tms manual

Transportation Materials Sampling

HIGHWAY TECHNICIAN CERTIFICATION PROGRAM University of Wisconsin-Platteville 049 Ottensman Hall 1 University Plaza Platteville, WI 53818-3099 Office Phone: 608-342-1545 Fax: 608-342-1982

PREFACE

The WisDOT Certified Aggregate Sampling Technician Course Manual was prepared and developed by the Highway Technician Certification Program staff at the University of Wisconsin-Platteville, the Highway Technician Certification Program instructors, and other contributors from WisDOT and the highway industry. The information contained in this course manual is intended to be used to train WisDOT personnel to conduct ONLY SAMPLING of aggregates on all types of WisDOT highway construction projects. The intent of this manual is to provide AASHTO-based training as it applies to aggregate sampling. It is the responsibility of the WisDOT Certified Aggregate Sampling Technician to follow all current WisDOT specification parameters and procedures when conducting work assignments for the Wisconsin Department of Transportation. The WisDOT Certified Aggregate Sampling Technician course manual was developed with these valuable resources:

1. ASTM D 3665 – Standard Practice for Random Sampling of Construction Materials

2. WisDOT Construction and Materials Manual (C & M Manual) 3. WisDOT Standard Specifications for Highway and Structure Construction 4. Supervisors Safety Manual, Fifth Edition 5. The Aggregate Handbook, National Stone, Sand, and Gravel Association 6. Portland Cement Concrete Materials Manual, FHWA 7. Hot-Mix Bituminous Paving Manual, FHWA

ACKNOWLEDGEMENTS

The HTCP Certified Aggregate Sampling Technician Manual committee members have been instrumental contributors to the contents of this course manual. The committee members are: Robert Jewell – The Kraemer Company Eric Zeinert – Michels Materials Jeff Michalski – WisDOT North Central Region Joseph White – WisDOT, Bureau of Technical Services, Retired John Brophy – WisDOT North Central Region Richard Sorensen-WisDOT QMP Engineer WisDOT Technical Assistance Hotline Representative:

Tom Brokaw, WisDOT, Bureau of Technical Services (608.246.7934)

TABLE OF CONTENTS

Course Overview TOPIC A Safety Considerations TOPIC B Aggregate Properties for Base Course TOPIC C ASTM D 3665 Standard Practice for Random Sampling Aggregates TOPIC D WisDOT Aggregate Sampling Procedures TOPIC E Hot Mix Asphalt-Truck Box Sampling TOPIC F Data Entry TOPIC G WisDOT Standard Specification Part 3: Bases and Subbases (for Aggregate Gradations) Section 301, 305 Part 4: Pavements (for Aggregate Gradations) Section 460-460.2.2.3 Part 5: Structures (for Aggregate Gradations) Section 501-501.2, 501.2.5.1-501.2.5.5 QMP: Base Aggregates Lab Exam Laboratory Exam QMP Award Expanded QMP Award Corr. / Eval. Corrections and Course Evaluation

Course Syllabus i 8:00 – 8:15 Registration, Introductions, Course Objectives, Course Syllabus 8:15 – 8:30 Safety Considerations 8:30 – 9:30 Aggregate Properties for Crushed Aggregate Base Course (CABC)

FHWA Segregation Video 9:30 – 9:45 Break 9:45 – 10:45 ASTM D 3665 Standard Practice for Random Sampling Aggregates, Hot Mix Asphalt-Truck Box Sampling, Data entry 10:45 – 11:45 Laboratory Demonstration of WisDOT Aggregate Sampling Procedures

Sample Size Requirements

Sampling from Stopped Conveyor Belt

Sampling from a Conveyor Belt Discharge

Sampling from Stock Piles

Sampling from Roadbed Windrows

Sampling after being Placed Roadbed 11:45 – 12:45 Lunch Break 12:45 – 1:45 Laboratory Student Hands-on Practice WisDOT Aggregate Sampling Procedures


