contract Documents;
Hot-formed, welded or seamless tubing conforming to the requirements of
ASTM A501, coated in accordance with the Contract Documents;
ASTM A847 when weathering characteristics are required; or
As indicated elsewhere in he Contract Documents.
962-8.4.2 Testing: Structural steel tubing subjected to tensile stresses used in
main load carrying members or components (as defined in Section 460) shall meet the impact
test requirements of ASTM A709 for non-fracture and fracture critical tension components for
Zone 1. Minimum Average energy shall be 15 ft-lbf at 70F (non-fracture critical); or 25 ft-lbf at
70F (fracture critical).
962-8.5 Steel for Concrete Reinforcement: Requirements for concrete reinforcement
are contained in Section 931.
962-8.6 Steel Guardrail: Requirements for steel guardrail are contained in Section 967.
962-8.7 Field Splice Filler Materials: Provide field splice filler materials in accordance
with the Contract Documents. If unspecified and less than 3/16 inches thick provide
ASTM A606 or ASTM A1011.
962-8.8 Steel Pipe Piling: Provide seamless, or longitudinal or helical welded pipe
conforming to the requirements of API 5L Grade L320, X46 or higher, or ASTM A252 Grade 3.
Provide longitudinal or helical welded pipe with only complete joint penetration (CJP) welds
conforming to the requirements of API 5L or AWS D1.1.
1086
962-9 Galvanizing.
962-9.1 Plates, Structural Shapes, Bars, and Strip: When galvanizing is specified in
the Contract Documents for ferrous metal products, other than fasteners and hardware items,
provide galvanizing in accordance with the requirements of ASTM A123, Specifications for Zinc
(Hot-Dip Galvanized) Coatings on Iron and Steel Products.
962-9.2 Fasteners and Hardware: When zinc coating is required in the Contract
Documents, fasteners and hardware items shall be galvanized in accordance with the
requirements of ASTM A153, Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware, except for high strength fasteners as noted below:
1. Do not galvanize ASTM A490 bolts.
2. Mechanically galvanize ASTM A325 Type 1 bolts in accordance with
ASTM B695, Class 50.
3. For all anchor rods and hardware treat the coated rods, nuts and washers with
chromate after coating in a water solution containing 0.2% sodium dichromate
3 ounces/10 gallons. Coat the bolt, nut and washer used in the fastener assembly by the same
zinc process, and provide a test report on the zinc coating thickness.
4. For anchor rods fabricated from material having a yield strength greater than
80,000 psi apply an electroplated zinc coating SC 3, Type II in accordance with ASTM B633.
962-9.3 Qualifications of Galvanizer: Use galvanizers listed on the Departments
Qualified Providers List (QPL). Listing must occur prior to commencing the work.
962-10 Certifications and Verification.
962-10.1 General: Supply a certified mill analysis to the Engineer for all metal materials
to be used in fabrication, including but not limited to plates, bars, shapes, and fasteners in
accordance with their respective ASTM or AASHTO specification. Show or attach the full and
complete designation of the project for which the materials are intended for use and specifically
cross-identify each furnished piece to the order material.
Material meeting equivalent AASHTO and ASTM specifications may be supplied
under either specification. Provide materials in accordance with the latest edition of the
specifications shown below, as approved by the Engineer.
962-10.2 Conformance: The certified mill analysis will indicate that the material is in
conformance with the applicable material specification and will include actual values from
required tests. Check the certified mill analysis against the appropriate specification to ensure
that materials conform to Contract Documents.
962-10.3 Certified Mill Analysis Source: The certified mill analysis must originate from
the producer of the material and not from a supplier. Material from stock may only be accepted if
it can be positively identified and the appropriate documentation is provided.
962-10.4 Verification Samples: Provide verification samples in accordance with
Section 6.
962-11 Heat Treatments.
Provide procedures and perform heat treatments in accordance with Section 460.
1087
SECTION 965
GENERAL PROVISIONS FOR ALUMINUM ITEMS
(Including Welding)
965-1 Surface Appearance and Protection.
The exterior surfaces of aluminum castings, pipes, tubes, formed sheets, and structural
shapes shall, when placed in the work, have a clean, uniform silvery appearance, free of dark
streaks and discoloration.
Aluminum members (including specifically aluminum light poles and signs poles) which
are of such size or shape that the surfaces might be marred during transit and prior to their being
installed, shall be appropriately and adequately protected against such damage, by wrapping with
paper or by other effective means.
965-2Certification and Mill Analysis.
For aluminum materials used, submit to the Engineer, prior to installation, a certified mill
analysis and certification by the producer that the parts and components are of the alloys
specified and comply with the requirements of this Section.
965-3 Welding Aluminum Sign Structures.
The proportioning of weld details and the operation of welding, for aluminum sign
structure, shall be in accordance with Section 5 of the AASHTO Standard Specifications for
Structural Supports for Highway Signs, Luminaries and Traffic Signals; ANSI and AWS D1.2
Structural Welding Code - Aluminum, including the requirements for qualifications of
procedures and welders, as specified therein.
(a) Alloys: The aluminum alloys to welded under these specifications may be any
of the following alloys:
Wrought Nonheat-treatable Alloys:
Alloy 3003
Alloy Alclad 3004
Alloy 5052
Alloy 5083
Alloy 5086
Alloy 5456
Wrought Heat-treatable Alloys:
Alloy 6061
Alloy 6063
Cast Heat-treated Alloy
Alloy SG-70A (ASTM Designation)
(b) Filler Metals: The filler metals to be used with particular base metals shall be
as shown in the table below except that other filler metals may be used if approved by the
Engineer.
Base Metal
3003 to 3003
Alclad 3004 to Alclad 3004
Filler Metal
ER1100
ER4043
1088
Base Metal
5052 to 5052
5083 to 5083
5086 to 5086
5456 to 5456
6061 to 6061
6063 to 6063
SG-70A to 6061
SG-70A to 6063
Filler Metal
ER5356*
ER5183
ER5356*
ER5556
ER5356*
ER5356*
ER4043
ER4043
*ER5183, ER5356, and ER5556 may be used interchangeably for these base metals.
965-4 Welding Aluminum Structures Other Than Sign Structures.
The welding of aluminum structures, other than sign structures, such as aluminum bridge
and railing structures and their aluminum components, shall be in accordance with ANSI and
AWS D1.2 Structures Welding Code-Aluminum, including the requirements for qualifications
of procedures and welders, as specified therein.
1089
SECTION 967
RAIL ELEMENTS FOR GUARDRAIL
967-1 Steel Guardrail.
Steel guardrail materials shall meet the requirements of AASHTO M180, (except as
specified below), and for either Class shown. Type 2 zinc coating will be required.
As an exception to the requirements of AASHTO M180, the coating properties,
sampling, test methods, inspection, and certification related to galvanizing regardless of the
method of galvanization of the rail elements shall meet the requirements of ASTM A123.
All supports, fastenings and other accessories, including bolts, nuts, washers, etc., (and
including the steel trailing end-anchorage rods required to be used with aluminum guardrail)
shall be galvanized as specified in ASTM A153.
Acceptance of steel guardrail materials shall be based on manufacturers certified mill
analysis of test results meeting the specification limits of the ASTM or AASHTO designation as
stated above. Certification of these test values, representing each shipment of guardrail materials,
shall be provided to the Engineer for each project.
1090
PAVEMENT MARKINGS, COATINGS AND RECYCLED MATERIAL
(MISCELLANEOUS)
SECTION 970
MATERIALS FOR RAISED RETROREFLECTIVE PAVEMENT
MARKERS AND BITUMINOUS ADHESIVE
970-1 Raised RetroReflective Pavement Markers (RPM).
970-1.1 Composition: The marker shall consist of materials conforming to
ASTM D4280.
970-1.2 Physical Requirements: The physical size of the RPM shall conform to the
requirements of ASTM D4280. Laboratory and field samples for RPMs and bituminous
adhesives shall meet the requirements of ASTM D4280 and include the following requirements:
The minimum area of each reflective face shall be 2.5 square inches. The
minimum base size shall be 12 square inches.
970-1.2.1 Designation of Marker Type, Color and Classification: The marker
description shall be in order of type, color and reflective surface condition in accordance with
ASTM D4280 and the following chart.
Class
A
Description
Temporary marker
RPM Class
Expected Normal Service
Up to six months
Permanent marker
Long life
D
E
Work zone marker
Temporary work zone
Per project requirement
Up to five days
ASTM Surface Designation
none
H, hard abrasion resistant
lens
none
none
970-1.3 Performance Requirements: The RPM shall meet the performance
requirements specified in ASTM D4280, Section 6.2, for luminous intensity, flexural strength,
compressive strength, resistance to cracking, and thermal cycling, as modified herein. Test
method FM 5-566 will be used to evaluate marker performance.
970-1.3.1 Class A Markers: Meet the coefficient of luminous intensity
requirements of ASTM D4280. Abrasion treatment is not required for Class A Markers.
970-1.3.2 Class B (Abrasion Resistant) Markers: Meet the coefficient of
luminous intensity requirements of ASTM D4280 after abrasion. Each marker shall be marked as
abrasion resistant by the manufacturer.
970-1.3.3 In-service Minimum Reflective Intensity: The Class B reflective
pavement marker shall retain a minimum coefficient of luminous intensity for 18 months of not
less than 30% of the values shown in Table 1 of ASTM D4280, and a minimum luminous
intensity of 0.2 cd/fc at the end of two years.
970-1.4 Application Properties: Application properties shall meet the requirements of
Section 706.
970-1.5 Packaging and Labeling: Shipment shall be made in containers which are
acceptable to common carriers and packaged in such a manner as to ensure delivery is in perfect
1091
condition. Each package shall be clearly marked as to the name of the manufacturer, type, color,
quantity enclosed and date of manufacture. Show the designation of the marker in accordance
with ASTM D4280.
970-2 Bituminous Adhesive for Pavement Markers.
970-2.1 General: Bituminous adhesive as recommended by the marker manufacturer
shall be used for bonding the markers to the pavement.
970-2.2 Specific Requirements for Bituminous Adhesives: The bituminous adhesive
shall meet the properties of adhesives per ASTM D4280 Section A1, including filler-free and
filler alone properties.
970-2.3 Performance Requirements: The performance of the adhesive shall be
determined in accordance with the test methods listed in ASTM D4280.
970-3 Product Acceptance on the Project.
Acceptance will be made in accordance with the requirements of Section 706.
Manufacturers seeking evaluation of their product shall submit an application in accordance with
Section 6.
1092
SECTION 971
TRAFFIC MARKING MATERIALS
971-1 General Requirements.
971-1.1 Packaging and Labeling: All traffic marking materials shall be shipped in
strong containers plainly marked with the weight in pounds per gallon, the volume of traffic
marking materials content in gallons, the color, user information, date of manufacture, batch and
DOT code number. Each batch manufactured shall have a unique number. A true statement of
the percentage composition of the pigment, the proportion of pigment to vehicle, and the name
and address of the manufacturer, also shall be shown. The label shall warn the user of any special
handling or precautions of the material, as recommended by the manufacturer. Any package not
so marked will not be accepted for use under these specifications.
Preformed thermoplastic materials and permanent tape products shall be marked
with content, color, date of manufacture and batch number.
971-1.2 Storage: Any traffic marking materials which, although inspected and approved
at the point of manufacture, hardens or livers in the containers so that it cannot be readily broken
up with a paddle to a smooth, uniform painting consistency, will be rejected. All materials shall
have a container storage life of one year from date of manufacture. Any traffic marking materials
not acceptable for proper application will be rejected, even though it conforms to these
Specifications in all other respects.
971-1.3 Mixing: All paints shall be delivered to the project completely mixed, and ready
to be used without additional oil or thinner. Gasoline shall not be used for thinner under any
circumstances.
971-1.4 Qualified Products List (QPL): All traffic marking materials shall be one of the
products listed on the Departments Qualified Products List (QPL). Manufacturers seeking
evaluation of their product shall submit an application in accordance with Section 6 accompanied
by a copy of the infrared identification curve (2.5 to 15 m) for the vehicle component. Products
may only be used for applications recommended by the manufacturer. A notation of the number
of coats and the thickness of each coat at which the product passes testing may be placed on the
QPL. When listed, this will be the minimum criteria for application of the traffic marking
material.
971-1. 5 Samples: Field samples will be obtained in accordance with the Departments
Sampling, Testing and Reporting Guide Schedule.
971-1. 6 Color: Materials for pavement markings shall meet the following performance
requirements.
The initial daytime chromaticity for yellow materials shall fall within the box
created by the following coordinates:
Initial Daytime Chromaticity Coordinates (Corner Points)
X
Y
1
0.530
0.456
2
0.510
0.485
3
0.455
0.444
4
0.472
0.400
The in-service daytime chromaticity for yellow materials shall fall within the box
created by the following coordinates:
In-Service Daytime Chromaticity Coordinates (Corner Points)
1093
X
Y
1
0.530
0.456
2
0.510
0.485
3
0.435
0.429
4
0.449
0.377
The nighttime chromaticity for yellow materials shall fall within the box created
by the following coordinates:
Nighttime Chromaticity Coordinates (Corner Points)
X
Y
1
0.575
0.425
2
0.508
0.415
3
0.473
0.453
4
0.510
0.490
971-1.7 Additional Requirements: Traffic stripe materials shall be characterized as nonhazardous as defined by Resource Conservation and Recovery Act (RCRA) 40 CFR 261 and the
material shall not exude fumes which are hazardous, toxic or detrimental to persons or property.
Provide supporting independent analytical data or product material safety data sheets (MSDS)
identifying nonhazardous designations.
Additionally, traffic stripe materials shall contain no more that 5.0 ppm lead by
weight when tested in accordance with the RCRA reference above. Provide supporting
independent analytical data.
971-2 Glass Spheres.
971-2.1 General Requirements: Glass spheres shall be of a composition designed to be
highly resistant to traffic wear and to the effects of weathering for the production of a reflective
surface, creating night visibility of the pavement markings without altering day visibility of the
marking. The general requirements of 971-1 apply to glass spheres.
971-2.2 Specific Properties: The large (Type 3 or larger) glass spheres used for drop on
beads shall have an adhesion coating. Type 1 glass spheres used for drop on beads shall have a
dual coating. Beads used in the intermix of materials are not required to be coated.
The following physical requirements apply:
Property
Roundness*
Test Method
Specification
ASTM D1155
Min: 70 % by weight
Roundness**
ASTM D1155
Refractive Index* Becke Line Method (25+/-5C)
Refractive Index** Becke Line Method (25+/-5C)
Min: 80% by weight
1.5 minimum
1.9 minimum
*Type 1, 3, 4 and 5 beads
**High Index beads
Sieve Size
No. 8
No. 10
No. 12
Percent by Mass Passing Designated Sieve (ASTM D1214)
Grading Designation
Type 1
Type 3 (FP 96) Type 4 (FP 96) Type 5 (FP 96) High Index
(AASHTO)
100
100
95 - 100
100
95 - 100
80 - 95
1094
Sieve Size
No. 14
No. 16
No. 18
No. 20
No. 25
No. 30
No. 40
No. 50
No. 80
No. 100
Percent by Mass Passing Designated Sieve (ASTM D1214)
Grading Designation
Type 1
Type 3 (FP 96) Type 4 (FP 96) Type 5 (FP 96) High Index
(AASHTO)
95 - 100
80 - 95
10 - 40
100
80 - 95
10 - 40
0-5
100
10 - 40
0-5
0-2
95 - 100
0-5
0-2
95 - 100
0-2
75 - 95
55 - 85
15 - 45
15 - 35
0-5
0-5
Provide the Engineer Certified test reports from the manufacturer confirming that
all glass spheres conform to the requirements of this Section.
971-2.3 Sampling:
971-2.3.1 Sampling: A random 50 lb sample of glass spheres shall be obtained
for each 50,000 lb shipped. Upon arrival, the quantity of material will be reduced in a sample
splitter to a size of approximately one quart by the Engineer, or one 50 lb unopened bag.
971-2.3.2 Containers: The spheres shall be furnished in new 50 lb moistureproof bags. All containers shall meet ICC requirements for strength and type and be marked in
accordance with AASHTO 247 Part 5.
971-3 Standard Waterborne Fast Dry Traffic Paint.
971-3.1 General: Standard waterborne fast dry traffic paints intended for use under this
Specification shall include water reducible products that are single packaged and ready mixed.
Upon curing, these materials shall produce an adherent, reflective pavement marking capable of
resisting deformation by traffic. The material shall have the capability of being cleaned and
flushed from the striping machines using regular tap water and any required rust inhibitors. The
manufacturer shall have the option of formulating the material according to his own
specifications. However, the requirements delineated in this Specification and Section 710 shall
apply regardless of the type of formulation used. The material shall be free from all skins, dirt
and foreign objects.
971-3.2 Composition:
Component
Total Solids, by weight
Pigments, by weight
Vehicle Solids % of Vehicle*
TiO2, Type II Rutile (white paint only)
Volatile Organic Content, (VOC)
Test Method
ASTM D2369
ASTM D3723
ASTM D476
ASTM D3960
Criteria
minimum 75%
minimum 57%
minimum 40%
minimum 1.0 lb/gal
maximum 150 g/L
*Vehicle Solids % of Vehicle = % total solids - % pigment
100 - % pigment
971-3.3 Physical Requirements: The material shall meet the following criteria:
1095
Property
Density
Viscosity at 77F
Fineness of Grind
Dry Opacity at
5 mils WFT
Bleed Ratio
Flexibility
Abrasion Resistance
Test Method
ASTM D1475
ASTM D562
ASTM D1210
Minimum
13.5 1.4 lb/gal
80 KU
3(HS)
Maximum
100 KU
ASTM D2805
0.92
ASTM D969
ASTM D522
Method B
971-3.3.2
0.95
Pass
Pass
971-3.3.1 Set To Bear Traffic Time: The material shall set to bear traffic in not
more than two minutes.