Sampling from Stopped Conveyor Belt

Sampling from a Conveyor Belt Discharge

Sampling from Stock Piles

Sampling from Roadbed Windrows

Sampling after being Placed Roadbed 1:45 – TBA Practical Laboratory Student Examination TBA Break TBA WisDOT Standard Specifications, Section 301, 305, 460, and 501 and 501, for Aggregate Gradations TBA Review for Written Examination TBA Written Examination Adjourn

Course Overview ii Introduction The Highway Technician Certification Program (HTCP) welcomes you to the Certified Aggregate Sampling Technician course. This course requires eight hours of classroom/laboratory attendance. The course content will cover safety considerations; aggregates properties for base aggregate dense (BAD); ASTM D 3665 standard practice for random sampling; WisDOT aggregate sampling procedures; and WisDOT standard specifications Sections 301, 305, 310, 311 and 501 for aggregate gradations. Course Prerequisites None required. A person may earn 0.8 continuing education units (CEU’s) upon successful completion of this course. Certification Requirements The written examination will be limited to a maximum duration of one (1) hour. The written examination will be “open book and open notes” and will consist of true/false and multiple-choice questions, and essay problems. A student will be required to obtain a passing score of 70 percent to be certified as an Aggregate Sampling Technician. Recertification Requirements Recertification is mandatory every three (3) years. The HTCP will send a recertification notice to each certified technician and the firm or agency before the expiration date of the highest certification level(s) of certification obtained. The certified technician must apply for recertification before the expiration date of the highest level(s) obtained. Each certified technician is responsible for obtaining his/her recertification.

Revocation/Suspension of Certification Upon written request from any individual, firm, agency, or contractor associated with the HTCP, the HTCP director will provide technical assistance in investigating any alleged report(s) of either certified technician incompetence or act(s) of malfeasance. The HTCP director will then notify WisDOT of the report findings concerning certified technician incompetence or misconduct.

Course Overview iii Highway Technician Certification Program Goal The principle goal of the Highway Technician Certification Program (HTCP) is to certify that individuals have demonstrated the abilities to engage in quality control/quality assurance activities in highway work contracted by the Wisconsin Department of Transportation (WisDOT). Introduction of Course Participants At this time, you will be asked to introduce yourself, company name, years of service to the highway construction materials industry, and your present occupational duty. What do you expect from this Training Course? This is your opportunity, as a course participant, to ask the course instructor to cover any other topics related to the Certified Aggregate Sampling Technician course. Please list and identify topics below: Duties and Responsibilities of an Aggregate Sampling Technician: The duties and responsibilities of an Aggregate Sampling Technician are:

Know the safety, handling, and storage requirements for the equipment.

Know how to collect non-biased aggregate samples utilizing ASTM D 3665 Random Sampling mathematical method.

Know who is responsible for sampling, where samples, minimum frequency of sampling, and sample size for specified designation.

Know the proper WisDOT sampling aggregate procedures.

Be able to procure, properly label, and promptly deliver appropriate size samples to specified designation.

Course Overview iv Definitions and Terminology

Aggregate An inert mineral material such as sand, crushed gravel, crushed stone, or combinations thereof.

Absorption The process of a solid taking up liquid into its interior by capillarity.

Base Course The layer or layers of specified or selected material of designed thickness placed on a subbase or a subgrade to support a surface course.

Blue Tops Wooden hubs or stakes driven into the subgrade to indicate the finished subgrade elevation.

Borrow Suitable material from sources outside the right-of-way limits of the project, used primarily for embankments.

Coarse Aggregate Aggregate predominately retained on the No. 4 sieve.

Dense Graded Aggregate

A well-graded aggregate proportioned to contain a relatively small percentage of voids.

Density The weight per unit volume of a material, usually expressed in pounds per cubic foot.

Embankment The mound of soil, soil-aggregate, or broken rock constructed above the embankment foundation and below the subgrade.

Fine Aggregate Those aggregates which entirely pass the 3/8" sieve, almost entirely pass the No. 4 sieve, and are predominately retained on the No. 200 sieve.

Fineness Modulus A numerical value obtained by adding the total percentages of a sample of the aggregate retained on each of a specified series of sieves and then by dividing the sum by 100.

Gradation

A general term used to describe the composition by size of the aggregate particles in a mixture. It is usually expressed as the proportion (percent) of the aggregate that will pass a series of designated standardized sieves.

Granular Backfill Backfill of a specified gradation and consisting of sand, gravel, crushed gravel, crushed stone, or other fragmented material.

Moisture Content The proportion of moisture present in a material, expressed as a percentage of the oven-dry weight of the material.

Moisture-Density Relationship

The effect of moisture content on the density of a soil compacted according to specified conditions.

Nominal Maximum Particle Size

The nominal maximum size as indicated by the appropriate specification or description. If the specification or description does not indicate a nominal maximum size (for example a sieve size indicating 90-100% passing), use the maximum size (that sieve or size indicating 100% passing).

Open Graded Aggregate

A well-graded aggregate containing little or no fine aggregate and with a relatively large percentage of voids.

Optimum Moisture Content

The moisture content at which a particular soil will be brought to the greatest density obtainable with a specified compactive effort.

Pavement Structure

The combination of subbase, base course, and surface course placed on a subgrade to support the traffic load and distribute it to the road bed.

Course Overview v

Definitions and Terminology (continued)

Plastic Limit

The moisture content which is the boundary between the moldable and semi-solid states of consistency of a soil. It is defined as the moisture content at which a soil will just begin to crumble when rolled into a thread approximately 1/8-inch in diameter.

Quarry A deposit of ledge rock from which the rock is excavated by cutting or blasting.

Quartering A method of reducing the size of a sample with segregation.

Red Tops Wooden hubs or stakes driven into the base course to indicate the finished base course elevation, in preparation for final surface course.

Roadbed The graded portion of a highway which is contained within top and slide slopes and is prepared as a foundation for the pavement structure and shoulders.

Roadbed Material The material below the subgrade in cuts and fills (embankments) and in embankment foundations extending to such depth as affects the support of the pavement structure.

Sand Granular material almost entirely passing the No. 4 sieve and predominately retained on the No. 200 sieve.

Segregation Nonuniform distribution of the various particle sizes within an aggregate.

Sieve In materials testing work, a screen or series of screens have a standardized square opening and are used for subdividing a material into separate successive sizes.

Splitting Reduction in the size of a material sample preparatory to testing by means of a standardized method.

Stationing

A system used to specify the relative position of any point along the reference line. The starting point is usually designed with some arbitrary value, for example, 10 + 00 or 100 + 00, although 0 + 00 can be used. If the beginning point was 10 + 00, the first stake 100 ft along the line from it would be designated 11 + 00, the one 200 ft the line 12 + 00, and so on. The term full station is applied to each of these points set at 100-ft increments. A point located between two full stations, say 84.9 ft beyond station 17 + 00, would be designated 17 + 84.9. Thus locations of intermediate points are specified by their nearest preceding full station and their plus. In the designation of state 17 + 84.9, the plus is 84.9.

Statistically Random Sampling

Sampling at times or at locations determined in advance by the use of a table of numbers so arranged that every digit has an equal chance of occurring.

Subbase Course The layer or layers of specified or selected material of designed thickness placed on a subgrade to support a base course.

Subgrade The top surface of an earthen roadbed upon which the pavement structure and shoulders are constructed.

TOPIC A: Safety Considerations

TOPIC A: Safety Considerations Page A-1

Project Safety Precautions Safety is of prime importance while serving your occupational duty on the Wisconsin Department of Transportation (WisDOT) construction projects. Approximately 15% of all accidents are caused by unsafe mechanical or physical conditions. The other 85% of accidents result from absentmindedness, negligence, or ignorance of risk. No mysteries should surround an accident. All personnel involved with the project must be able to identify potentially dangerous situations and be prepared for preventive corrective action. Diagnosis of Any Accident There are five key elements in the diagnosis of any accident: 1. The agency or source of the

accident, [the item(s) directly related to the accident]

2. The type of accident [manner in which the person(s) were injured]

3. The unsafe condition [unsafe practice of person(s)]

4. The unsafe act (unsafe practice of the person)

5. The body part and kind of injury Each contributing element should be carefully analyzed and reported so a plan of corrective action can be developed and carried out to prevent future unnecessary accidents. While conducting your occupational duties on your project, remember to keep in mind the following considerations:


Know Your Safety Officer o Emergency Phone Numbers o Nearest Hospital Location

Safety Equipment o First Aid Kit o Fire Extinguishers o Fire Proof Gloves o Eye Protection o Ear Protection o Hard Hats o Safety Vest o Proper Ventilation

Equipment Operators o Always keep good eye

contact with operators when working close to heavy equipment.