971-3.3.2 Abrasion Resistance: Test four samples per LOT using a Taber
Abrader. The paint shall be applied to specimen plates using a drawdown blade having a
clearance of 26 mils. Air dry each sample for 30 minutes and bake at 220F for 18 hours. Clean
with a soft brush and weigh each sample. Abrade samples for 1,000 cycles with 500 g weights
and CS-10 wheels. Clean the samples with a soft brush and weigh again. The average weight loss
for the four plates shall not exceed 50 mg per plate.
971-3.3.3 Retroreflectivity: The white and yellow pavement markings shall
attain an initial retroreflectance of not less than 300 mcd/lxm2 and 250 mcd/lxm2. The
retroreflectance of the white and yellow pavement markings at the end of the six month service
life shall not be less than 150 mcd/lxm2.
971-3.4 Packaging and Labeling: The traffic paint shall be placed in 55 gallon open-end
steel drums with a re-usable multi-seal sponge gasket. No more than 50 gallons of material shall
be placed in any drum to allow for expansion during transport and storage.
971-4 Fast Dry Solvent Traffic Paint.
971-4.1 General: Fast dry traffic paints intended for use under this Specification shall
include products that are single packaged and ready mixed. Upon curing, these materials shall
produce an adherent, reflective pavement marking capable of resisting deformation by traffic.
The manufacturer shall have the option of formulating the material according to his own
specifications. However, the requirements delineated in this Specification and Section 710 shall
apply regardless of the type of formulation used. The material shall be free from all skins, dirt
and foreign objects.
971-4.2 Composition:
Component
Test Method
Total Solids, by weight
ASTM D2369
Pigments, by weight
ASTM D3723
Vehicle Solids, % on Vehicle*
TiO2, Type II Rutile (white paint only) ASTM D476
Volatile Organic Content, (VOC)
ASTM D3960
Criteria
75% minimum
57% minimum
40% minimum
1.5 lb/gal minimum
150 g/L maximum
971-4.3 Physical Requirements: The material shall meet the following criteria:
1096
Property
Density
Viscosity at 77F
Fineness of Grind
Dry Opacity at
5 mils WFT
Bleed Ratio
Flexibility
Abrasion Resistance
Test Method
ASTM D1475
ASTM D562
ASTM D1210
ASTM D2805
ASTM D969
ASTM D522
Method B
971-4.3.2
Minimum
13.5 0.37 lb/gal
80 KU
3(HS)
Maximum
N/A
100 KU
0.92
0.95
Pass
Pass
971-4.3.1 Set To Bear Traffic Time: The material shall set to bear traffic in not
more than two minutes.
971-4.3.2 Abrasion Resistance: Test four samples per LOT using a Taber
Abrader. The paint shall be applied to specimen plates using a drawdown blade having a
clearance of 26 mils. Air dry each sample for 30 minutes and bake at 220F for 18 hours. Clean
with a soft brush and weigh each sample. Abrade samples for 1,000 cycles with 500 g and CS-10
wheels. Clean the samples with a soft brush and weigh again. The average weight loss for the
four plates shall not exceed 50 mg per plate.
971-4.3.3 Retroreflectivity: The white and yellow pavement markings shall
attain an initial retroreflectance of not less than 300 mcd/lxm2 and 250 mcd/lxm2, respectively.
The retroreflectance of the white and yellow pavement markings at the end of the six month
service life shall not be less than 150 mcd/lxm2.
971-4.4 Application Properties: Application properties shall meet the requirements of
Section 710.
971-4.5 Packaging and Labeling: The traffic paint shall be placed in 55 gallon open-end
steel drums with a re-usable multi-seal sponge gasket. No more than 50 gallons of material shall
be placed in any drum to allow for expansion during transport and storage.
971-5 Thermoplastic Materials for Traffic Stripes.
971-5.1 General: Upon cooling to normal pavement temperature, these materials shall
produce an adherent, reflective pavement marking capable of resisting deformation by traffic.
The manufacturer shall utilize alkyd based materials only and shall have the option of
formulating the material according to his own specifications. However, the requirements
delineated in this Specification and Section 711 shall apply regardless of the type of formulation
used. The pigment, glass spheres, and filler shall be well dispersed in the resin. The material
shall be free from all skins, dirt and foreign objects.
971-5.2 Composition:
1097
Component
Binder
TiO2, Type II Rutile
Glass Spheres
Test Method
ASTM D476
AASHTO T250
White
20.0% minimum
10.0% minimum
40.0% minimum
Yellow Pigment
Calcium Carbonate and Inert Filler (200 mesh sieve)
30.0% maximum
Yellow
20.0% minimum
40.0% minimum
% minimum per
manufacturer
37.5% maximum
Percentages are by weight.
The alkyd/maleic binder must consist of a mixture of synthetic resins (at least one
synthetic resin must be solid at room temperature) and high boiling point plasticizers. At least
one-half of the binder composition must be 100% maleic-modified glycerol of rosin and be no
less than 15% by weight of the entire material formulation.
971-5.3 Glass Spheres: The glass spheres in the intermix shall consist of 50% Type 1
and 50% Type 3. Glass spheres shall meet the requirements of 971-2.
971-5.4 Sharp Silica Sand: Sharp silica sand used for bike lane symbols and pedestrian
crosswalk lines shall meet the following gradation requirements:
Sieve Size
20
50
% Passing
100
0 to 10
971-5.5 Physical Requirements: Laboratory samples shall be prepared in accordance
with ASTM D4960 and shall meet the following criteria:
Property
Water Absorption
Softening Point
Low Temperature
Stress Resistance
Specific Gravity
Indentation Resistance
Impact Resistance
Flash Point
Test Method
ASTM D570
ASTM D36
Minimum
195F
Maximum
0.5%
-
AASHTO T250
Pass
Water displacement
ASTM D2240*
Shore Durometer, A2
ASTM D256, Method A
ASTM D92
1.9
2.3
40
75
1.0 Nm
475F
*The durometer and panel shall be at 110F with a 4.4 lb load applied. Instrument measurement shall be taken after 15 seconds.
971-5.5.1 Set To Bear Traffic Time: The thermoplastic shall set to bear traffic in not
more than two minutes.
971-5.5.2 Retroreflectivity: The white and yellow pavement markings shall attain an
initial retroreflectance of not less than 450 mcd/lxm2 and not less than 350 mcd/lxm2,
respectively. The retroreflectance of the white and yellow pavement markings at the end of the
three year service life shall not be less than 150 mcd/lxm2.
1098
971-5.5.3 Durability: Durability is the measured percent of thermoplastic material
completely removed from the pavement. The thermoplastic material line loss must not exceed
5.0% at the end of the service life.
971-5.6 Application Properties: Application properties shall meet the requirements of
Section 711.
971-5.7 Packing and Labeling: The thermoplastic material shall be packaged in suitable
biodegradable or thermo-degradable containers which will not adhere to the product during
shipment and storage. The container of thermoplastic material shall weigh approximately 50 lb.
The label shall warn the user that the material shall be heated in the range as recommended by
the manufacturer.
971-6 Preformed Thermoplastic Materials for Traffic Stripes.
971-6.1 General: Upon cooling to normal pavement temperature, these materials shall
produce an adherent, reflective pavement marking capable of resisting deformation by traffic.
The manufacturer shall have the option of formulating the material according to his own
specifications. However, the requirements delineated in this Specification and Section 711 shall
apply regardless of the type of formulation used. The pigment, glass spheres, and filler shall be
well dispersed in the resin. The material shall be free from all skins, dirt and foreign objects.
971-6.2 Composition: The preformed thermoplastic shall consist of high quality
materials, pigments and glass spheres or other reflective material uniformly distributed
throughout their cross-sectional area, with a reflective layer of spheres or other reflective
material embedded in the top surface.
971-6.3 Glass Spheres: Material shall contain no less than 30% glass spheres by weight.
971-6.4 Color: Materials shall meet the performance requirements specified in 971-1 and
the following additional requirements. The initial luminance factor, Cap Y, shall not be less
than 55.
971-6.5 Physical Requirements: Laboratory samples shall be prepared in accordance
with ASTM D4960 and shall meet the following criteria:
Property
Softening Point
Low Temperature
Stress Resistance
Indentation Resistance
Impact Resistance
Test Method
ASTM D36
Minimum
195F
Maximum
-
AASHTO T250
Pass
40
75
1.0 Nm
ASTM D2240*
Shore Durometer, A2
ASTM D256, Method A**
*The durometer and panel shall be at 110F with a 4.4 lb load applied. Instrument measurement shall be taken after 15 seconds.
**The test specimen for ASTM D256 shall be 1 in. x 1 in. x 6 in. and shall not be notched.
971-6.5.1 Retroreflectivity: The white and yellow pavement markings shall
attain an initial retroreflectance of not less than 300 mcd/lxm2. The retroreflectance of the white
pavement markings at the end of the three year service life shall not be less than 150 mcd/lxm2.
All pedestrian crosswalks, bike lane symbols and messages in a proposed bike lane shall attain
initial retroreflectivity of not less than 275 mcd/lxm2.
971-6.5.2 Skid Resistance: The surface of the stripes and markings shall provide
a minimum skid resistance value of 35 BPN (British Pendulum Number) when tested according
to ASTM E303. Bike lane symbols and pedestrian crosswalks shall provide a minimum skid
resistance value of 55 BPN.
1099
971-6.5.3 Durability: Durability is the measured percent of thermoplastic
material completely removed from the pavement. The thermoplastic material line loss must not
exceed 5.0% at the end of the service life.
971-6.6 Application Properties: Application properties shall meet the requirements of
Section 711.
971-6.7 Packing and Labeling: The thermoplastic material shall be packaged in suitable
biodegradable or thermo-degradable containers which will not adhere to the product during
shipment and storage.
971-7 Permanent Tape Materials for Pavement Stripes and Markings.
971-7.1 General: The materials for pavement stripes and markings shall consist of white
or yellow weather-resistant reflective film as specified herein. The markings are divided into two
classes: Standard and High Performance. The classes are differentiated by their durability and
retroreflectivity. The pigment, glass spheres, and filler shall be well dispersed in the resin.
However, the requirements delineated in this Specification and Section 713 shall apply. The
material shall be free from all skins, dirt and foreign objects.
971-7.2 Composition: The pavement stripes and markings shall consist of high-quality
plastic materials, pigments, and glass spheres uniformly distributed throughout their crosssectional area, with a reflective layer of spheres embedded in the top surface.
971-7.3 Skid Resistance: The surface of the stripes and markings shall provide a
minimum skid resistance value of 35 BPN when tested according to ASTM E303. Bike lane
symbols and pedestrian crosswalks shall provide a minimum skid resistance value of 55 BPN.
971-7.4 Thickness: The QPL will list the specified thickness of each approved product.
971-7.5 Durability and Wear Resistance: When properly applied, the material shall
provide neat, durable stripes and markings. The materials shall provide a cushioned resilient
substrate that reduces sphere crushing and loss. The film shall be weather resistant and, through
normal wear, shall show no significant tearing, rollback or other signs of poor adhesion.
Durability is the measured percent of pavement marking material completely removed from the
pavement. The pavement marking material line loss must not exceed 5.0% of surface area at the
end of its service life.
971-7.6 Conformability and Resealing: The stripes and markings shall be capable of
conforming to pavement contours, breaks and faults under traffic at pavement temperatures
recommended by the manufacturer. The film shall be capable of use for patching worn areas of
the same types of film in accordance with the manufacturers recommendations.
971-7.7 Tensile Strength: The stripes and markings shall have a minimum tensile
strength of 40 psi when tested according to ASTM D638. A rectangular test specimen 6 inches
by 1 inch by 0.05 inches minimum thickness shall be tested at a temperature range of 40 to 80F
using a jaw speed of 0.25 inch/min.
971-7.8 Elongation: The stripes and markings shall have a minimum elongation of 25%
when tested in accordance with ASTM D 638.
971-7.9 Plastic Pull test: The stripes and markings shall support a dead weight of 4 lb
for not less than five minutes at a temperature range of 70 to 80F. Rectangular test specimen
size shall be 6 inches by 1 inch by 0.05 inches minimum thickness.
971-7.10 Pigmentation: The pigment shall be selected and blended to provide a material
which is white or yellow conforming to standard highway colors through the expected life of the
stripes and markings.
971-7.11 Glass Spheres: The stripes and markings shall have glass retention qualities
such that, when at room temperature a 2 inches by 6 inches specimen is bent over a 0.5 inch
1100
diameter mandrel axis, a microscopic examination of the area on the mandrel shall show no more
than 10% of the spheres with entrapment by the material of less than 40%. The bead adhesion
shall be such that spheres are not easily removed when the film surface is scratched firmly with a
thumbnail.
971-7.12 Standard Markings: The preformed materials for pavement stripes and
markings shall have a service life of three year. The materials shall attain an initial
retroreflectance of not less than 300 mcd/lxm2 for white and contrast markings and not less than
250 mcd/lxm2, for yellow markings. The retroreflectance of the white, yellow and contrast
pavement markings at the end of the three year service life shall not be less than 150 mcd/lxm2.
All pedestrian crosswalks, bike lane symbols and messages in a proposed bike lane shall attain
initial retroreflectivity of not less than 275 mcd/lxm2.
971-7.13 High Performance Markings: The preformed materials for pavement stripes
and markings shall have a service life of five years. The materials shall attain an initial
retroreflectance of not less than 450 mcd/lxm2 for white and contrast markings and not less than
350 mcd/lxm2 for yellow markings. The pavement stripes and markings shall retain a minimum
retroreflectance for two years of not less than 300 mcd/lxm2 for white and contrast markings
and not less than 250 mcd/lxm2 for yellow markings. The retroreflectance of the white, yellow
and contrast pavement markings at the end of the five year service life shall not be less than
150 mcd/lxm2.
971-8 Two Reactive Component Materials For Traffic Stripes And Markings.
971-8.1 General: Two reactive component materials intended for use under this
Specification shall include, but not be limited to, epoxies, polyesters and urethanes. Upon curing,
these materials shall produce an adherent, reflective pavement marking capable of resisting
deformation by traffic. The manufacturer shall have the option of formulating the material
according to his own specifications. However, the criteria outlined in this Specification and
Section 709 shall apply regardless of the type of formulation used. The material shall be free
from all skins, dirt and foreign objects.
971-8.2 Composition:
Component
TiO2, Type II Rutile
(white material only)
Volatile Organic Content, (VOC)
Test Method
Criteria
ASTM D476
minimum 10% by weight
ASTM D3960
maximum 150 g/L
971-8.3 Physical Requirements: The material shall meet the following criteria:
Property
Adhesion to Concrete
Hardness
Abrasion Resistance
Test Method
ASTM D4541, ASTM D7234
or ACI 503
ASTM D2240 (Shore D)
971-8.3.2
Minimum
Maximum
Concrete Failure
75
Pass
971-8.3.1 Set To Bear Traffic Time: The material shall set to bear traffic in not
more than two minutes.
971-8.3.2 Abrasion Resistance: Test four samples per LOT using a Taber
Abrader. The material shall be applied to specimen plates using a drawdown blade having a
1101
clearance of 26 mils. Air dry each sample for 30 minutes and bake at 220F for 18 hours. Clean
with a soft brush and weigh each sample. Abrade samples for 1,000 cycles with 500 g weights
and CS-10 wheels. Clean the samples with a soft brush and weigh again. The average weight loss
for the four plates shall not exceed 50 mg per plate.
971-8.3.3 Retroreflectivity: The white and yellow pavement markings shall
attain an initial retroreflectance of not less than 450 mcd/lxm2 and not less than 350 mcd/lxm2,
respectively. The retroreflectance of the white and yellow pavement markings at the end of the
three year service life shall not be less than 150 mcd/lxm2.
971-8.4 Application Properties: Application properties shall meet the requirements of
Section 709.
971-8.5 Packaging and Labeling: The two reactive component material shall be placed
in 55 gallon open-end steel drums with a re-usable multi-seal sponge gasket. No more than
50 gallons of material shall be placed in any drum to allow for expansion during transport and
storage. Other containers will be used for applicable products. Each container shall designate the
color, generic type (e.g. epoxy), user information, manufacturers name and address, batch
number and date of manufacture. Each batch manufactured shall have a unique number. The
label shall warn the user of hazards associated with handling or using the material.
971-9 Thermoplastic Material for Audible and Vibratory Traffic Stripes.
971-9.1 General: Upon cooling to normal pavement temperature, the thermoplastic
material shall produce an adherent, reflective pavement marking capable of resisting deformation
by traffic. The manufacturer shall utilize alkyd based materials only and shall have the option of
formulating the material according to his own specifications. However, the requirements
delineated in this Specification shall apply regardless of the type of formulation used. The
pigment, reflective elements, and filler shall be well dispersed in the resin. The material shall be
free from all skins, dirt and foreign objects.
971-9.2 Composition:
Component
Binder
TiO2, Type II Rutile
Test Method
ASTM D476
Reflective Elements
AASHTO T250
White
20.0% minimum
10.0% minimum
% minimum per
manufacturer
Yellow Pigment
Calcium Carbonate and Inert Filler (200 mesh sieve)
% minimum per
manufacturer
Yellow
20.0% minimum
% minimum per
manufacturer
% minimum per
manufacturer
% minimum per
manufacturer
Percentages are by weight.
The alkyd/maleic binder must consist of a mixture of synthetic resins (at least one
synthetic resin must be solid at room temperature) and high boiling point plasticizers. At least
one-half of the binder composition must be 100% maleic-modified glycerol of rosin and be no
less than 15% by weight of the entire material formulation.
971-9.3 Retroreflective Elements: The reflective elements in the intermix shall be
determined by the manufacturer and identified for the QPL System.