Legal Background Subsection 107.7 of the Standard Specifications requires the contractor to comply with all federal, state, and local laws governing safety, health and sanitation, and to provide necessary safety devices, protective equipment and safeguards. The contractor shall also take all action reasonably needed to protect the life and health of employees on the job and the safety of the public. Wisconsin Statute 101.11 requires every employer to furnish safe employment and a safe place of employment for employees and frequenters. The employer shall furnish and require the use of safety devices, protective devices and safeguards, shall adopt and use methods and processes reasonably adequate to render the employment and the pace of employment safe, and do everything reasonably necessary to protect the life, health, safety and welfare of employees and frequenters. (Note: A frequenter is anyone who is not an employee of the contractor or not a trespasser.)

The Occupational Safety and Health Administration (OSHA), of the U.S. Department of Labor, is empowered to adopt rules or orders, having the full force of law, necessary for the safety and welfare of employees in the private sector. Thus, employees of the contractor and subcontractors are protected by the OSHA rules. OSHA administers and enforces their own rules. The Mine Safety and Health Act of 1977 and all applicable provisions of Title 30, Code of Federal Regulations are required when entering any mine, quarry, or sand and gravel operation.


The Wisconsin Department of Industry, Labor and Human Relations (DILHR) is empowered under Wisconsin Statute 101.055 to adopt safety rules or orders, having the full force of law, necessary for the safety and welfare of public employees. Thus, employees of the state, county, town, city and other political subdivisions of government are protected by the rules of DILHR. DILHR administers and enforces their own rules.

Under the Worker’s Compensation Act, which is administered by DILHR, a death benefit or compensation for an injury shall be increased if the employer failed to comply with adopted rules or orders of DILHR or OSHA. The death benefit or compensation for an injury shall be reduced if the employee failed to use safety devices required by DILHR or OSHA and provided by the employer, or if injury results from the employee’s failure to obey any reasonable safety rule adopted and enforced by the employer (Wisconsin Statutes 102.57 and 102.58).

Quarry & Gravel Pit Safety Precautions All outside personnel must immediately

check in at office before entering mine property.

All outside personnel must be accompanied by mine quarry personnel while on mine property.

Sampling at Quarry & Gravel Pit Operations Sampling, production or stockpile, is

never performed by outside personnel.

Due to moving conveyors, mobile equipment, and unstable stockpiled materials, all sampling at mining operations must be performed by qualified company personnel.


Effects of High Temperatures As a sampling technician, you may be faced with working in a high temperature environment. Working in high temperatures causes your body to work harder (increasing your heart rate) to cool off your body. The capillaries in your skin dilate to bring more blood to the surface so both the rate of cooling and the temperature of the body are increased. You need to be aware of three high temperature conditions which may be life threatening: Heatstroke (also known as sunstroke)

caused by body is unable to cool itself. Symptoms are hot, dry skin, severe headache, visual disturbances, rapid temperature rise, and loss of consciousness. Heat stroke is the most serious of the high temperature conditions. The victim should be removed from the high temperature environment immediately as the body should be cooled as quickly as possible (being wrapped in cool, wet sheets). Professional medical help should be

obtained as soon as possible. Heat cramps may result from exposure

to high temperatures for a relatively long period of time, typically accompanied by heavy exertion with excessive loss of salt and moisture from the body. Heat cramps cause cramping of the muscles of either the skeletal system or the intestines.


Heat Exhaustion may result from

physical exertion in a high temperature environment. The body cannot react quickly enough to cool itself. Symptoms of heat exhaustion consist of relatively low temperature, paleness, weak pulse, dizziness, profuse sweating, and a cool mist to the skin. Prevention of heat cramps and exhaustion may be treated with the use of salt tables. Generally, an adequate supply of salt is provided by a well balanced diet.

Carrying and Lifting An aggregate sampling technician will constantly be exposed to carrying and lifting as part of sampling duties. The general rules to carrying and lifting include: 1. Never permit personnel to overexert

themselves when carrying or lifting. Keep loads small by carrying and lifting smaller size samples.

2. Lift gradually, without jerking, to

minimize the effects of accelerated lifting.

3. Keep the load close to your body. 4. Lift without twisting your body.

TOPIC B: Aggregate Properties for Base Courses

TOPIC B: Aggregate Properties for Base Courses Page B-1

Description of Aggregates Aggregate is any hard, inert material used in graded sizes (fine to coarse), which are a part of the hot mix asphalt (HMA) pavement, Portland cement concrete (PCC), or aggregate base course. Aggregate is also referred to as rock, gravel, mineral, crushed stone, slag, sand, rock dust and fly ash. Several types of aggregate, which are available, are given below. Aggregates are also produced by crushing, screening, and grading to required sizes. Material which has been salvaged from old concrete pavements and structures as well as from asphaltic pavements. Aggregates, depending on use, have certain desired physical and chemical properties. These are given later in this section on aggregates used in HMA and base courses. Natural Aggregates Natural rocks occur either as outcrops at or near the surface or as gravel deposit usually along an old streambed. They are classified into three groups: igneous, metamorphic, and sedimentary. These classifications are based on the way the rocks were formed and they will not be further discussed here. Natural aggregates can be Pit or Bank-Run Aggregates or Process Aggregates.


Pit or Bank-Run Aggregates These include both gravel and sand, which are taken directly from the deposit without processing. Processed Aggregates These include pit or bank-run aggregates which have been crushed to make it more suitable for HMA. Crushing normally improves the particle shape by making the rounded particles more angular. Crushing can also improve the size distribution and range. Crushed stone is also a processed aggregate. It is created when the fragments of bedrock and large stone are crushed so that all particle faces are fractured. The crushed stone can be sized by screening; and the rock dust, which results from crushing, can be removed by washing. This rock dust can be used as crushed sand or as mineral filler in HMA. Recycled Aggregates Reclaimed asphalt pavements (RAP) and concrete pavements both contain valuable aggregates. The aggregate, if of good quality when placed, is most likely still of good quality and it can be reused in HMA pavements or in base courses. The properties desired of an aggregate, whether from RAP or from concrete pavements, or virgin material, are the same. These properties are given in the section on aggregates for HMA.


Typically, HMA mixtures may contain recycled materials. It is important that mixtures containing recycled materials meet the same specification that would be required of a virgin mixture. Synthetic Aggregates Aggregates produced by altering both the physical and chemical properties of a material are called synthetic or artificial. Aggregates are lightweight aggregate, which is produced by heating clay to a very high temperature, and slag, which is normally produced in the blast furnace during steel production. Synthetic aggregates are sometimes used in HMA. Rocks and Minerals Naturally occurring aggregates are a mixture of minerals and rock. Minerals are defined as naturally occurring inorganic substances of a definite chemical composition and a specific crystalline structure. Rocks are generally composed of one or more minerals. Rocks compose most of the coarse aggregates and mineral composes most of the fine aggregates. Aggregate Sources Aggregate sources are generally gravels and crushed stone. Naturally occurring aggregates are called gravels. Sometimes gravels are put through a crushing operation to reduce their size or to improve their shape. Some artificial aggregates are used but generally for specific purpose concretes such as lightweight concrete made from expanded clay.


Quarries and Gravel Pits About half of the concrete aggregates used in the United States come from gravels, the other half come from a rock source such as a quarry where the rock has been put through a crusher. Natural Fine Aggregate Natural fine aggregate is simply the smaller fragments that result when the edges of rocks are worn away. Due to the way it is formed, natural sand is generally quite round. If there is a shortage of natural sand, manufactured sand may be used. These are generally much more angular, however, and may cause different working characteristics in the concrete. Gradation Analysis Grading of aggregates is the distribution of particles among various sizes. The gradation is determined by doing an analysis with a set of sieves. Sieves are stacked with larger sizes on top. Gradation is usually expressed in terms of a percentage passing or a percentage retained on the various sieves.