971-9.4 Physical Requirements: Laboratory samples shall be prepared in accordance
with ASTM D4960 and shall meet the following criteria:
1102
Property
Water Absorption
Softening Point
Low Temperature
Stress Resistance
Specific Gravity
Indentation Resistance
Impact Resistance
Flash Point
Test Method
ASTM D570
ASTM D36
Minimum
210F
Maximum
0.5%
-
AASHTO T250
Pass
Water displacement
ASTM D2240*
Shore Durometer, A2
ASTM D256, Method A
ASTM D92
1.9
2.3
65
1.0 Nm
475F
*The durometer and panel shall be at 80F, but not exceeding 90F with a 4.4 lb load applied. Instrument measurement shall be
taken after 15 seconds.
971-9.4.1 Set To Bear Traffic Time: When applied at the temperatures and
thickness specified by Section 701, the baseline material shall set to bear traffic in not more than
two minutes. The audible bump shall set to bear traffic in not more than 10 minutes at ambient
air temperatures of 80F or less and in not more than 15 minutes for ambient air temperatures
exceeding 80F.
971-9.4.2 Retroreflectivity: The white and yellow pavement markings shall
attain an initial retroreflectance of not less than 300 mcd/lxm2 and not less than 250 mcd/lxm2,
respectively. The retroreflectance of the white and yellow pavement markings at the end of the
three year service life shall not be less than 150 mcd/lxm2.
971-9.4.3 Durability: Durability is the measured percent of thermoplastic
material completely removed from the pavement. The thermoplastic material line loss must not
exceed 5.0% at the end of the three year service life. Durability shall also include flattening of
the profile or raised portions of the line. The flattening of the profile or raised portion of the line
shall not exceed 25% at the end of the three year service life.
971-9.5 Application Properties: Application properties shall meet the requirements of
Section 701.
971-9.6 Packing and Labeling: The thermoplastic material shall be packaged in suitable
biodegradable or thermo-degradable containers which will not adhere to the product during
shipment and storage. The container of thermoplastic material shall weigh approximately 50 lb.
The label shall warn the user that the material shall be heated in the range as recommended by
the manufacturer.
971-10 Thermoplastic Material for Wet Weather Pavement Markings.
971-10.1 General: Upon cooling to normal pavement temperature, the thermoplastic
material shall produce an adherent, reflective pavement marking capable of resisting deformation
by traffic. The manufacturer shall utilize alkyd based materials only and shall have the option of
formulating the material according to their specifications. However, the requirements delineated
in this specification shall apply regardless of the type of formulation used. The pigment,
reflective elements, and filler shall be well dispersed in the resin. The material shall be free from
all skins, dirt and foreign objects.
971-10.2 Composition:
1103
Component
Binder
TiO2, Type II Ructile
Reflective Elements
(intermix)
Yellow Pigment
Calcium Carbonate
and Inert Filler (-200
mesh sieve)
Test Method
ASTM D476
AASHTO T250
White
20.0% minimum
10.0% minimum
% minimum per
manufacturer
N/A
% minimum per
manufacturer
Yellow
20.0% minimum
N/A
% minimum per manufacturer
% minimum per manufacturer
% minimum per manufacturer
Percentages are by weight.
971-10.3 Retroreflective Elements: The reflective elements in the intermix shall be
determined by the manufacturer and identified for the QPL System.
971-10.4 Physical Requirements: Laboratory samples shall be prepared in accordance
with ASTM D4960 and shall meet the following criteria:
Property
Water Absorption
Softening Point
Low Temperature
Stress Resistance
Specific Gravity
Indentation Resistance
Impact Resistance
Flash Point
Test Method
ASTM D570
ASTM D36
Minimum
200F
Maximum
0.5%
-
AASHTO T250
Pass
Water displacement
ASTM D2240*
Shore Durometer, A2
ASTM D256, Method A
ASTM D92
1.9
2.3
40
1.0 Nm
475F
*The durometer and panel shall be at 90F with a 4.4 lb load applied. Instrument measurement shall be taken after 15 seconds.
971-10.4.1 Set To Bear Traffic Time: When applied at the temperatures
and thickness specified by Section 702, the baseline material shall set to bear traffic in not more
than two minutes. When the audible bump is required, the bump shall set to bear traffic in not
more than 10 minutes at ambient air temperatures of 80F or less and in not more than
15 minutes for ambient air temperatures exceeding 80F.
971-10.4.2 Retroreflectivity: The white and yellow pavement markings
shall attain an initial dry retroreflectivity of not less than 300 mcd/lxm2 and not less than
250 mcd/lxm2, respectively, and also attain an initial wet recovery retroreflectivity of not less
than 150 mcd/lxm2 and not less than 125 mcd/lxm2, respectively. The dry retroreflectance of
the white and yellow pavement markings at the end of the three year service life shall not be less
than 150 mcd/lxm2, and also the wet recovery retroreflectivity at the end of the service life shall
not be less than 75 mcd/lxm2. The retroreflectivity will be determined in accordance with
Florida Method FM-5-541 for dry and ASTM E2177 (Bucket Method) for wet recovery.
971-10.4.3 Durability: Durability is the measured percent of
thermoplastic material completely removed from the pavement. The thermoplastic material line
loss must not exceed 5.0% at the end of the three year service life. When an audible bump is
required, durability shall also include flattening of the profile or raised portions of the line. The
flattening of the profile or raised portion of the line shall not exceed 25% at the end of the three
year service life.
1104
971-10.5 Application Properties: Application properties shall meet the requirements of
Section 702.
971-10.6 Packing and Labeling: The thermoplastic material shall be packaged in
suitable biodegradable or thermo-degradable containers which will not adhere to the product
during shipment and storage. The container of thermoplastic material shall weigh approximately
50 lb. The label shall warn the user that the material shall be heated in the range as recommended
by the manufacturer.
1105
SECTION 972
RECYCLED PLASTIC PRODUCTS
972-1 Description.
Recycled plastic products shall include certified test reports from an approved
independent test laboratory that shows the material meets all specifications herein and the
manufacturer shall certify the following:
a. The source of the recycled plastic waste, including the state (FL, GA, etc.) from
which the recycled plastic was obtained, and type of waste (consumer or industrial).
b. The total percent of recycled plastic in the final product.
972-2 Definitions.
972-2.1 Recycled Plastic: Those plastics composed of post-consumer material or
recovered industrial material only, or both, that may or may not have been subjected to
additional processing steps designed to afford products such as regrind or reprocessed or
reconstituted plastics.
972-2.2 Post-Consumer Materials: Those products generated by a business or
consumer that have served their intended end use and that have since been separated or diverted
from solid waste for the purpose of collection, recycling, and re-disposition.
972-2.3 Recovered Material: Materials and by-products that have been recovered or
diverted from solid waste, but not including those materials and by-products generated from, and
commonly used within, an original manufacturing process.
972-3 Materials.
The materials used for recycled plastic products shall consist of a minimum of 70% by
weight of recycled plastic. The products shall exhibit good workmanship and shall be free of
burns, discoloration, contamination, and other objectionable marks or defects which affect
appearance or serviceability. Only chemicals, including fillers and colorants, designed to inhibit
photo degradation, biological/biochemical decomposition, insect infestation, or burning will be
permitted to enhance durability. The use of sufficient additives to inhibit photo degradation over
the lifetime of the product is required.
972-4 Sampling.
One additional product per 1,000, or a minimum of one per order shall be included in the
order for Department testing.
1106
SECTION 973
STRUCTURAL PLASTICS
973-1 Description.
This work covers structural plastic components including fiberglass structurally
reinforced composite lumber (SCL) and smaller dimensional fiberglass fiber reinforced
composite lumber (FFRCL).
973-2 Product Acceptance.
Use only products listed on the Departments Qualified Products List (QPL).
Manufacturers seeking evaluation of products must submit an application in accordance with
Section 6 and include independently certified test reports that the material meets the
requirements of this Section.
In accordance with Section 6, provide manufacturers certification that the material meets
the requirements of this Section.
973-3 Materials.
Use polyethylene made from recycled post consumer or post industrial thermoplastics.
Mix the plastic with appropriate colorants, UV inhibitors, hindered amine light stabilizers and
antioxidants so that the resulting product meets the material property requirements specified in
Tables 1 and 2. Structural plastic must not corrode, rot, warp, splinter or crack. The skin must be
smooth and black in color unless otherwise specified in the Contract Documents. Skin is the
surface material exposed to the atmosphere. Core is the material that surrounds and bonds to the
fiberglass reinforcing rods. The use of separate materials for skin and core is at the discretion of
each manufacturer; however, if a single material is used, that material must meet the
requirements for both skin and core.
Manufacture structural plastic as one continuous piece with no joints or splices to the
dimensions and tolerances in accordance with Table 3. Interior voids shall not exceed 3/4 inches
in diameter. Structural plastic members shall be free of twist and curvature.
Reinforce 10 inch x 10 inch fiberglass structurally reinforced composite lumber with a
minimum of four 1-1/2 inch fiberglass reinforcing rods placed in the corners of the section.
Reinforcing rods must be continuous and offer a minimum flexural strength of 70.0 ksi
when tested in accordance with ASTM D4476 and a minimum compressive strength of 40.0 ksi
when tested in accordance with ASTM D695. Steel reinforcing rods are not permitted.
Reject any sections of structural plastic containing cracks or splits. Also, inspect the ends
of the reinforcing rods and reject any sections containing reinforcing rods with voids or cracks.
Add a minimum of 15% (by weight) chopped fiberglass reinforcement to the
polyethylene used for fiberglass structurally reinforced composite lumber and a minimum of
15% (by weight) chopped fiberglass reinforcement for smaller dimensional fiberglass fiber
reinforced composite lumber. The fiberglass reinforcement may be reduced when other means of
controlling cracking are specified with test results which show long term cracking is nonexistent.
Fiberglass structurally reinforced composite lumber must meet the minimum structural
properties listed in Table 4.
Smaller dimensional fiberglass fiber reinforced composite lumber must meet the
minimum physical properties listed in Table 5.
1107
Table 1
Plastic Material Properties - SCL
Density
ASTM D792
Skin
55-63 pcf
Density
ASTM D792
Core
4863 pcf
2 hrs:<1.0% weight increase
Water Absorption
ASTM D570
Skin
24 hrs:<3.0% weight increase
Brittleness temperature to be less
Brittleness
ASTM D746
Skin
than - 40C
ASTM D256
Impact Resistance
Skin
Greater than 0.55 ft-lbs/in
Method A (Izod)
Hardness
ASTM D2240
Skin
44-75 (Shore D)
ASTM D4329
Skin
500 hours<10% change in Shore D
Ultraviolet
UVA
Durometer Hardness
Skin/Core
ASTM D756 or
Sea Water
<1.5% weight increase
Chemical Resistance
ASTM D543
Gasoline
< 9.5% weight increase
No. 2 Diesel
<6.0% weight increase
Tensile Properties
ASTM D638
Core
Minimum 2200 psi at break
Compressive Modulus
ASTM D695
Core
Minimum 40 ksi
Static Coefficient of
ASTM D1894
Skin
Maximum 0.25, wet
Friction
Nail Withdrawal or
Minimum 60 lb (nail)
ASTM D6117
Skin/Core
Screw Withdrawal
Minimum 400 lb (screw)
Table 2
Plastic Material Properties - FFRCL
Density
ASTM D792
50-65 pcf
Impact Resistance
ASTM D256 Method A (Izod)
Greater than 2.0 ft-lbs/in
Hardness
ASTM D2240
44-75 (Shore D)
500 hours <10% change in
Ultraviolet
ASTM D4329 (UVA)
Shore D Durometer Hardness
ASTM D756 or ASTM D543
Sea Water
<1.5% weight increase
Chemical Resistance
Gasoline
<7.5% weight increase
No. 2 Diesel
<6.0% weight increase
Tensile Properties
ASTM D638
Minimum 3000 psi at break
Static Coeffecient of Friction
ASTM D2394
Minimum 0.25, wet or dry
Nail Withdrawal or
Minimum 250 lb (nail)
ASTM D6117
Screw Withdrawal
Minimum 400 lb (screw)
Structural Plastic
Length
Width SCL
Table 3
Dimensions and Tolerances
Dimension
Per order (80 ft Maximum)
See Contract Plans
1108
Tolerance
0/+6 inch
1/2 inch
Width FFRCL
Height SCL
Width FFRCL
Skin Thickness
Distance from outer surface
to center rebar elements (SCL)
Straightness (gap, bend or
inside while lying on a flat
surface)
3/16 inch minimum
1/4 inch
1/2 inch
1/4 inch
n/a
2 inches
1/2 inch
See Contract Plans
<1-1/2 inches per 10 feet
Table 4
Structural Properties for SCL
Member Size
Modulus of Elasticity
Stiffness, E.I.
Yield Stress in Bending
Weight
Modulus of Elasticity
Flexural Strength
Compressive Strength
Compressive Strength
Perpendicular to grain
ASTM D6109
ASTM D6109
ASTM D6109
10 inches x 10 inches
521 ksi
4.05E+08 lb-inch2
5.3 ksi
30-37 lb/ft
Table 5
Properties for FFRCL
ASTM D6109
ASTM D6109
ASTM D6108
300,000 psi
2,500 psi
2,200 psi
ASTM D6108
700 psi
The values stated in these tables are the required minimums.
1109
SECTION 975
STRUCTURAL COATING MATERIALS
975-1 General Requirements.
975-1.1 General: Upon curing, all coatings and/or coating systems must produce an
adherent coating that is visually uniform. The composition of the coating is left to the discretion
of the manufacturer but the finished product shall meet all requirements of this Section. All coats
of multi-coat systems shall be supplied by the same manufacturer. Multi-component coatings
shall be prepackaged in the required ratios.
975-1.2 Environmental Requirements: Coating materials and their waste shall be
characterized as non-hazardous as defined by Resource Conservation and Recovery Act (RCRA)
Subarticle C rules, Table 1 of 40 CFR 261.24 Toxicity Characteristic.
Volatile Organic Compounds (VOC) shall be less than 3.5 lb/gal when tested in
accordance with ASTM D3960.
975-1.3 Qualified Products List (QPL): All polymeric coating materials except the
materials in 975-4 shall be listed on the Departments Qualified Products List (QPL).
Manufacturers seeking evaluation of their products shall submit (1) the product data sheets, (2)
performance test reports from an independent laboratory showing the product meets the
requirements of this section, (3) a Product MSDS or performance test reports showing percent
weight compositional analysis including Chemical Abstract Number, ACGIH time weighted
average and ceiling exposure limits for all components, lower and upper explosive limits, flash
point, boiling point, amount of volatile organic compounds by weight, and specific gravity for
each component of the coating system, and (4) a QPL application in accordance with Section 6.
975-1.4 Packaging and Labeling: Materials shall be shipped in containers legibly
marked with application instructions, lot number, batch number, date of manufacture, shelf life,
and Department QPL number. Each lot or batch manufactured must have a unique number.
975-2 Structural Steel Coating Systems.
975-2.1 General: Structural steel coatings shall meet the application requirements of
Section 560.
975-2.2 Performance Requirements: Outdoor exposure testing will be performed by the
Department. Prepare four composite and four flat-scribed test panels in accordance with
AASHTO R-31 (Federal Standard 595B, Shade X6134 or X4062) and submit to the State
Materials Office. Also submit 1-quart wet samples of each component of each coating
incorporated in the system being evaluated. Panels will be exposed at the Departments outdoor
test site in accordance with ASTM G7. All coatings, regardless of color, shall meet the
requirements below.
Laboratory Testing
Property
Slip Coefficient
Test Method
AASHTO R31
Salt Fog Resistance
AASHTO R31
Cyclic Weathering
Resistance
AASHTO R31
Requirement
Min. Class B
(primer only)
Blister Size = 10
Average Rust Creep at the Scribe 0.1 inches
Blister Size = 10
Average Rust Creep at the Scribe 0.2 inches,
1110
Abrasion Resistance
AASHTO R31
Color Retention E 8, Gloss loss less than
30 units
Wear Index 2.7 mg/cycle
Adhesion
AASHTO R31
Avg. system tensile strength 800 psi
Freeze Thaw Stability
AASHTO R31
Avg. tensile strength 800 psi
Coatings
Fourier Transform Infrared IR scan (2.5 to 15 um) for each base, catalyst,
Identification
Spectroscopy
and mixed coating.
Greater than 25 inch/lbs, 1/2 impact,
Impact Resistance
ASTM D2794
intrusion
AASHTO R31,
Flexibility
ASTM D522,
No cracking
1 inch cylindrical mandrel
Outdoor Testing
Property
Test Method
Requirement
Rusting
ASTM D610
ASTM D1654 (scribed)
ASTM D1654 (un-scribed)
9 after 5 years
9 after 5 years
9 after 5 years
Blistering
ASTM D714
10 after 5 years
Adhesion
ASTM D4541;annex A4
800 psi (un-scribed area) after 5 years
Color Retention
ASTM D2244
E 8 after 2 years
Gloss
ASTM D523
30 gloss units after 2 years
975-2.3 Structural Steel Coating Systems for New Structures.
975-2.3.1 High Performance Coating Systems (Color Pigmented):
975-2.3.1.1 Prime Coat: Zinc dust pigment shall be a minimum of
Type II in accordance with ASTM D520. Inorganic zinc rich primers shall meet the requirements
of the Society for Protective Coatings (SSPC) Paint 20, Type I, Level 2.
975-2.3.1.2 Intermediate Coat: Intermediate coatings, when required by
the manufacturer, shall be a component of the full coating system.
975-2.3.1.3 Finish Coat: The finish coat shall provide the color and gloss
required for the completed coating system. A finish coat may be comprised of a single pigmented
coat or a pigmented coat with a clear coat. The clear coat shall contain a dissipating colorant.
The dissipating colorant shall be visible for a minimum of 12 hours after application and shall
completely dissipate within 96 hours after application.
1111
975-2.3.2 Inorganic Zinc Coating System: Zinc dust pigment shall be a
minimum of Type II in accordance with ASTM D 20. Inorganic zinc rich primers shall meet the
requirements of SSPC Paint 20, Type I, Level 2. The performance requirements for gloss and
color retention are not applicable.