Coarse Aggregate Sieves To make testing of aggregates more manageable, the aggregates are generally divided into classifications; coarse aggregate and fine aggregate. The distinction between these two size classes is based on whether or not the aggregate will pass a particular sieve. The most common sieve used for this purpose for concrete is the 4.75 mm (No. 4) sieve. This sieve has openings, which are just slightly smaller than a lead pencil. Any aggregates not passing this sieve are classified as coarse aggregates. Any aggregates passing this sieve are classified as fine. This slide depicts typically sieves used in a coarse aggregate analysis. Fine Aggregate Sieves There are many sieve sizes that could be used for analysis of fine aggregates. This is a listing of some of the most commonly used sieves for fine aggregates associated with highway work. Notice that each sieve is about one-half the size of the sieve above it. This assures you that there will be no gaps in your gradation analysis. Results of Sieve Analysis The results of the sieve analysis are sometimes plotted on a gradation chart. An experienced inspector can tell a great deal about the character of a concrete mix by examining the gradation chart. Limits or ranges are usually specified for the percentage of material passing each sieve.


Objectives of Aggregate Sampling The objectives of sampling aggregates are to ensure and maintain the integrity of what is being sampled. Properly procured aggregate samples are crucial to determining representative test results. Warning: “the use of improper sampling techniques and equipment may affect the actual results of the aggregate product quality. Also, valuable project productivity time and other personnel may be affected by ignoring specified WisDOT sampling methods and procedures.” Aggregate Sampling Concerns There are three potential sampling concerns, which may affect the way aggregate samples are procured. The aggregate sampling concerns are related to segregation, degradation, and contamination.


Segregation Segregation occurs when larger coarse particles separate from smaller, finer sized particles. Segregation occurs anytime the combined aggregate is moved. There is no real cure to totally avoid segregation problems between different sized particles. However, use extreme care to avoid segregated areas while obtaining representative aggregate samples. Degradation Degradation is the physical, chemical, and environmental conditions, which can cause a breakdown of the aggregate structure. For example: As a certified AGGTEC sampling technician, you will be required to sample aggregate material off a roadbed. It is extremely crucial to ensure the procured sample will be taken and collected prior to compaction by heavy equipment. Compaction by heavy equipment will change the particle shape of the aggregate, causing the introduction of increased fines into the aggregate sample. In turn, the additional fines generated by the compaction of the heavy equipment will not represent the actual roadbed material, which was placed. Sampling compacted roadbed material may contribute to erroneous test results. Contamination Contamination occurs when foreign material is subjected into the aggregate sample being procured. Aggregate sample contamination may occur at anytime while producing the sample on a project. Extreme care and attention to details must be exercised to avoid sample contamination. For example, aggregate sampling from the road, a certified AGGTEC sampling technician must know the depth of crushed aggregate base course before producing aggregate sample. Sampling below the depth of the crushed aggregate base will lead to sample contamination, thus procuring a misrepresentative aggregate sample

TOPIC C: ASTM D 3665 – Random Sampling for Aggregate Production and Roadbed Samples

TOPIC C: ASTM D 3665 – Random Sampling for Aggregate Production Page C-1

Definitions

Contractor Process Control Testing - contractor testing taken at the contractor’s initiative for process control. (non-random) Engineer Directed Testing - testing performed by the contractor as requested by the engineer. (also non-random) Independent Assurance - separate unbiased review, performed by the Department, to evaluate the sampling and testing of the quality control and verification technicians including personnel qualifications, procedures, and equipment. Quality Control Testing - testing performed by the contractor and used by the Department for product acceptance. The methods and minimum frequencies shall be as specified in the appropriate provision. Verification Testing - independent sampling and testing performed by the Department to validate the quality of the product.

Sample Size Aggregate sampling for obtaining minimum sample sizes shall be in accordance with the C & M Manual. The use of larger samples should be considered by the QC staff to increase the probability of obtaining a respective sample. When split samples are required by the provision, the field sample size shown in the C & M Manual needs to be doubled.

Random Sampling

The quality management program special provision specification requires the contractor to test "randomly selected samples" for the following properties: 1) material finer than 200 sieve, 2) sieve analysis of fine and coarse aggregates, 3) open base No. 1 and No. 2, and 4) fractured particles. The use of random sampling practice is specified with the intention of eliminating bias in the sample selection process and, thus, increasing the representative state of samples. Greater reliability is assigned to test results from this process and the "strength of data" is improved for statistical purposes.

The standard method recommended for selecting random samples is ASTM Method D 3665, "Standard Practice for Random Sampling of Construction Materials." Random numbers may be selected by following the instructions or by using a calculator with a random number generator or other commonly accepted methods of selecting random numbers.


The selection of random sampling points should be done by the contractor QC personnel. In order to fully ensure the selection of samples is random, only those who need the information (i.e. QC personnel) should be notified. The operator(s) SHALL NOT be advised in advance as to when samples are to be taken. The effectiveness of process control sampling is completely reliant on unbiased sampling and testing. Collusion between the QC personnel and plant operator(s), in this regard, may be cause for DECERTIFICATION of the sampling technician. Details of the sample selection processes will be addressed under the specific discussion for sampling aggregate. Sampling from Production Selection of Random Sample

When the contractor is producing material for a specific project, aggregate samples shall be selected randomly for testing. For example, at the beginning of each day, the contractor shall specify the anticipated tonnage of base course to be produced for the day. The frequency of sampling will then be determined from the quality management special provisions. In this example, test gradation once per 1500 tons during initial production. The anticipated tonnage will be split into appropriate lots and a sample obtained randomly from each lot. An example for an anticipated production of 3000 tons of base course in a day would be:

Minimum number of samples per day = 2 [from special provisions]

Sample 1: from 0 to 1500 tons

Sample 2: from 1500 to 3000 tons The tonnage for obtaining each sample within the lot shall be determined by selecting two (2) random numbers as described in the Method for Statistical Sampling, pages G-9 and G-10. The random numbers selected shall be multiplied by the tonnage lots selected for the day. These numbers shall then be added to the final tonnage of the previous lot to yield the approximate total tonnage when the samples are to be taken.


Calculations for the above example are: +Final Tons Tonnage Tonnage Random Lot Size Previous = for Sample Range Number X Random No. Lot Sampling

1 0 - 1500 x 0.569 = 854 + 0 = 854 2 1500 - 3000 x 0.335 = 503 + 1500 = 2003

This procedure is to be used for any number of samples selected randomly per day.

Example: ASTM D 3665 Random Sampling Method From Production At the beginning of the day, the contractor told the QC person that they would produce 3000 tons of CABC. The tests shall be taken from the conveyor belt. Determine the tonnage for sampling using the three-digit chart of numbers. Make sure to identify each random number with the designated line and column numbers. Frequency Daily Production (Tons) Number of Tests (per day) 0 - 1500 1 1500 - 3000 2

Sample No. 1st

Random No.

2nd

Random No.

Line No. Column No. Random No.

1 .842 .306 84 3 0.282

2 .259 .771 25 7 0.941

Sample

Tonnage Range

Random Number

Increments x

Random No.

+ Final Tons

Previous = Increment

Tonnage for

Sampling

1 1-1500 x 0.282 = 423 + 0 = 423

2 1500-3000

x 0.941 = 1412 + 1500 = 2912


Sampling from Roadbed The contractor quality control or quality assurance personnel shall obtain randomly selected samples of base course aggregate after the material has been placed out on the roadbed.