975-2.3.3 Interior Box Girder Coating System:
975-2.3.3.1 Prime Coat: Inorganic zinc dust pigment shall be a minimum
of Type II in accordance with ASTM D520. Inorganic zinc rich primers shall meet the
requirements of SSPC Paint 20, Type I, Level 2.
975-2.3.3.2 Finish Coat: The finish coat shall be one coat of white
polyamide or cycloaliphatic amine epoxy coating. The performance requirements for gloss and
color retention are not applicable.
975-2.4 Structural Steel Coating Systems for Existing Structures.
975-2.4.1 Prime Coat: Zinc dust pigment shall be a minimum of Type II in
accordance with ASTM D520. Organic zinc rich primers shall meet the requirements SSPC
Paint 20, Type II, Level 2.
975-2.4.2 Intermediate Coat: Intermediate coatings, when required by the
manufacturer, shall be a component of the full coating system.
975-2.4.3 Finish Coat: Finish coating shall provide the color and gloss required
for the completed coating system. A finish coat may be comprised of a single pigmented coating
or a pigmented coating with a clear coat. The clear coat shall contain a dissipating colorant. The
dissipating colorant shall be visible for a minimum of 12 hours after application and shall
completely dissipate within 96 hours after application.
975-3 Galvanized Steel Coating System.
Coatings applied over galvanized steel shall meet the outdoor exposure requirements of
975-2.2 with the exception that test panels shall be galvanized in accordance with ASTM A123
prior to application of subsequent coatings.
Coatings applied over galvanized steel strain poles, mast arms, and monotube assemblies
shall meet the requirements of Section 649 and 975-4.
975-4 Painting Strain Poles, Mast Arms and Monotube Assemblies.
Paint systems used on galvanized steel strain poles, galvanized steel mast arms and
galvanized steel monotube assemblies shall meet the color requirements as specified in the
Contract Documents and shall exhibit no loss of adhesion or loss of color greater than 8Es for
five years after final acceptance as specified in 5-11. A galvanized steel strain pole, mast arm or
monotube assembly that exhibits a cumulative surface area of delamination in excess of
100 square inches will constitute an adhesion failure. Delamination shall be defined as any area
of exposed metal surface subsequent to hand tool cleaning in accordance with SSPC-SP2. A
change in the coating color in excess of 8Es per the CIE L*a*b* 1976 will constitute a color
retention failure. The Department will measure the CIE 1976 color chromaticity coordinates for
the color of the top coat of the two sample coupons provided with a BYK-Gardner Handicolor
colorimeter using D65 illuminant and 2 degree geometry settings. The Department-measured
L*a*b* chromaticity coordinates shall define the initial color and will be used for resolution of
color retention failures and the resolution of color retention disputes. All paint systems shall
possess physical properties and handling characteristics that are compatible with the application
requirements of Section 649. Materials shall be specifically intended for use over galvanized
steel.
1112
975-5 Elastomeric Coatings.
975-5.1 General: Use an elastomeric coating system to provide a waterproof barrier over
post-tensioning anchorages or other areas designated in the Plans. The components of the coating
system shall be supplied by a single manufacturer and sold as a waterproof coating system. The
surface preparation and application of the coating system shall be performed in strict accordance
with the manufacturers specifications.
975-5.2 Physical Properties: The use of an epoxy prime coat is dependent upon the
requirements of the manufacturers waterproofing system. The polyurethane chemistry may be
either waterborne aromatic (moisture-curing) or aromatic (moisture-sensitive). The minimum
thickness of the system shall not be less than 30 mils. The elastomeric coating shall meet the
following requirements:
Property
Hardness, Shore A
Tensile Strength
Elongation
Tear Strength
Abrasion Resistance H-18
wheels 1,000 gm/wheel
Crack Bridging 1,000 Cycles
Elongation Recovery
Test Method
ASTM D2240
ASTM D412
ASTM D412
ASTM C957
Requirement
Between 60 and 90
750 psi
400%
>70 pli
ASTM C957
350 mg loss / 1,000 revs.
ASTM C957
ASTM C957
System Passes
94%
975-5.3 System Modifications for Use on Bridge Substructure: Supply the elastomeric
coating system with a 100% acrylic aliphatic polyurethane top coating.
975-6 Class 5 Applied Finish Coatings.
975-6.1 General: All coatings shall possess physical properties and handling
characteristics compatible with the application requirements of Section 400. Unless otherwise
specified, the color of the finish coat shall meet Federal Color Standard No. 595, Table VIII,
Shade No. 36622, or No. 36642 for uncoated weathering steel bridges.
975-6.2 Coating Requirements: Use 4 inch by 8 inch (except as required below) fiber
cement test panels with a mass of 7 to 9 pounds per square foot of surface area to perform the
laboratory tests. Coating performance shall meet the following requirements:
Property
Resistance to Wind Driven
Rain
Freeze thaw resistance
Water Vapor Transmission
Abrasion Resistance
Laboratory Testing
Test Method
ASTM D6904
AASHTO R31
ASTM D1653; Method B,
Condition C
ASTM D968,
3,000 liters of sand
1113
Requirement
No visible water leaks, and if the
rear face of the block is damp, the
average gain in weight of the
three 8x16x2 blocks must be
less than 0.2 lb.
No disbondment
WVT10 perms
No loss of coating thickness
ASTM D6132
Property
Salt Spray (fog) resistance
Fluorescent UV-Condensation
Exposure
Fungal Resistance
Laboratory Testing
Test Method
ASTM B117, 2,000 hours
Requirement
No disbondment
No blistering (ASTM D714),
ASTM D4587, 2000 hours, cracking (visual), or delamination
4 hours UV, 4 hours
(visual). chalking
condensation
(ASTM D4214Method D) rating
no less than 8.
ASTM D3273
Rating of 10, ASTM D3274
Submit four fiber cement test panels and a 1 quart wet sample of each component
of each coating incorporated in the total system being evaluated. Prepare test panels by applying
the finished coating at a rate of 50 plus or minus 10 square feet per gallon. In addition,
completely seal the corners of all test panels with a high build epoxy or equivalent to prevent
moisture ingress at corners and cut edges.
975-7 Anti-Graffiti Coating Materials.
975-7.1 General Requirements: Anti-graffiti coatings intended for use under this
specification shall be of a composition capable of preventing the adhesion of and facilitating the
removal of acrylic, polyurethane, and alkyd spray paint. All anti-graffiti coatings shall possess
the physical and handling characteristics that are compatible with the requirements of
Section 563.
Anti-graffiti coatings shall contain less than 5.0 lb per gallon volatile organic
compounds (VOC) as defined by 40 CFR Part 59, Subpart D, and evaluated as per
ASTM D3960.
The manufacturer shall supply the following additional information:
a. Graffiti removal instructions, including any solvents or other materials,
as necessary. Graffiti removal must be accomplished with nonproprietary cleaners as defined in
ASTM D6578.
b. Sacrificial Coating Removal instructions, as applicable.
c. Identification of coating components.
975-7.2 Performance Requirements: For laboratory testing, use flat test panels prepared
in accordance with AASHTO R31. Outdoor exposure testing will be performed by the
Department. Submit four 4 inch by 8 inch fiber cement test panels to the State Materials Office.
Panels will be exposed at the Departments outdoor test site in accordance with ASTM G .
Laboratory Testing - Non-Sacrificial
Test Method
Requirement
No blistering, cracking, checking, chalking,
or delamination; color change less than
AASHTO R31
3 Delta E CIE LAB units; Retention of
60oGloss ratio >= 0.80
ASTM D6578. Complete
removal of solvent-based
Graffiti Resistance
acrylic, polyurethane, and
Cleanability Level 8, 9, or 10.
(solvent cleanable)
alkyd spray paint; after
exposure; and recleanability
Property
Cyclic Weather
Testing (solvent
cleanable and
water cleanable)
1114
Laboratory Testing - Non-Sacrificial
Property
Test Method
Requirement
ASTM D1308 Spot Test;
Fluid Resistance
No blistering, discoloration, softening or
Paint Thinner,
(solvent cleanable)
adhesion loss.
Gasoline
Outdoor Exposure Testing Non-Sacrificial
Property
Test Method
Requirement
ASTM G7:
Complete removal of solvent based acrylic,
Graffiti Resistance 6 months exposure at FDOT
polyurethane, and alkyd based spray paint.
(water cleanable)
test site
No delamination or visual defects.
2500 psi using pressure washer
Laboratory Testing - Sacrificial
Test Method
Requirement
AASHTO R31, no salt fog,
Cyclic Weather
95F, 0%- 90% Relative
No melting or disbondment
Testing
Humidity, 500 hours,
alternating RH every 100 hours
Outdoor Exposure Testing - Sacrificial
Property
Test Method
Requirement
Complete removal of solvent based acrylic,
Sacrificial Coating ASTM G7: 6 months exposure
polyurethane, and alkyd based spray paint
removability
at FDOT test site
from substrate
Property
1115
EROSION CONTROL MATERIALS
SECTION 981
TURF MATERIALS
981-1 General.
The types of seed and sod will be specified in the Contract Documents. All seed and sod
shall meet the requirements of the Florida Department of Agriculture and Consumer Services
and all applicable state laws, and shall be approved by the Engineer before installation.
All seed, sod and mulch shall be free of noxious weeds and exotic pest plants, plant parts
or seed listed in the current Category I List of Invasive Species from the Florida Exotic Pest
Plant Council (FLEPPC, http://www.fleppc.org ). Any plant officially listed as being noxious or
undesirable by any Federal Agency, any agency of the State of Florida or any local jurisdiction
in which the project is being constructed shall not be used. Any such noxious or invasive plant or
plant part found to be delivered in seed, sod or mulch will be removed by the Contractor at his
expense and in accordance with the law.
All materials shall meet plant quarantine and certification entry requirements of Florida
Department of Agriculture & Consumer Services, Division of Plant Industry Rules.
981-2 Seed.
The seed shall have been harvested from the previous years crop. All seed bags shall
have a label attached stating the date of harvest, LOT number, percent purity, percent
germination, noxious weed certification and date of test.
Each of the species or varieties of seed shall be furnished and delivered in
separate labeled bags. During handling and storing, the seed shall be cared for in such a manner
that it will be protected from damage by heat, moisture, rodents and other causes.
All permanent and temporary turf seed shall have been tested within a period of
six months of the date of planting.
All permanent and temporary turf seed shall have a minimum percent of purity and
germination as follows:
1. All Bahia seed shall have a minimum pure live seed content of 95% with a
minimum germination of 80%.
2. Bermuda seed shall be of common variety with a minimum pure live seed
content of 95% with a minimum germination of 85%.
3. Annual Type Ryegrass seed shall have a minimum pure live seed content of
95% with a minimum germination of 90%.
981-3 Sod.
981-3.1 Types: Unless a particular type of sod is called for in the Contract Documents,
sod may be either centipede, bahia, or bermuda at the Contractors option. It shall be well matted
with roots. Where sodding will adjoin, or be in sufficiently close proximity to, private lawns,
other types of sod may be used if desired by the affected property owners and approved by the
Engineer.
981-3.2 Dimensions: The sod shall be taken up in commercial-size rectangles, or rolls,
preferably 12 inches by 24 inches or larger, except where 6 inch strip sodding is called for, or as
1116
rolled sod at least 12 inches in width and length consistent with the equipment and methods used
to handle the rolls and place the sod. Sod shall be a minimum of 1-1/4 inches thick including a
3/4 inch thick layer of roots and topsoil. Reducing the width of rolled sod is not permitted after
the sod has been taken up from the initial growing location. Any netting contained within the sod
shall be certified by the manufacturer to be bio-degradable within a period of three months from
installation.
981-3.3 Condition: The sod shall be sufficiently thick to secure a dense stand of live
turf. The sod shall be live, fresh and uninjured, at the time of planting. It shall have a soil mat of
sufficient thickness adhering firmly to the roots to withstand all necessary handling. It shall be
planted within 48 hours after being cut and kept moist from the time it is cut until it is planted.
No sod which has been cut for more than 48 hours may be used unless specifically authorized by
the Engineer. A letter of certification from the turf Contractor as to when the sod was cut, and
what type, shall be provided to the Engineer upon delivery of the sod to the job site.
The source of the sod may be inspected and approved by the Engineer prior to
being cut for use in the work.
981-4 Mulch.
The mulch material shall be compost meeting the requirements of Section 987, hardwood
barks, shavings or chips; or inorganic mulch materials as approved by the Engineer; or
hydraulically applied wood fiber mulch or bonded fiber matrix (BFM) for the establishment of
turf material.
1117
SECTION 982
FERTILIZER
982-1 Fertilizers.
Fertilizers shall comply with the State fertilizer laws.
The numerical designations for fertilizer indicate the minimum percentages (respectively)
of (1) total nitrogen, (2) available phosphoric acid, and (3) water-soluble potash, contained in the
fertilizer. At least 50% of the nitrogen shall be from a slow-release source.
982-2 Certification.
The Contractor shall provide the Engineer a certified test report from the manufacturer of
the commercial fertilizer confirming that the requirements of this Section are met. The certified
test report shall conform to the requirements of Section 6 and include test results for total
nitrogen, available phosphoric acid, water-soluble potash, and sulfur. Each certification shall
cover one batch per type for dry type fertilizer.
982-3 Fertilizer Rates.
Soil laboratory fertilization recommendations are based on the amount (lbs) of nutrients
(N, P2O5, K2O) to apply per given area (usually 1,000 square feet.). From this recommendation it
is necessary to select an appropriate fertilizer grade and then determine how much of this
fertilizer to apply to the area.
If a complete fertilizer (containing all three primary nutrients) is not available in the ratio
of N-P-K necessary to match the ratio required in the fertilizer recommendation, mixed-grade or
single-nutrient fertilizers should be used to satisfy each nutrient requirement.
To calculate fertilizer rates:
1. Measure the area to be fertilized in square feet.
2. Select fertilizers) to be used based on the soil testing laboratory
recommendations by matching the ratio of nutrients recommended to the fertilizer grades
available.
3. Determine the amount of fertilizer to apply to a given area (1,000 square feet.)
by dividing the recommended amount of nutrient by the percentage of the nutrient (on a decimal
basis) in the fertilizer. Apply no more than 0.25 lbs P2O5/1000 square feet per application prior to
planting.
4. Adjust the amount of fertilizer to the project area.
1118
SECTION 983
WATER FOR GRASSING
The water used in the grassing operations may be obtained from any approved source.
The water shall be free of any substance which might be harmful to plant growth. Effluent water
shall meet all Federal, State and local requirements.
1119
SECTION 985
GEOTEXTILE FABRICS
985-1 Fabric.
985-1.1 General: Geotextiles shall be woven or nonwoven fabrics that will allow the
passage of water. Geotextiles shall be packaged in a protective covering sufficient to protect it
from sunlight, dirt, and other debris during shipment and storage, upon which the manufacturers
name, product name, style number, roll dimensions and LOT numbers are clearly labeled.
985-1.2 Application: The applications of geotextile fabrics are divided into the following
three main classes:
1. Drainage- under all rubble riprap, including cyclopean stone and under
gabions; wrapped around drains, pipe joints, and edge-drains; filter behind walls, etc.
2. Erosion Control- silt fence, staked silt barrier, plastic erosion mat.
3. Stabilization- separator between embankment and soft subsoil, reinforcement
and pipe bedding.
985-2 Physical Requirements.
Unless restricted in the Plans or Specifications, the geotextile fabric shall be a woven or
non woven fabric consisting of long-chain polymeric filaments or yarns such as polypropylene,
polyethylene, polyester, polyamides or polyvinylidene chloride formed into a stable network
such that the filaments or yarns retain their relative position to each other. The base plastic shall
contain stabilizers and/or inhibitors to make the filaments resistant to deterioration due to ultraviolet light (except for subsurface and stabilization classification), heat exposure and potential
chemically damaging environment. The fabric shall be free of any treatment which may
significantly alter its physical properties. The edges of the fabric shall be selvaged or otherwise
finished to prevent the outer yarn from pulling away from the fabric. The fabric shall conform to
the physical requirements on Design Standards, Index No. 199 according to its application.
985-3 Overlaps and Seams.
Overlaps shall be as specified in the Plans, Specifications, or Design Standards for each
particular application. To reduce overlaps, the geotextile fabric may be sewn together. Seams of
the fabric shall be sewn with thread meeting the chemical requirements and minimum seam
strength requirements given for the fabric and application as shown on Design Standards, Index
No. 199.
985-4 Certification.
Furnish two certified copies of a test report from the manufacturer certifying that the
geotextile to be incorporated into the completed project meets the requirements of this
Specification and the Design Standards, Index No. 199. The certified test reports shall be attested
to by a person having legal authority to bind the manufacturing company. Also, furnish two
(4 inch by 8 inch) samples of the geotextile for product identification. The manufacturer shall
maintain test records as required by this Specification. These records shall be made available to
the Department upon request.
1120
SECTION 987
PREPARED SOIL LAYER MATERIALS
987-1 Description.
All material shall be suitable for plant growth. The organic matter content of the prepared
soil layer after mixing shall be a minimum of 2.5%, a maximum of 10%, in accordance with
FM 1-T-267 and have a pH value of 4.5 or greater and less than or equal to 8.5 as determined in
accordance with FM 5-550. The organic matter content shall be created using any of the
following materials.
987-2 Materials.
Prepared soil layer materials may be obtained from either, or a combination of, the
following sources:
(1) Excavation within the limits of construction on the project. Such material may
be stockpiled or windrowed on the project in areas approved by the Engineer.
(2) Designated borrow pits for the project.
(3) From other sources of organic soil materials provided by the Contractor.
987-2.1 Organic Soil: This may consist of muck, mucky peat and peat and shall have an
organic matter content of 30% or more if the mineral fraction is more than 50% clay, or more
than 20% organic matter if the mineral fraction has no clay.
987-2.2 Blanket Material: Meet the material classification shown on the plans and
Design Standards, Index No. 505.
987-2.3 Compost: Meet the requirements of Florida Department of Environmental
Protection Rule 62.709.550 Type Y (yard waste), Type YM (yard waste and manure), Type A
(municipal solid waste compost) or Rule 62.640.850 Type AA (composted biosolids) and have
unrestricted distribution.
987-2.3.1 Compost for use as a Soil Amendment: If the electrical conductivity
(EC) value of the compost exceeds 4.0dS (mmhos/cm) based on the saturated paste extract
method, the compost shall be leached with water prior to application.
987-2.3.2 Compost for use as a Mulch: The compost shall contain no foreign
matter, such as glass, plastic or metal shards. The compost shall be slightly coarse to coarse in
nature (over half of the solids shall be from particles 1/2 inches in size and no greater than
6 inches). Preference shall be given to compost or mulch made from uncontaminated woody
waste materials.
1121
TRAFFIC CONTROL MATERIALS
SECTION 990
TEMPORARY TRAFFIC CONTROL DEVICE MATERIALS
990-1 General.
This Section specifies the material requirements for temporary traffic control devices.
990-2 Retroreflective Sheeting for Temporary Traffic Control Devices.
990-2.1 Qualified Products List (QPL): Sheeting for use on Temporary Traffic Control
Devices shall be one of the products listed on the Departments Qualified Products List (QPL).
Manufacturers seeking evaluation of their product shall submit an application in accordance with
Section 6.
990-2.1.1 Sign Panels, Bands for Tubular Markers, Vertical Panels,
Barricades and other Devices: Sign panels, bands for tubular markers, vertical panels,
barricades and other devices shall meet the requirements of ASTM D4956 for Type III or higher
retroreflective sheeting materials identified in Section 994 except for mesh signs shall meet the
color, daytime luminance and nonreflective property requirements of Section 994, Type VI.
990-2.1.2 Collars for Traffic Cones: Collars for traffic cones shall meet the
requirements of ASTM D4956 Type VI.
990-2.1.3 Drums: Drums shall meet the requirements of ASTM D4956 for
Type III or higher retroreflective sheeting materials identified in Section 994 including
supplementary requirements for reboundable sheeting.
990-3 Portable Devices (Arrow Boards, Changeable (Variable) Message Signs, Regulatory
Signs and Radar Speed Display Units).
990-3.1 General: All portable devices shall meet the physical display and operational
requirements of the Manual on Uniform Traffic Control Devices (MUTCD) and be listed on the
Departments Approved Products List (APL). Manufacturers seeking approval of their portable
devices shall provide a working sample to be evaluated by the Department that meets all
requirements specified herein.
990-3.1.1 Electrical Systems:
990-3.1.1.1 Diesel Engine: The diesel engine shall meet the following:
(a) The power supply and electrical system shall be self-contained within
the unit.
(b) The engine shall have an electrical starting system.
(c) The power source furnished shall be of sufficient size to provide the
required maximum load energy plus 25%.
(d) The electrical system shall meet the National Electrical Code (NEC)
where applicable.
(e) A backup power system that will operate the unit for a minimum of
three hours automatically when the motor driven generator fails to operate.
(f) The starting batteries and back-up power supply system batteries shall
be automatically charged when the generator is operating.
(g) The engine shall be supplied with an ammeter and the generator shall
be supplied with a voltmeter showing voltage to the sign assembly.
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990-3.1.1.2. Solar Powered Unit: The solar powered unit shall meet the
following:
(a) The unit shall provide automatic recharging of power supply batteries
to normal operating levels with meters showing charge.
(b) Solar array recovery time for arrow boards and regulatory signs shall
be accomplished in a maximum of three hours.
(c) Arrow boards and changeable variable message signs shall be designed
to provide 180 days of continuous operation with minimum onsite maintenance.
990-3.1.1.3 Battery Life Test: Meet the following:
(a) The photovoltaic unit shall be designed to provide 21 days of
continuous operation without sunlight with a minimum of onsite maintenance for arrow boards
and changeable message signs, or 10 days of continuous operation without sunlight with a
minimum of onsite maintenance for regulatory signs and radar speed display units.
(b) The battery shall be equipped with a battery controller to prevent
overcharging and over-discharging. An external battery level indicator shall be provided.
(c) The battery, controller, and power panel shall be designed to be
protected from the elements and vandalism.
(d) Automatic recharging of power supply batteries shall be provided with
charge indicator meter.
(e) An AC/DC battery charger unit shall be provided.
990-3.1.2 Display Panel and Housing:
(a) The display housing assembly shall be weather-tight.
(b) All nuts, bolts, washers and other fasteners shall be of corrosion
resistant material.
(c) The display assembly shall be equipped with an automatic dimming
operational mode capable of a minimum of 50% dimming and a separate manual dimmer switch
(d) The display panel background and frame for the display assembly shall
be painted flat black and shall meet Federal Specification TT-E-489.
(e) The display panel for arrow boards and changeable message signs,
when raised in the upright position, shall have a minimum height of 7 feet from the bottom of the
panel to the ground, in accordance with the MUTCD. The display panel for radar speed display
units, when raised in the upright position, will have a minimum height of 5 feet from the bottom
of the panel to the ground.
(f) The regulatory speed sign panel for regulatory signs and radar speed
display units, when raised in the upright position, shall have a minimum height of 7 feet from the
bottom of the regulatory sign panel to the ground.
(g) The unit shall have an accessible mechanism to easily raise and lower
the display assembly. A locking device shall also be provided to ensure the display panel will
remain in the raised or lowered position.
990-3.1.3 Controller: The Controller shall meet the following:
(a) Controller and control panel shall be housed in a weather, dust, and
vandal resistant lockable cabinet.
(b) Controller and associated on-board circuitry shall meet the
requirements of the Federal Communications Commission (FCC) Title 47, Subpart B, Section 15
regulations concerning the emission of electronic noise by Class A digital devices.
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(c) For changeable variable message signs and arrow boards ensure that
the sign control software provides an on-site graphical representation that visibly depicts the
message displayed on the sign face.
(d) For changeable variable message signs, if remote communication is
included, meet the following National Transportation Communications for ITS Protocol
(NTCIP) requirements: Ensure that the sign controller software implements all mandatory
objects as defined in the FDOT Standard Global MIB v01 in Appendix A, all mandatory objects
as defined in the FDOT Standard DMS MIB v01 in Appendix B, and all mandatory objects as
defined in the FDOT Specific DMS MIB v01 in Appendix C. Ensure that additional objects
implemented by the software do not interfere with the standard operation of mandatory objects.
990-3.1.4 Support Chassis: The support chassis shall meet the following:
(a) The support chassis shall be self-contained and self-supporting without
the use of additional equipment or tools.
(b) Both trailer and truck-mounted units are allowed for arrow boards.
Trailer mounted units are required for changeable message signs, regulatory signs and radar
speed display units.
(1) Trailer mounted unit:
(a) The sign, power supply unit and all support systems
shall be mounted on a wheeled trailer.
(b) The trailer shall be equipped with Class A lights, using
a plug adaptor.
(c) The trailer shall be equipped with adjustable outrigger
leveling pads, one on each of the four frame corners.
(d) The trailer shall be designed to be set up at the site with
its own chassis and outriggers, without being hitched to a vehicle.
(e) The trailer shall be equipped with fenders over the tires
and shall be made from heavy-duty material sufficient to allow a person to stand and operate or
perform maintenance on the unit.
(f) The trailer shall meet all equipment specifications set
forth in Chapter 316 of the Florida Statutes, and by such rule, regulation or code that may be
adopted by the Department of Highway Safety and Motor Vehicles.
(g) The trailers should be delineated on a permanent basis
by affixing retroreflective material, known as conspicuity material, in a continuous line on the
face of the trailer as seen by oncoming road users.
(2) Truck mounted unit:
(a) The truck-mounted assembly shall be designed to fit on
a 1/2 ton or greater duty truck.
(b) The unit shall be self-contained with its own power
supply, controls, raising and lowering device and shall be capable of being operated by one
person.
(c) The unit shall be secured in the vehicle for normal
operation.
990-3.1.5 Other Requirements: Meet the following:
(a) The portable device assembly shall be designed to function in dry, wet,
hot or cold weather (ambient temperature ranges from minus 30F to 165F. Other environmental
requirements shall be as specified in Section A-615 of the Minimum Specifications for Traffic
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Control Signal Devices (MSTCSD), which can be located at the following URL:
http://www.dot.state.fl.us/trafficoperations/Traf_Sys/terl/apl4.shtm .
(b) The controller shall not be affected by mobile radio, or any other radio
transmissions.
(c) An operators manual shall be furnished with each unit.
(d) The manufacturers name and FDOT approval number shall be affixed
on the equipment.
990-3.2 Portable Arrow Board:
990-3.2.1 Arrow Board Matrix:
(a) The minimum legibility distance for various traffic conditions are
based on the decision-sight distance concept. The minimum legibility distance is the distance at
which a driver can comprehend the arrow board message on a sunny day or a clear night. The
arrow board size that is needed to meet the legibility distance is listed as follows:
Type
Minimum Size
B
C
30 by 60 inches
48 by 96 inches
Minimum Number of
Elements
13
15
Minimum Legibility Distance
3/4 mile
1 mile
Type B arrow boards may be used on low to intermediate speed (0 mph to 50 mph)
facilities or for maintenance or moving operations on any speed facility. Type C arrow boards
shall be used for all other operations on high-speed (50 mph and greater) facilities and may be
substituted for Type B arrow boards on any speed facility.
(b) Devices shall meet all arrow board displays identified in the MUTCD.
(c) The element lens should be 5-3/4 inches in diameter. Smaller element
lens diameters are permissible only if they provide an equivalent or greater brightness indication
and meet the legibility criteria in 990-3.2.1(a).
(d) The color of the light emitted shall be in accordance with the MUTCD.
(e) There shall be a 360 degree hood for close-up glare reduction.
(f) For solar powered arrow boards the bulbs shall provide a 350 candle
power intensity for day use and an automatic reduction or dimming capacity for night use. The
dimmed night operation shall provide adequate indication without excessive glare.
(g) The flashing rate of the element shall not be less than 25 flashes or
more than 40 flashes per minute as required in the MUTCD.
(h) The minimum element on time shall be 50% for the flashing arrow
and 25% for the sequential chevron.
990-3.3 Changeable Variable Message Sign:
990-3.3.1 Message Matrix:
(a) Message matrix panel shall be a maximum height of 7 feet by a
maximum width of 10 feet.
(b) The message matrix panel shall contain three separate lines. Each line
shall consist of eight characters, equally spaced a minimum of 3 inches. Each character shall
contain 35 pixels in a 5 inch by 7 inch horizontal to vertical grid arrangement.
(c) Each message line of the 7 foot by 10 foot portable changeable
message sign shall provide for characters 13 inches in width by 18 inches in height minimum and
variable graphic and symbol sizes to a minimum of 18 inches in height.
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(d) For flip disk matrix signs, the disk elements shall be coated on the
display side with a highly reflective florescent yellow Mylar material, and on the back with a flat
black to blend in with the flat black background.
(e) Similar components shall be interchangeable.
990-3.3.2 Operation and Performance:
(a) The message shall be displayed in upper case except when lower case
is project specific and is allowed by the MUTCD.
(b) The message matrix panel shall be visible from one-half mile and
legible from a distance of 650 feet under both day and night conditions. Under variable light
level conditions the sign shall automatically adjust its light source to meet the 650 feet visibility
requirement. The message panel shall have adjustable display rates, so that the entire message
can be read at least twice at the posted speed.
(c) The control panel shall have the capability to store a minimum 50 preprogrammed messages.
(d) The controller in the control panel shall be able to remember messages
during non-powered conditions.
(e) The controller shall allow the operator to generate additional messages
on site via the keyboard.
(f) For a portable changeable message sign using Flip-Disk technology,
the controller shall have the capability to provide a stipulated default message upon loss of
controller function.
(g) All messages shall be flashed or sequenced. In the sequence mode, the
controller shall have the capability to sequence three line messages during one cycle.
990-3.4 Portable Regulatory Signs:
990-3.4.1 Sign Panel Assembly: The sign panel assembly shall consist of a
24 inches by 30 inches SPEED LIMIT XX sign panel and a WHEN FLASHING sign panel,
intended to notify oncoming traffic the speed limit where workers are present. The sign panel
assembly shall meet the following minimum physical requirements:
(a) all nuts, bolts, washers, and other fasteners shall be of corrosion
resistant material.
(b) the sign panel shall fold down and be pinned in place for towing.
Maximum travel height shall be 80 inches.
(c) construct the sign panel and light housing to allow the unit to be
operated in the displayed position at speeds of 30 mph. Design the sign panel assembly to
withstand transport speeds of 65 mph.
(d) construct the sign panel such that, when in the raised position, the sign
panel will have a height of 7 feet from the bottom of the lowest panel to the ground, in
accordance with the MUTCD.
(e) provide the unit with a mechanism to raise and lower the sign panel.
Provide the unit with a device to lock the sign panel in the raised and lowered position.
990-3.4.2 Flashing Lights: Provide a pair of hooded PAR 46 LED advance
warning flashing lamps on each side of the top of the sign panel. These lamps shall be visible
day or night at a distance of one mile with a flash rate of approximately 55 flashes per minute.
The lamp lens should be at least 5-3/4 inches in diameter. Smaller
diameter lens are permissible if they provide an equivalent or greater brightness indication and
meet the legibility criteria above.
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The color of the light emitted shall be in accordance with the MUTCD.
For solar powered units, the bulbs shall provide a 350 candlepower intensity for day use and an
automatic reduction or dimming capacity for night use. The dimmed night operation shall
provide adequate indication without excessive glare.
990-3.5 Radar Speed Display Unit:
990-3.5.1 Display Unit Panel and Housing: Meet the requirements of 990-3.1.2
and the following physical requirements as a minimum:
(a) Provide capability to mount a 24 inches by 30 inches regulatory sign
with interchangeable numbers showing the posted speed limit above the message display.
(b) Provide legend YOUR SPEED either above or below the message
display.
990-3.5.2 Message Display: The message display shall meet the following
physical requirements as a minimum:
(a) Provide a bright LED, two-digit speed display on a flat black
background with bright yellow LEDs.
(b) Each digit shall contain either a seven-segment layout or matrix-style
design. Each digit shall measure a minimum 18 inches in height.
(c) Speed display shall be visible from a distance of at least one-half mile
and legible from a distance of at least 650 feet under both day and night conditions.
(d) Display shall adjust for day and night operation automatically with a
photocell.
990-3.5.3 Radar: The radar unit shall not be affected by normal radio
transmissions and meet the following physical requirements as a minimum:
(1) Approach-Only sensor.
(2) Equipped with a low power K-Band transmitter.
(3) Part 90 FCC acceptance, 3 amps, 10.8 vdc to 16.6 vdc. Fuse and reverse
polarity protected.
(4) Range of 1,000 feet for mid-size vehicle, capable of accurately sensing speeds
of 10 mph to 99 mph with over speed function that operates when a vehicle approaches over the
posted speed limit.
990-4 Removable Tape.
990-4.1 Composition: Removable tape shall be one of the products listed on the QPL.
The pavement stripes and markings shall consist of high quality plastic materials, pigments, and
glass spheres or other retroreflective materials uniformly distributed throughout their crosssectional area, with a reflective layer of spheres or other retroreflective material embedded in the
top surface. No foil type materials shall be allowed.
990-4.2 Skid Resistance: The surface of the stripes and markings shall provide a
minimum skid resistance value of 35 BPN (British Pendulum Number) when tested according to
ASTM E303. Bike lane symbols and pedestrian crosswalks shall provide a minimum skid
resistance value of 55 BPN.
990-4.3 Thickness: The QPL will list the specified thickness of each approved product.
990-4.4 Durability and Wear Resistance: When properly applied, the material shall
provide neat, durable stripes and markings. The materials shall provide a cushioned resilient
substrate that reduces sphere crushing and loss. The film shall be weather resistant and, through
normal wear, shall show no significant tearing, rollback or other signs of poor adhesion.
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Durability is the measured percent of pavement marking material completely removed from the
pavement. The pavement marking material line loss must not exceed 5.0% of surface area.
990-4.5 Conformability and Resealing: The stripes and markings shall be capable of
conforming to pavement contours, breaks and faults under traffic at pavement temperatures
recommended by the manufacturer. The film shall be capable of use for patching worn areas of
the same types of film in accordance with the manufacturers recommendations.
990-4.6 Tensile Strength: The stripes and markings shall have a minimum tensile
strength of 40 psi when tested according to ASTM D638. A rectangular test specimen 6 inches
by 1 inch by 0.05 inches minimum thickness shall be tested at a temperature range of 40F to
80F using a jaw speed of 0.25 inches per minute.
990-4.7 Elongation: The stripes and markings shall have a minimum elongation of 25%
when tested in accordance with ASTM D638.
990-4.8 Plastic Pull test: The stripes and markings shall support a dead weight of
4 pounds for not less than five minutes at a temperature range of 70F to 80F. Rectangular test
specimen size shall be 6 inches by 1 inch by 0.05 inches minimum thickness.
990-4.9 Adhesive: Precoat removable tape with a pressure sensitive adhesive capable of
being affixed to asphalt concrete and portland cement concrete pavement surfaces without the
use of heat, solvents, and other additional adhesives or activators. Ensure that the adhesive does
not require a protective liner when the removable tape is in rolled form for shipment. Ensure that
the adhesive is capable of temporarily bonding to the roadway pavement at temperatures of 50F
and the above without pick-up distortion by vehicular traffic.
990-4.10 Color: Meet the requirements of 971-1.6.
990-4.11 Removability: Ensure that the manufacturer shows documented reports that the
removable tape is capable of being removed intact or in substantially large strips after being in
place for a minimum of 90 days and under an average daily traffic count per lane of at least
5,000 vehicles per day.
990-5 Temporary Retroreflective Pavement Markers.
Temporary retroreflective pavement markers (RPMs) shall meet the requirement of
970-1.2.1, be one of the products listed on the QPL and be certified as meeting the following:
(a) Composition: Use markers made of plastic, ceramic or other durable materials.
Markers with studs or mechanical attachments will not be allowed.
(b) Dimensions: Marker minimum and maximum surface dimensions is based on
an x and y axis where the y dimension is the axis parallel to the centerline and the x axis is
90 degrees to y. Class E markers shall be 4 inches by2 inches by 1 inches.
The x and y dimension of Class D markers shall be a maximum of 5 inches. The x
dimension shall be a minimum of 4 inches and the minimum y dimension shall be 2.25 inches.
The maximum installed height of Class D markers shall be 1 inch. The maximum
installed height of Class E markers shall be 2 inches. Use Class D markers having a minimum
reflective face surface of 0.35 square inches. Use Class E markers having a minimum reflective
surface area of 1 square inch.
The markers reflective face shall be completely visible and above the pavement surface
after installation, measured from a line even with the pavement perpendicular to the face of the
marker.
(c) Optical Performance: Ensure that the specific intensity of each white reflecting
surface at 0.2 degrees observation angle shall be at least the following when the incident light is
parallel to the base of the marker:
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Horizontal Entrance Angle
0 deg.
20 deg.
Specific Intensity (SI)
3
1.2
For yellow reflectors, the specific intensity shall be 60% of the value for
white.
For red reflectors, the specific intensity shall be 25% of the value for
white. Reflectivity of all RPMs shall not be less than 0.2 specific intensity any time after
installation.
(d) Strength requirements: Markers shall support a load of 5,000 pounds. Three
markers per lot or shipment will be randomly tested as follows:
Position the marker base down, between the flat, parallel 0.5 inch steel
plates of a compression testing machine. Place on top of the marker, a flat piece of 60 (Shore A)
durometer rubber, 6 inches by 6 inches by 0.37 inches, centered on the marker. Apply the
compressive load through the rubber to the top of the marker at a rate of 0.1 inches per minute.
Either cracking or significant deformation of the marker at any load less
than 5,000 pounds will constitute failure.
(e) Adhesion: Use bituminous adhesive materials for bonding the markers to the
pavement that meet the requirements of Section 970 and are listed on the QPL.
(f) Removability: Ensure that the pavement marker is removable from asphalt
pavement and portland cement concrete pavement intact or in substantially large pieces, either
manually or by mechanical devices at temperatures above 40F, and without the use of heat,
grinding or blasting.
990-6 Temporary Glare Screen.
990-6.1 Design and Installation: Meet the following requirements:
(a) Glare screen units shall be manufactured in lengths such that when installed
the joint between any one modular unit will not span barrier sections. Color shall be green,
similar to Federal Color Standard 595-34227.
(b) Blades, rails and/or posts shall be manufactured from polyethylene, fiberglass,
plastic, polyester or polystyrene, and be ultraviolet stabilized and inert to all normal atmospheric
conditions and temperature ranges found in Florida.
(c) For paddle type designs, the blade width shall not be more than 9 inches.
Blades or screen for individual or modular systems shall be 24 inches to 30 inches high and
capable of being locked down at an angle and spacing to provide a cut-off angle not less than
20 degrees.
(d) For glare screen mounted on temporary barrier wall, a strip (6 inches by
12 inches) of reflective sheeting as specified in 994-2 shall be placed on a panel, centered in each
barrier section (at a spacing not to exceed 15 feet) and positioned in such a manner as to permit
total right angle observation by parallel traffic. When glare screen is utilized on temporary
concrete barriers, warning lights will not be required.
(e) Prior to approval an impact test shall be performed by the manufacturer to
verify the safety performance of the proposed system. The minimum impact strength of the
posts, blades, rail and the barrier attachment design shall be sufficient to prevent the unit from
1129
separating from the barrier when impacted by a 3 inches outside diameter steel pipe traveling at
30 mph and impacting mid-height on the glare screen assembly.
(f) All hardware shall be galvanized in accordance with ASTM A123 or stainless
steel in accordance with AISI 302/305.
Alternative designs for temporary glare screen may be submitted as a Cost
Savings Initiative Proposal in accordance with 4-3.9.
990-6.2 Qualified Products List: Manufactured glare screen systems may be modular or
individual units listed on the QPL.
990-7 Temporary Traffic Control Signals.
990-7.1 General: Temporary traffic control signals shall be one of the products listed on
the APL. Meet the physical display and operational requirements of conventional traffic signal
described in the MUTCD for portable traffic signals. The standard includes but is not limited to
the following:
(a) Use signal heads having three 12 inch vehicular signal indications (Red,
Yellow and Green). Ensure there are two signal heads for each direction of traffic.
(b) The traffic signal heads on this device will be approved by the Department.
(c) Department approved lighting sources will be installed in each section in
accordance with the manufacturers permanent directional markings, that is, an Up Arrow, the
word UP or TOP, for correct indexing and orientation within a signal housing.
(d) The masts supporting the traffic signal heads will be manufactured with the
lowest point of the vehicular signal head as follows:
(1) Eight feet above finished grade at the point of their installation for
pedestal type application or
(2) Seventeen to 19 feet above pavement grade at the center of roadway
for overhead type application.
(e) The yellow clearance interval will be programmed 3 seconds or more. Under
no condition can the yellow clearance interval be manually controlled. It must be timed
internally by the controller as per Department specifications.
(f) The green interval must display a minimum of 5 seconds before being
advanced to the yellow clearance interval.
(g) The controller will allow for a variable all red clearance interval from
0 seconds to 999 seconds.
(h) Portable traffic control signals will be either manually controlled or traffic
actuated. Indicator lights for monitoring the signal operation of each approach will be supplied
and visible from within the work zone area.
(i) When the portable traffic control signals are radio actuated the following will
apply:
(1) The transmitter will be FCC Type accepted and not exceed 1 watt
output per FCC, Part 90.17. The manufacturer must comply with all Specific limitations noted
in FCC Part 90.17.
(2) The Controller will force the traffic signal to display red toward the
traffic approach in case of radio failure or interference.
(j) The trailer and supports will be painted construction/maintenance orange
enamel in accordance with the MUTCD color.
(k) The device will meet NEMA environmental standard. The test report certified
by an independent laboratory will be provided.
1130
(l) Ensure the certification number is engraved or labeled permanently on
equipment.
(m) Ensure the device has an external, visible, water resistant label with the
following information: Certification of this device by the Florida Department of Transportation
allows for its use in Construction Zones Only.
990-8 Work Zone Signs.
Provide steel flanged U-channel or square tube steel meeting the mechanical
requirements of ASTM A499, Grade 60. For each U-channel or square tube, punch or drill
3/8 inch diameter holes on 1 inch centers through the center of the post, starting approximately
1 inch from the top and extending the full length of the post. Ensure that the weight per foot of a
particular manufacturers post size does not vary more than plus or minus 3.5% of its specified
weight per foot. Taper the bottom end of the post for easier installation. Machine straighten the
U-channel to a tolerance of 0.4% of the length. Use only non-corrosive metal, aluminum, or
galvanized steel attachment hardware. Work zone sign systems shall be one of the products listed
on the QPL.
990-9 Temporary Raised Rumble Strips:
990-9.1 General: Temporary raised rumble strips shall be one of the products listed on
the QPL. Meet the physical display and operational requirements in the MUTCD for temporary
raised rumble strips. The temporary raised rumble strip may be either a removable polymer
striping tape type or a molded engineered polymer material type as described below:
990-9.1.1 Removable Polymer Striping Tape:
Characteristic
Composition:
Color:
Cross-section:
Requirement
Removable Polymer Striping Tape with pre-applied adhesive
White, Black or Orange
0.25 in. to 0.50 in. (height) x 4 in. (wide)
990-9.1.2 Molded Engineered Polymer Material:
Characteristic
Composition:
Weight
Color:
Shape
Cross-section:
Requirement
Molded Engineered Polymer Material
Internally ballasted to provide proper weight to maintain position in use
without the use of adhesives or mechanical fasteners
White, Black or Orange
Beveled on the leading edge
0.625 in. to 0.875 in. (height) x 12 in. (wide)
990-10 Automated Flagger Assistance Devices (AFAD):
990-10.1 General: AFADs shall be one of the products listed on the APL. Meet the
physical display and operational requirements in the MUTCD for the AFAD as well as the
detailed requirements below.
990-10.1.1 Stop/Slow Automated Flagger Assistance Devices: Provide a
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Stop/Slow AFAD including a Stop/Slow sign that alternately displays the stop face and the slow
face of a Stop/Slow paddle without the need for a flagger in the immediate vicinity of the AFAD
or on the roadway.
Ensure that the Stop/Slow AFAD includes a gate arm that descends to a
down position across the approach lane of traffic when the stop face is displayed and then
ascends to an upright position when the slow face is displayed.
Ensure the gate arm is fully retroreflectorized on both sides, with vertical
alternating red and white stripes at 16 inch intervals measured horizontally in accordance with
the MUTCD. When the arm is in the down position blocking the approach lane:
A. The minimum vertical aspect of the arm and sheeting shall be
2 inches; and,
B. The end of the arm shall reach at least to the center of the lane
being controlled.
990-10.1.2 Red/Yellow Lens Automated Flagger Assistance Devices: Provide a
Red/Yellow Lens AFAD that alternately displays a steadily illuminated circular red lens and a
flashing circular yellow lens to control traffic without the need for a flagger in the immediate
vicinity of the AFAD or on the roadway.
Ensure that the Red/Yellow Lens AFAD includes a gate arm that descends
to a down position across the approach lane of traffic when the steady circular red lens is
illuminated and then ascends to an upright position when the flashing circular yellow lens is
illuminated.
Ensure that the gate arm is fully retroreflectorized on both sides, with
vertical alternating red and white stripes at 16 inch intervals measured horizontally in accordance
with the MUTCD. When the arm is in the down position blocking the approach lane:
A. The minimum vertical aspect of the arm and sheeting shall be
2 inches; and,
B. The end of the arm shall reach at least to the center of the lane
being controlled.
Do not provide a change interval between the display of the steady circular
red indication and the display of the flashing circular yellow indication. Provide a steady
illuminated circular yellow indication, with at least a 5 second duration, between the transition
from flashing circular yellow indication and the display of the steady circular red indication. The
Engineer may approve a different duration, provided it falls within the range recommended by
the MUTCD.
1132
SECTION 992
HIGHWAY LIGHTING MATERIALS
992-1 General.
992-1.1 Pole Design Criteria: The light poles and bracket arms shall be in accordance
with the requirements of the AASHTO Standard Specifications for Structural Supports for
Highway Signs, Luminaires and Traffic Signals, the FDOT Structures Manual and with the
specific requirements contained in this Section.
992-1.2 Luminaires: Luminaires shall comply with UL 1598 and be listed and labeled
for installation in wet locations by an OSHA recognized Nationally Recognized Testing
Laboratory (NRTL).
992-1.3 Conductors: All conductors shall be color-coded stranded copper meeting the
requirements of NEMA WC 70.
Service and circuit conductors shall be single-conductor cable Type THWN-2 and
shall not be smaller than No. 6 AWG.
Bonding ground conductor shall have a green jacket and shall not be smaller than
No. 6 AWG.
992-1.4 Conduit: Conduit shall be used in accordance with the National Electrical Code
and as specified in the Plans. All conduit shall be UL or NRTL listed and meet the following
material requirements:
992-1.4.1 Rigid Metal Conduit: Rigid steel conduit shall meet the requirements
of UL 6. The steel conduit shall be hot-dip galvanized with a minimum coating of 1.24 oz/ft2 on
both the inside and outside of the conduit. The weight of the zinc coating shall be determined
using ASTM A90.
992-1.4.2 Polyvinyl-Chloride: Polyvinyl-chloride conduit shall be high impact,
Schedule 40 or Schedule 80 conduit meeting the requirements of UL 651.
992-1.4.3 Rigid Aluminum: Rigid aluminum conduit shall meet the requirements
of UL 6A.
992-1.4.4 High Density Polyethylene (HDPE): HDPE conduit shall meet the
requirements of UL 651A.
992-1.4.5 Liquid tight Flexible Metal: The conduit shall meet the requirements
of UL 360.
992-1.5 Electrical Ground Rod: The electrical ground rods shall be 5/8 inch copper clad
steel. Electrical ground rods shall be sectional type where length exceeds 10 feet.
992-1.6 Fittings and Bends: Fittings, bends and miscellaneous hardware shall be in
accordance with the National Electrical Code (NEC) and shall be compatible with the adjacent
conduit and materials.
992-1.7 Conductor Splices: Unless otherwise shown in the Design Standards or
authorized by the Engineer, splices shall be made with compression sleeves or split bolt
connectors. The connector shall be sealed in silicone gel that easily peels away leaving a clean
connection. The gel will be contained in a closure that when snapped around the split bolt will
provide a waterproof connection without the use of tools or taping. This closure will be
UV resistant, impact resistant and abrasion resistant.
992-1.8 Pull Boxes: Pull boxes shall meet the requirements of Section 635, except that
the minimum size for highway lighting shall be 13 inches wide, 24 inches long and 12 inches
1133
deep. The cover shall be marked lighting and shall be bonded to the ground rod if of metal
construction.
992-1.9 Distribution Service Point Equipment: All electrical equipment shall be
provided with 75C terminal lug connectors.
992-1.9.1 Service Main: Two pole 480 V, 25,000 AIC, solid neutral, NEMA 4X
stainless steel, enclosed circuit breaker rated for service entrance.
992-1.9.2 Control Panel Enclosure: NEMA 4X stainless steel enclosure ground
mounted per Design Standards, Index No. 17736. Dimensions shall be as necessary for
equipment inside.
992-1.9.3 Control Panel Main Disconnect: Single phase, 480V, 2-wire with
ground bus in NEMA 1 enclosure, with two pole, 18,000 AIC branch circuit breakers. Number
and rating of branch circuit breakers shall be as indicated in Plans.
992-1.9.4 Lighting Contactor: Two pole, 120V electrical contactor in NEMA 1
enclosure.
992-1.9.5 Electrical Panel: Two pole, 480V, 25,000 AIC with solid neutral in
NEMA 1 enclosure.
992-1.9.6 Surge Protection Device: Surge protective device shall be Type 1, UL
or NRTL listed to 1449, 3rd Edition. Surge current rating on per phase basis shall equal or exceed
50KA. I-nominal rating shall be 10KA or 20KA. Modes of protection shall include L-G and N-G
having UL 1449-3 Voltage Protection Ratings of 2000V or lower.
992-2 Conventional Lighting.
992-2.1 Poles: Poles for conventional lighting shall be aluminum unless otherwise shown
in the Plans. Aluminum light poles shall be round, one piece, continuous-tapered high-strength
aluminum, and of an approved alloy meeting the requirements of the Design Standards. The
poles shall be of such length as to provide the approximate luminaire mounting height shown in
the Plans. Poles installed on bridges, walls and concrete median barriers shall be equipped with
internal vibration damping devices.
992-2.1.1 Concrete Poles: Concrete poles may be used only when specified in
the Plans. When specified, concrete poles shall meet the requirements of Section 641 and Design
Standards, Index No. 17725 for a Type P-III pole.
992-2.2 Bases: Aluminum poles shall be installed on transformer bases with the
exception of lights installed on bridge pilasters or on top of median barrier. Transformer base
poles shall have a grounding lug in the transformer base. The base shall be arranged for
anchoring to a transformer base with four 1 inch anchor bolts (minimum size).
992-2.3 Bracket Arms: Bracket arms shall be aluminum, truss-type construction,
consisting of upper and lower members with vertical struts, and shall have the luminaire end
formed to accommodate a 2 inch pipe slipfitter. The bracket arms shall meet the design
requirements of 992-1.1. Bracket arms shall be attached to aluminum poles, with machine bolts
and pole adapters, unless approved otherwise.
992-2.4 Luminaires, Ballasts, etc: Luminaires shall consist of a precision-cast
aluminum housing and reflector holder, a high-pressure sodium lamp, and a heat resistant, hightransmission glass refractor. Luminaire housing shall have a refractor-holder latch on the street
side, and a hinge with a safety catch on the house side of the luminaire and a slipfitter suitable
for attaching to a 2 inch mounting bracket. Pole top mounted luminaires which shall have a
2 inch tenon. Housing shall be IP 66 rated.
1134
High-pressure sodium lamps shall meet the following requirements:
NEMA C78.42, CRI 21(Min.), CCT 2100 K and average rated life of 24,000 hours minimum.
Luminaires shall have internal ballasts of the regulated output (constant wattage)
type, suitable for operating on the circuits shown in the Plans. The ballasts shall be pre-wired to
the lamp socket and terminal board, requiring only connection of the power-supply leads to the
ballast primary terminals. The ballast shall have a power factor of at least 90%. The ballast shall
provide for regulation within plus or minus 6% variation in lamp watts at a primary voltage
variation of plus or minus 10% for lamps of 400w or less.
The luminaires shall meet the requirements shown in the Plans.
92-2.5 Luminaire Cable: Pole and bracket cable shall be multi-conductor Type XHHW2 XLP TC with three No. 10AWG.
992-2.6 In Line Fuse Holders: In line fuse holders shall provide a breakaway
connection and be UL recognized per Guide IZLT2 and rated for 600V. The wire connections in
the fuse holders shall be of the copper setscrew type. Fused connections shall utilize and ATQ or
FNQ 10 amp time delay fuse rated for 500V. Fuses shall be UL listed to Standard 248-14. The
rating for the fuse holders shall be water resistant or submersible rated.
992-2.7 Surge Protection Devices: The MOV based SPD shall be spotted in a manner to
be waterproof. UL listing is not required. SPDs per mode surge current rating shall be 20KA for
480V to ground and 40KA for neutral to ground. Maximum Continuous Operation Voltage
(MCOV) shall be not less than 550Vrms and not greater than 600Vrms. All wires and internal
spacings shall be insulated for 600Vrms.
992-2.8 Pole Cable Distribution System.
992-2.8.1 General: These requirements are applicable for all systems rated up to
and including 600 V. The installed system shall be in compliance with the Design Standards,
Index No. 17500. Systems installed as alternates to the Design Standards shall be one of the
products listed on the Departments Qualified Products List (QPL). Manufacturers seeking
evaluation of their product shall submit an application in accordance with Section 6.
Alternate Systems shall meet the following requirements:
a. A modular color coded cable system consisting of rubber cords
with integrally molded watertight submersible connectors, inline fuses, submersible surge
arrestor and breakaway connectors shall be installed. The cables shall extend from an
underground pull box near the base of the pole to the luminaires at the top of the pole. A cable
system shall be required at each pole.
The cable system shall consist of the following described components:
a. Distribution Block: The red molded body shall contain a three
wire female outlet integrally molded to a 24 inch length of 10/3 SOOW cable with an end
molded to the body and the other end shall be spliced in the field to the distribution cable that
feeds through the underground pull box near the base of the pole. The block shall be watertight
and submersible when the integrally fused plug on the power cable is engaged and fully seated.
Dimensions shall be approximately 2 inches by 3 inches by 3 inches. The size is important
because of limited space.
b. Surge Arrestor Cable: Provide a 12 inch length of 10/2 SOOW
cable with a red male plug to match the red female connector cable extending from the fused
plug on the power cable. The other end of the surge arrestor cable shall be integrally molded to a
MOV waterproof surge arrestor. The red male plug shall make a submersible connection when
mated to the red female connector on the power cable. A separate 12 inch length of
1135
No. 10 THWN green ground wire shall be provided from the surge arrestor to attach to the
ground system in the pull box.
c. Power Cable: This cable feeds the luminaire cable and the surge
arrestor cable from the load side of its integrally fused red male plug end. The red fused plug
shall contain 10 amp 500 volt fuses (13/32 inch by 1-1/2 inch) or equal. A solid copper slug shall
be installed on neutral side for line to neutral service. Both lines shall be fused for line to line
service. The section that feeds the luminaire Cable shall be a 10 foot section of 10/3 SOOW
cable with an orange female connector molded to the end extending up into the base of the pole.
This female connector shall pass easily through a standard size 1-1/4 inch PVC elbow and make
a submersible connection when mated with the orange male plug on the luminaire cable. The
section that feeds the surge arrestor cable shall be 12 inches in length of 10/2 SOOW cable with
a red female connector on the end. The red female connector shall make a submersible
connection when mated to the red male plug on the surge arrestor cable.
d. Luminaire Cable: This cable is Type XHHW-2 XLP-TC with
three No. 10AWG an orange male molded plug molded to match the orange female end of the
power cable. The connector shall require 25 pounds of force to mate or disengage from the
female end. When engaged the connection shall be watertight and submersible. The cable strain
relief shall extend approximately 2 inches from the connector.
The distribution block and each connector shall be made of thermosetting
synthetic polymer which is non-flame supporting and which remains flexible over a temperature
range of minus40F to plus 190F. Hardness of the molded rubber shall be 65 durometer.
992-2.8.2 Testing and Performance Criteria: The system shall pass the
following performance criteria in accordance with NEC 110 2.
a. Dielectric Test: No breakdown shall occur with a test potential of
1,960 volts applied between the primary conductors (tied together) and the protective ground for
a period of one-minute.
b. Leakage Current Test: Leakage current shall be measured on the mated
connectors between the primary conductors and the protective ground conductor. When tested at
the rated operating voltage, the leakage current shall not exceed 0.5 mA. The mated connectors
shall then be wrapped in aluminum foil and the leakage current measured between the primary
conductors and the foil wrap. When tested at the rated operation voltage the leakage current shall
not exceed 0.5 mA.
c. Flame Retardant Test: Flammability tests shall be conducted on the
cable, the molded body of the connectors, and the molded protective caps. These materials shall
be subjected to five flame application, on for 15 seconds and off for 15 seconds. The materials
shall self-extinguish within one minute upon removal of the flame and not burn through.
d. Internal Temperature Test: The internal temperature rise of the contact
area of the mated connectors shall not exceed a temperature rise of 54F referenced to 73F
ambient temperature when operated at the maximum current rating.
e. External Temperature Test: The external temperature rise of the mated
connectors and the cable shall not be greater than 54F referenced to 73F ambient temperature
when operated an the maximum current rating.
f. Fault Test: The mated connectors shall be fault tested by applying a test
current of 1,000 amperes, 60 HZ for a minimum of 3 cycles (50 ms). The mated connectors shall
then satisfactorily pass the dielectric test.
1136
g. Drop Test: The connectors shall not break, crack or suffer other damage
when subjected to eight consecutive drop tests from 3 feet above the concrete floor with the
connectors having been rotated 45 degrees between each drop.
h. Crushing Test: No breakage of deformation shall result when the mated
and unmated connectors are subjected to a crushing force of 500 pounds for one minute.
Following the crush test, the dielectric test shall be satisfactorily passed.
i. Impact Test: No breakage or deformation shall result when the
connectors are subjected to an impact caused by dropping a cylindrical 10 pound weight having
a flat face 2 inches in diameter from a height of 18 inches.
j. Flex Test: No detachment or loosening shall result when each connector
is subjected to a 5,000 cycle flex test at the cable/bond area back and forth in a plane through an
angle of 180 degrees. Following the flex test the dielectric test shall be satisfactorily passed.
k. No Load Endurance Test: No excessive wear shall result when the male
and female connectors and protective cap and female connector were subjected to 2,000 cycles
of complete insertion and withdrawal.
l. Rain Test: The mated and capped connectors shall be subjected to a
continuous water spray (simulating worst case outdoor rain down pour) for at least one hour at a
rate of at least 18 inches per hour at an operating pressure of 5 psi. The dielectric and leakage
current tests shall be satisfactorily passed. The connectors shall be unmated and caps removed.
Inspection shall indicate that water had been successfully prevented from reaching the contact
areas of the connectors.
m. Watertight (Immersion) Test: The mated and capped connectors shall
be immersed in water for one hour in which the highest point of the test samples in as least 3 feet
below the water level. Immediately following the immersion, a satisfactory dielectric and
leakage current tests shall be performed. The connectors shall be unmated and caps removed.
Inspection shall indicate that water had been successfully prevented from reaching the contact
areas of the connectors.
n. Exposure to Deteriorating Liquids: The cable and connectors shall be
dried at 212F for one hour. The samples shall then be immersed in ASTM Reference Oil No. l
and ASTM Reference Fuel C liquids for one hour. The samples shall show no evidence of
bubbling, cracking or corrosion. Within one hour after being removed from the fluids, the test
samples shall satisfactorily pass the flammability test.
992-3 High Mast Lighting.
992-3.1 Poles: Poles for high mast lighting shall be galvanized steel unless otherwise
shown in the Plans. Steel high mast poles shall be continuous-tapered, round or minimum of
12 sided poles and meet the requirements of the Design Standards.
Each pole shall include a galvanized steel wench plate of sufficient size to mount
the winch, portable drive unit mounting tube, circuit breaker panel and surge arrestor.
992-3.2 Luminaires and Ballasts: The reflector with its aluminum cover shall be firmly
attached to a cast ring. This ring shall have keyhole slots in its upper surface such that the
reflector/refractor assembly may be readily attached to, or detached from, the luminaire bracket
entry and lamp support assembly without completely removing the support bolts.
High pressure sodium lamps shall meet the following requirements:
NEMA C78.42, CRI 21(min), CCT 2100 K and average rated life of 24,000 hours (min).
1137
Each luminaire shall contain an integral auto-regulator type ballast. The luminaire
ballast shall be enclosed within an aluminum housing which integrally attaches to the luminaire
bracket entry and lamp support assembly. It shall be readily removable without removing the
luminaire from the bracket arm. The ballasts shall be pre-wired to the lamp socket and terminal
board, requiring only connection of the power supply leads to the ballast primary terminals. The
ballast shall have a power factor of at least 90%. The ballast shall provide for regulation within
plus or minus 6% variation in lamp watts at a primary voltage variation of plus or minus 13% for
lamps of 750w or greater.
The luminaire shall be attached to the bracket arm by means of a bracket entry
and lamp support assembly. The assembly shall include a side entry slipfitter designed for 2 inch
pipe with provision for 3 adjustments for leveling the luminaire. An enclosed terminal block
shall be included such that all electrical connections shall be protected from exposure to weather.
All electrical connections shall be made waterproof or be made inside a weather
resistant enclosure. All luminaires shall be ANSI/IES light distribution as indicated in the Plans.
Each luminaire shall be labeled with a permanent label which states the type of lamp, voltage
input, power input, power factor, ballast type, socket position, ANSI/IES light distribution, and
such other catalog information that a complete replacement can be readily ordered.
992-3.3 Surge Protective Devices: Surge protective devices (SPD) shall be Type 1 or
Type 2. UL or NRTL listed to UL 1449 3rd Edition. Surge current rating on a per phase basis
shall be equal or exceed 50KA. I-nominal rating shall be 10KA or 20KA. Modes of protection
shall include L-G and N-G having UL 1449-3 Voltage Protection Ratings (VPRs) of 2000V or
lower.
992-3.4 Lowering System: The lowering system may be either a top latch or bottom
latch system. The lowering system shall consist of the following.
992-3.4.1 Head frame and Covers: The head frame unit shall rigidly mate the
top of the pole to the head frame platform. The platform with its associated sheaves shall be
covered to prevent water from entering the top of the pole. The head frame structure shall be
stainless steel and attach to the pole by stainless steel bolts or by means of a galvanized steel
slipfitter. The head frame shall utilize two stainless steel cable sheaves for each lowering cable.
The cable sheaves shall be a minimum of 5 inches in diameter and grooved to the exact cable
diameter, for 180 cable bearing surface. The power cord shall travel on sheaves or a combination
of rollers providing a radius for the cord of 6 inches or larger. Each end of the sheaves or rollers
shall have a keeper to prevent the cable from jumping out of the roller track or sheave cover that
will act as a keeper. Bearings shall have permanent lubrication. For top latch systems the head
frame shall include latch mechanisms which support the luminaire ring in the latched position
and prevent the luminaire ring from rotation. For bottom latch systems the head frame shall
include centering guides which center the luminaire ring and prevent the ring from rotation.
992-3.4.2 Luminaire Ring: The luminaire ring assembly shall consist of the
luminaire ring, hoisting cable terminator tubes, and weather proof junction box. The luminaire
ring and the junction box shall be fabricated of stainless steel. The ring shall be supplied with
bolt on 2 inch stainless steel pipe tenons for the required number of luminaires. Two of the
stainless steel tenons shall have a 1 inch half coupling welded to the tenon for the possible
installation of FAA approved obstruction lights. The inner portion of the ring shall be equipped
with a PVC shock absorbing tubes or shall utilize roller contact spring-loaded centering arms
which center the luminaire ring and protect the pole and luminaire ring during raising or
lowering operations. A 600 volt terminal block, completely prewired shall be included in the
1138
junction box. The luminaire ring shall be prewired with distribution wiring suitable for proper
application and operation of the luminaires. A male flanged receptacle shall be mounted on the
luminaire ring to allow testing of the luminaire while in the lowered position. The receptacle
shall face away from the pole for easy access.
992-3.4.3 Lowering Cables: For bottom latch lowering systems, a minimum of
two cables shall be used to lower the luminaire ring. Lowering cables for bottom latch systems
shall be stainless steel aircraft cables of 1/4 inch or greater diameter. Where the wire cables bend
over sheaves or the winch drum, the maximum working stress in the outer fibers of wire cable
shall not exceed 20% of the cable manufactures rated ultimate stress. The hoisting cable shall
manually latch at the base of the pole and shall remove the load from the winch system. Each
latch point shall be capable of supporting the entire weight of the luminaire ring assembly
including luminaires. All moving parts of the latch mechanism shall be within reach from the
ground level.
For top latch lowering systems, three stainless steel aircraft cables of
3/16 inches or greater diameter shall be provided. The transition yoke, hardware connecting the
lowering cables to the transition yoke and hardware connecting the winch cable to the transition
yoke shall be stainless steel. Where the wire cables bend over sheaves or the winch drum, the
maximum working stress in the outer fibers of wire cable shall not exceed 20% of the cable
manufacturers rated ultimate stress. All latching systems shall remove the load from the winch
system. Each latch point shall be capable of supporting the entire weight of the luminaire ring
assembly including luminaires.
992-3.4.4 Modular Power Cable System: The modular cable system shall
consist of cables with weathertight connectors. All portions of the cable system shall be rated up
to and including 600 V. The plugs and connectors shall be UL or NRTL listed to UL 498 twistlock type devices with a NEMA L16-30R configuration for 480V line to neutral systems or for
480V line to line systems. The X designated prong shall be the hot leg for 480V line to neutral
systems. The X and Z designated prongs shall be the hot legs for 480V line to line systems. The
Z designated prong shall always be treated as a neutral leg. The plugs and connectors shall be
equipped with watertight safety shrouds meeting UL 4X enclosure rating. Plugs and connectors
when used on cord sets shall be equipped with IP 55 rated waterproof boots.
The power cable shall be a minimum of 10/3 SOOW cable that is wired
from distribution cable in the pull box near the base of the pole to the line side of the circuit
breaker panel.
The circuit breaker cable shall be an 8 foot length of 10/3 SOOW
(minimum) cable that is connected to the load side of the circuit breaker panel and a female
receptacle on the other end. This female receptacle shall mate with the male plug on the pole
cable, the male flanged receptacle on the luminaire ring and the male plug on the portable stepdown transformer.
The pole cable shall be the length of the mounting height of the pole plus
6 feet. The cable shall be a minimum of 10/3 SOOW with a male plug on one end that mates
with the female receptacle on the circuit breaker cable. The other end fits under the lugs in the
junction box on the luminaire ring. The power cable shall be attached to the luminaire ring with a
stainless steel strain relief Kellems grip capable of withstanding the pull of the weight of the
cable. All power cables should be attached to the stainless steel weathertight wiring chamber
with weathertight cable connectors
1139
992-3.4.5 Winch Drum: The drum shall be constructed of stainless steel and be
designed to provide a level wind of wire cable. The winch shall be a reversible worm gear self
locking type with an integral friction drag brake to prevent free spooling. Raising speed of the
luminaire ring shall be a minimum of 12 feet per minute. Stainless steel 7 x 19 aircraft cables of
1/4 inch or greater diameter shall be supplied on the winch. The winch drums shall be designed
to provide smooth winding of the winch cables on the drum and to prevent cable slippage on the
drum.
992-3.4.6 External Portable Winch Motor (One per Project): The winch shall
be designed for hand operation or for operation by means of a 1/2 inch heavy duty reversing
electric drill motor or a portable reversible AC motor with a magnetic brake. Both portable
power units shall be mounted to the winch by a stainless steel mounting bracket and shall be
remote controlled to enable the operator to stand 25 feet from the pole. One portable drill motor
or portable motor power unit shall be provided for each project.
9923.4.7 Portable Step-Down Transformer (One per Project): A portable
1.5 KVA dry type transformer shall be provided for each project. The transformer shall stepdown the high mast distribution voltage to 120/240 volts. The transformer shall be mounted in a
NEMA 3R enclosure and have a male plug or receptacle which mates to circuit power cable. The
transformer shall also have a 120 volt grounded receptacle for use by electric drill motor or
portable motor power unit.
992-4 Sign Lighting.
992-4.1 Luminaires and Ballasts: The luminaire shall consist of a precision cast
aluminum with a corrosive resistant polyester powder coat finish. The standard color shall be
gray. The cover shall be attached to the housing utilizing stainless steel bolts, and the housing
shall be sealed to provide an IP 55 rating or greater. The mounting assembly for a sign light shall
be a slipfitter type to accommodate a 1-1/2 inch, Schedule 40 steel pipe connection. The
luminaire manufacturer shall place a permanent tag on the luminaire housing on which the
following is imprinted: the luminaire voltage, lamp wattage and a blank area for the Contractor
to inscribe the installation date. The refractor shall be tempered clear or microprismatic glass.
Induction lamps shall meet the following requirements: CRI 80, CCT 5000 K and
average rated life of 100,000 hours.
The generator/ballast may be internal or external to the fixture. If the generator is
internal to the fixture, the maximum operating temperature shall not exceed 130F when
measured at the base point. If the fixture is not compatible with the circuit voltage, step-down
transformers or other equivalent circuitry shall be provided by the fixture manufacturer to
provide for a complete installation. The manufacturer shall provide a five year non-prorated
warranty to the Department. The warranty shall begin on the installation date.
992-5 Underdeck Lighting.
992-5.1 Luminaires and Ballasts: Luminaires shall consist of a die-cast aluminum
housing and reflector holder and a heat-resistant, high-transmission glass prisomatic refractor.
Housing shall have gasketing between the reflector and the refractor and the socket entry.
Luminaires shall be high pressure sodium vapor unless otherwise indicated in the Plans.
High pressure sodium lamps shall meet the following requirements:
NEMA C78.42, CRI 21 (Min), CCT 2100 K and average rated life of 24,000 hours (min).
1140
Underdeck fixtures may be wall mounted or pendant mounted fixtures. Pendant
mounted fixtures shall be vibration tested in accordance with NEMA C136.31.
992-2.5.2 Conductors: Underdeck structure lighting conductors shall be Type RHW or
THW and shall not be smaller than No. 10 AWG.
992-6 Wooden Service Poles.
992-6.1 General: Wooden service poles shall meet the requirements of ANSI (ASA) and
shall be at least 35 feet in length. The pole shall be Class 5 unless otherwise specified in the
Plans or in the Specifications.
992-6.2 Treatment: Poles shall be treated in accordance with ASTM D1760, Pressure
Treatment of Timber Products, with the exceptions and additions as specified herein. Pressure
treatment shall be with creosote oil, pentachlorophenol solution, or salt preservative meeting the
requirements of 955-4 with the restriction that poles treated with pentachlorophenol solution
shall not be used in a salt water nor brackish water environment.
992-6.3 Retention of Preservative:
992-6.3.1 Creosote Oil: Retention shall be at least 9 pounds per cubic foot of
wood.
992-6.3.2 Pentachlorophenol Solution: Minimum retention shall be 0.45 pound
of dry pentachlorophenol chemicals per cubic foot of wood.
992-6.3.3 Salt Preservative (Chromated Copper Arsenate): Minimum
retention shall be 0.60 pounds of CCA oxide per cubic foot of wood.
992-6.3.4 Measuring Retention: With all preservatives, retention shall be by
assay of sample from the 0.50 to 2.00 inch zone, performed and certified to by the treating
company.
992-6.4 Penetration of Preservative:
992-6.4.1 Determination: Penetration shall be determined as specified in
955-6.4.
992-6.4.2 Sapwood Penetration: Sapwood penetration shall be as specified in
955-6.2.
992-6.5 Retreatment: Retreatment, when necessary, shall be as specified in 955-6.3.
992-6.6 Mounting Height: Mounting height of all equipment and lines shall meet the
requirements of the latest edition of the National Safety Code, the local ordinances, and the
specifications of the connecting utility.
992-7 Protection of Light Poles.
Each metal pole shall be appropriately and adequately protected by tire wrapping with
heavy paper, or by some other effective means, so that no chipping, gouging, or other significant
surface damage will be incurred during transit or installation. The poles, when installed, shall be
clean and uniformly free from dark streaks and discoloration.
1141
SECTION 993
OBJECT MARKERS AND DELINEATORS
993-1 Object Markers.
993-1.1 General: Object markers shall meet the general requirements outlined in the
Manual of Uniform Traffic Control Devices (MUTCD). For uniformity, all Type 1 markers shall
be either OM1-1 or OM1-3 style markers, all Type 2 markers shall be either OM2-1V or
OM2-2V style markers and all end of road markers shall be either OM4-1 or OM4-3 style
markers.
993-1.2 Retroreflectors: The reflectors shall be of acrylic plastic and shall be a
minimum of 3 inches in diameter. They shall be mounted in a heavy-duty housing with a back
plate.
The reflector shall consist of a clear and transparent plastic lens, which shall be
red or amber as specified, and a plastic back of the same material, fused to the lens under heat
and pressure around the entire perimeter, in such manner as to form a homogeneous unit,
permanently sealed against dust, water, and water vapor.
The lens shall consist of a smooth front surface, free from projections or
indentations (other than for identification or orientation) and a rear surface bearing a prismatic
configuration such that it will effect total internal reflection of light.
The acrylic plastic shall be of a type meeting the requirements of Federal
Specification L-P-380, Type I, Class 3, and, in order that the Department can readily check the
suitability of the raw material used, the manufacturer shall stipulate the raw material and the
particular molding compound to be furnished.
993-1.2.1 Durability Tests for Retroreflectors: Seal Test: The following test
will be used to determine if a reflector is adequately sealed against dust and water.
Submerge 20 samples in water bath at room temperature. Subject the
submerged samples to a vacuum of 10 inches gauge for five minutes. Restore atmospheric
pressure and leave samples submerged for five minutes, then remove and examine the samples
for water intake. Failure of more than two of the 20 samples tested shall be cause for tentative
rejection of the LOT.
993-1.2.2 Optical Requirements: The initial specific intensity of object markers
shall be at least equal to the minimum values shown below. Failure to meet the required specific
intensity shall constitute failure of the reflector being tested.
Observation
Angle
Entrance
Angle
0.1 degree
0.1 degree
0 degree
20 degree
Crystal
40
16
Specific Intensity
candelas/foot-candle
Yellow
24
10
Red
10
4
The reflector to be tested shall be spun so as to have an average
orientation effect, and shall be placed at a distance of 100 feet from a single light source having
an effective diameter of 2 inches. The light source shall be operated at approximately normal
efficiency. The return light from the reflector shall be measured by means of a photo-electric
photometer having a minimum sensitivity of 1 by 107 foot-candles per mm scale division. The
1142
photometer shall have a receiving aperture of 1/2 inch diameter, shielded to prevent the entry of
stray light. The distance from light source center to aperture center shall be 2.1 inches for the
0.1 degree observation angle.
If a test distance other than the stipulated 100 feet is used, the source and
the aperture dimensions, and the distance between source and aperture shall be modified directly
as the test distance.
993-1.2.3 Reflector Housing: The reflector shall be mounted in a housing
fabricated of aluminum alloy No. 3003-H 14 (or other alloy approved as equal for the purpose),
and having a thickness of 0.064 inches.
993-1.3 Retroreflective Sheeting:
993-1.3.1 Retroreflective Sheeting: The retroreflective sheeting for object
markers shall meet the requirements of Section 994, sheeting Types III, IV, or VII. The
retroreflective area shall be in accordance with the MUTCD. The retroreflective sheeting shall be
permanently adhered to 0.040 inch sheet aluminum for Type 2 markers and 0.080 inch sheet
aluminum for Type 1, 3 and end of the road markers. Aluminum shall be of 6061-T6
(ASTM B209) prepared in accordance with recommendations of the sheeting manufacturer.
993-1.3.2 Assembly: Type 2 and 3 markers shall be mounted directly to the post
by two holes on the face of the marker. The mounting holes shall be 1/4 inch square holes to
receive 1/4 inch carriage bolts, or other 1/4 inch bolts and shall be spaced to fit holes on the post
spaced at 1 inch centers.
993-1.4 Posts: The marker posts shall be of steel or aluminum as shown in the Design
Standards or Plans. Steel posts shall be 2.5 lb/ft. flanged U-Channel . The U-channel posts shall
meet the mechanical requirements of ASTM A499, Grade 60. Provide U-channel posts that have
been galvanized after fabrication in accordance with ASTM A123 and have a smooth uniform
finish free from defects affecting strength, durability and appearance. For each U-channel, punch
or drill 3/8 inch diameter holes on 1 inch centers through the center of the post, starting
approximately 1 inches from the top and extending the full length of the post. Punching or
drilling operations shall be completed prior to galvanization. The weight per foot of a
manufacturers U-channel size shall not vary more than plus or minus 3.5% of its specified
weight per foot. Machine-straighten the U-channel to a tolerance of 0.4% of the length. Uchannel posts shall be listed on the QPL. Round aluminum posts shall meet the requirements of
Design Standards, Index No. 11860.
Use attachment hardware (nuts, bolts, clamps, brackets, braces, etc.) of aluminum
or galvanized steel.
993-2 Delineators.
993-2.1 General: Delineators shall be classified into four types: recycled flexible post
delineators, nonflexible post delineators, high visibility median separator delineators, and high
performance delineators.
993-2.2 Flexible Post Delineators:
993-2.2.1 Dimensions: The post shall have a minimum width of 3 inches facing
traffic and of such length to generally provide a height of 48 inches above the pavement surface.
993-2.2.2 Color: The post shall be opaque white. The yellowness index shall not
exceed 12 when tested in accordance with ASTM D1925 or ASTM E313. The daylight
45 degree, 0 degree luminous directional reflectance shall be a minimum of 70 when tested in
accordance with ASTM E1347.
1143
993- 2.2.3 Retroreflective Sheeting: The reflective sheeting shall be Types III,
IV, V or VII and meet the requirements of Section 994. The reflective sheeting shall have a
minimum width of 3 inches and have a minimum area of 30 square inches.
993-2.2.4 Impact Performance: Posts shall be tested and evaluated according to
the National Testing Product Evaluation Program (NTPEP) Project Work Plan for Field
Evaluation of Flexible Surface Mounted Delineator Posts. A temperature of 65F or greater may
be used in lieu of the NTPEP temperature requirements. Posts shall be capable of returning to a
vertical position plus or minus 5 degrees with no delaminating, and one post may list no more
than 10 degrees. No post shall split, crack, break, or separate from base.
993-2.3 Nonflexible Post Delineators:
993-2.3.1 Posts: The posts shall meet the requirements of 993-1.4, except the
steel delineator post shall be 1.1 lb/ft.
993-2.3.2 Retroreflective Sheeting: The retroreflective sheeting shall be
Types III, IV, V or VII sheeting and meet the requirements of Section 994. The reflective
sheeting shall have a minimum width of 4 inches and have a minimum area of 32 square inches.
The retroreflective sheeting shall be permanently adhered to 0.040 inch sheet aluminum.
993-2.4 High Visibility Median Separator Delineators:
993-2.4.1 Dimensions: The delineator shall have a minimum height of 42 inches
above the surface of the separator.
993-2.4.2 Post Base: The base shall be manufactured to accommodate the
replacement of the post. The base shall be mechanically anchored to the separator and be capable
of withstanding ten vehicle impacts without damage.
993-2.4.3 Color: The plastic post shall be opaque white. The yellowness index
shall not exceed 12 when tested in accordance with ASTM D1925 or ASTM E313. The daylight
45 degree, 0 degree luminous directional reflectance shall be a minimum of 70 when tested in
accordance with ASTM E1347 or ASTM E1164.
993-2.4.4 Retroreflective Sheeting: The reflective sheeting shall be Types III,
IV, V or VII and meet the requirements of Section 994. The reflective sheeting shall have a
minimum width of 8 inches and have a minimum area of 230 square inches facing the approach
to the separator.
993-2.4.5 Impact Performance: The post, installed according to manufacturers
recommendations, shall be capable of returning to a vertical position plus or minus 5 degrees
when tested according to National Testing Product Evaluation Program (NTPEP). The NTPEP
requirement of one-half of the hits at 32 F is waived. All hits may be at 65 F or greater. NTPEP
data or independent test lab data shall be submitted for product approval.
993-2.5 High Performance Delineators:
993-2.5.1 Dimensions: The delineator shall have a minimum height of 48 inches
above the pavement surface and have a minimum dimension of 2 inches.
993-2.5.2 Post Base: The base shall be manufactured to accommodate the
replacement of the post. The base shall be mechanically anchored to the pavement and be
capable of withstanding fifty vehicle impacts without damage.
993-2.5.3 Color: The plastic post shall be opaque white. The yellowness index
shall not exceed 12 when tested in accordance with ASTM D1925 or ASTM E313. The daylight
45 degree, 0 degree luminous directional reflectance shall be a minimum of 70 when tested in
accordance with ASTM E1347 or ASTM E1164.
1144
993-2.5.4 Retroreflective Sheeting: The reflective sheeting shall be Type V
abrasion resistant sheeting and meet the requirements of Section 994. The reflective sheeting
shall have a minimum omni directional area of 30 square inches.
993-2.5.5 Impact Performance: The post, installed according to manufacturers
recommendations, shall be capable of returning to a vertical position plus or minus 5 degrees
with no delaminating after receiving fifty vehicle impacts when tested according to National
testing Product Evaluation Program (NTPEP). The NTPEP requirement of one-half of the hits at
32F is waived. All hits shall be at 65F or greater. NTPEP data or independent test lab data
shall be submitted for product approval. For acceptance purposes there should be no post failures
and no more than two posts may list between 5 and 10after receiving fifty vehicle impacts.
993-3 Retroreflector Units for Guardrail and Concrete Barrier Wall.
993-3.1 General: Retroreflector units for use on guardrail and concrete barrier wall
installations shall consist of retroreflective sheeting permanently adhered to 0.090 inch minimum
thick body. The body shall have a flexible hinge which allows the reflector to fold down and
spring back to an upright position after impact. Guardrail reflectors shall be designed for
mounting to the web of steel posts or designed for mounting to wood posts. Barrier wall
reflectors shall be designed for mounting to the top of the barrier wall.
993-3.2 Retroreflective Sheeting: The sheeting for these reflector units shall be
Type IV, V, or VII meeting the requirements of Section 994. The sheeting shall be yellow or
white, depending on the locations of use for each. The dimensions of the reflective sheeting shall
be 3 inches wide by 4 inches high. The sheeting shall be installed by the reflector manufacturer.
993-3.3 Installation: The reflector units shall be capable of being installed on the top of
guardrail posts or the top of the barrier wall.
993-4 Product Acceptance on the Project.
Acceptance will be made in accordance with the requirements of Section 705.
Manufacturers seeking evaluation of their product must submit an application in accordance with
Section 6.
1145
SECTION 994
RETROREFLECTIVE AND NONREFLECTIVE
SHEETING FOR TRAFFIC CONTROL DEVICES
994-1 Description.
994-1.1 General: This Section specifies the requirements for retroreflective and
nonreflective sheeting materials, transparent and opaque process inks for retroreflective sheeting
materials and film overlays for traffic control devices.
994-1.2 Classification: Retroreflective sheeting material Types III, IV, V, VI and XI
shall be classified in accordance with ASTM D4956. In addition, a special classification,
Type VII (Special) is added for super high intensity retroreflective sheeting. This special
classification shall include materials classified as Type VIII and above in accordance with
ASTM D4956.
994-1.3 Qualified Products List (QPL): All sheeting, process inks and film overlay
materials shall be listed on the Departments Qualified Products List (QPL). Manufacturers
seeking evaluation of their products shall submit product data sheets, performance test reports
from an independent laboratory showing the product meets the requirements of this section, and
a QPL application in accordance with Section 6. Information on the QPL application must
include the product colors included in the application, classification, adhesive backing class, and
liner type. Information on the QPL application for process inks and film overlay products must
also include the compatible reflective sheeting material.
994-2 Materials.
Sheeting shall meet the requirements of Types III, IV, V, VI, and XI in ASTM D4956 or
Type VII (Special) and fluorescent pink listed below in accordance with their approved usage.
994-3 Performance Requirements.
994-3.1 General: Sheeting, process inks and film overlay materials shall be tested in
accordance with, and meet all the performance requirements of ASTM D4956, including
Supplemental Requirement S2, Reboundable Sheeting Requirements, except as amended in this
Section. Classification Type VII (Special) shall be tested in accordance with, and meet the
performance requirements of ASTM D4956 Type VIII, except as amended in this Section. For
performance requirements that are color dependant, each color included in the QPL application
must be tested and meet the requirements identified in ASTM D4956 or this Section as
applicable. Process inks and film overlay materials shall be applied to reflective sheeting in
accordance with Section 994-4 for testing.
994-3.2 Retroreflective Intensity: The retroreflective sheeting shall meet the minimum
initial requirements as stated for 0.2 degree and 0.5 degree observation angles in ASTM D4956.
Type VI fluorescent pink sheeting and Type VII (Special) sheeting shall meet the minimum
retroreflectivity requirements listed below.
Type VII (Special) Sheeting
Minimum Coefficient of Retroreflection
(cd/foot-candleft2)(cd/fcft2)
Observation/Entrance
Angle (degree)
White
Yellow
Red
Orange
Blue
1146
Green
Brown
Fluorescent
Orange
Fluorescent
Yellow
Fluorescent
Yellow/Green
0.2/-4
0.5/-4
0.2/30
0.5/30
380
250
220
135
304
195
176
105
95
55
48
30
250
100
110
50
19
12
11
7
38
25
22
14
19
8
9
3
180
60
85
33
220
145
125
75
360
235
205
125
Type VI Sheeting
Minimum Coefficient of Retroreflection
(cd/foot-candleft2)(cd/fcft2)
Observation/Entrance Angle
Fluorescent Pink
(degree)
0.2/-4
160
0.5/-4
100
0.2/30
100
0.5/30
40
994-3.3 Color: The fluorescent pink initial color shall meet the following x, y
chromaticity coordinates:
Fluorescent Pink
x
y
1
.450
.270
2
.590
.350
3
.644
.290
4
.536
.230
Fluorescent pink sheeting shall have a minimum luminance factor of 25.
994-3.4 Outdoor Weathering: Outdoor weathering exposure of sign sheeting materials
shall be in accordance with, and meet the requirements of ASTM D4956 for each product color
and classification and conducted at an exposure location meeting the Tropical Summer Rain
Climate Type (Miami, Florida or equivalent). Outdoor weathering is not required for Type VI
fluorescent pink and fluorescent yellow.
994-4 Direct and Reverse Screen Processing.
The transparent and opaque process inks furnished for direct and reverse screen
processing shall be of a type and quality formulated for retroreflective sheeting materials as
listed on the QPL and applied in accordance with the manufacturers instruction. Screen
processing in accordance with the techniques and procedures recommended by the manufacturer
shall produce a uniform legend of continuous stroke width of either transparent or opaque ink,
with sharply defined edges and without blemishes on the sign background that will affect the
intended sign use.
The retroreflective sheeting shall permit color processing with compatible
transparent and opaque process inks as approved by the sheeting manufacturer and listed on the
QPL.
994-5 In-Service Minimum Requirements.
The retroreflective sheeting and screen processed retroreflective sheeting shall have the
minimum coefficient of retroreflection as shown in ASTM D4956, Outdoor Weathering
Photometric Requirements for All Climates except Type VI fluorescent pink and fluorescent
yellow. In addition, Type VII (Special) classified sheeting materials shall have a minimum
1147
coefficient of retroreflection of 80% of the values listed in the above table. Only the observation
angle of 0.2 degrees and an entrance angle of minus 4 degrees shall be used in measuring inservice minimums. The in-service life for opaque overlay films, black processing inks and
opaque lettering shall equal the life of the reflective sheeting to which it is applied.
994-6 Packaging and Labeling.
Packaging and labeling shall meet the requirements of ASTM D4956.
994-7 Samples.
Field samples will be obtained in accordance with the Departments Sampling, Testing
and Reporting Guide Schedule or on a random basis at the discretion of the Engineer.
1148
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