Selection of Random Samples for Gradation The tonnage points selected for sampling should be converted to correspond to stations on a project. This shall be accomplished by determining the station, which corresponds to the sample tonnage as close as is reasonably possible. Once the stationing is determined, the C&M Manual shall be followed for determining the field sample size and for sampling from the roadbed. The sampling procedure in the C&M Manual does not outline selection of sample lot locations by a mathematical random sample selection process. However, random sample selection should be used. For Example: It is determined the approximate station calculated tonnage is dumped on station 13+63. Next find the station offset for the actual sample location. The best solution to this is to set up an imaginary base line from existing field alignment stakes. Samples are typically taken from full depth base course (shoulder point to shoulder point). If the base course placement is too thick for one layer, more layers are used, and then samples are taken from each layer. Determine the width of aggregate based on layer placement. For this example, let us assume the width is 36 feet. The random number is 0.683. The offset from the base line (either side, but stay constant throughout the contract) is 36 X 0.683 = 25 feet rounded to nearest foot. Sampling shall take place after blading and shaping but prior to initiating compaction. The intent is to obtain samples as near to the final placement location of the material as possible so as to truly represent the aggregate placed. Sampling from roadbed windrows shall not be permitted, unless the subgrade is granular and with the prior approval of the engineer. Windrow samples are acceptable when it is not possible to differentiate the change in material between the CABC and the granular subgrade. Refer to the C&M Manual for the procedure in sampling from windrows. One sampling method outlined in the C&M Manual shall be adhered to throughout the work to facilitate data comparisons for the project. The contractor may make changes in sampling procedures if requested in writing and approved by the engineer.


Station 100+00

36 ft

100 ft

(baseline)

Example: ASTM D 3665 Random Sampling Method From Roadbed

Identify three randomly selected increments on the roadbed below. The roadbed is 36 feet wide and 100 feet in length. All three of the randomly selected increments shall be plotted starting at station 100 + 00.

1. Use the ASTM D 3665 random number procedure to determine the three sampling

increments. Select the line and column numbers for each increment using the space

provided.

Sample No. 1st Random No. 2nd Random No. Line No. Column No. Random No.

1) .623 .885 62 8 0.157 2) .436 .344 43 3 0 .370

3) .921 .406 92 4 0.498 4) .179 .241 17 2 0.537 5) .541 .928 54 9 0.586 6) .365 .473 36 4 0.044 2. Determine the three sample increments by multiplying the appropriate random numbers

by the width and length of roadbed.

1st Increment

1) 36 ft x .157 = 5.7 ft 2) 100 ft x .370 = 37.0 ft 2nd Increment 3) 36 ft x .498 = 17.9 ft 4) 100 ft x .537 = 53.7 ft 3rd Increment 5) 36 ft x .586 = 21.1 ft 6) 100 ft x .044 = 4.4. ft 3. Plot the designated sample increments on the roadbed (offset vs. length).


STUDENT EXERCISE: Sampling From Production 1. At the beginning of the day, the contractor told the QC person that they would

produce 3000 ton of CABC. The tests shall be taken from the conveyor belt. Determine the tonnage for sampling using the three-digit chart. Make sure to identify each random number with the designated line and column numbers. See B.1.5.1 – (2) Test gradation once per 1500 tons (1500 mg) during initial production.

Frequency Daily Production (Tons) Number of Tests (per day) 0 – 1500 1 1500 + 2

Sample No. 1st Random No.

2nd Random No.


1)

2)

Sample

Tonnage Range

Random Number

Increments x

Random No.

+ Final Tons

Previous = Increment

Tonnage

for Sampling

1)

2)


Station 100+00

36 ft

100 ft

STUDENT EXERCISE: Sampling from Roadbed 2. Identify three randomly selected increments on the roadbed below. The roadbed

is 36 feet wide and 100 feet in length. All three of the randomly selected increments shall be plotted starting at station 100 +00.

Use the ASTM D 3665 random number procedure to determine the three sampling

increments. Select the line and column numbers for each increment using the space provided.

Sample No. 1st Random No.

2nd Random No.


1)

2)

3)

4)

5)

6)

Determine the three sample increments by multiplying the appropriate random numbers by the width and length to determine the sample increments. 1st Increment 1) station = 2) offset = 2nd increment 3) station = 4) offset = 3rd Increment 5) station = 6) offset = Plot the designated sample increments on the roadbed (offset vs. length).

(Baseline)


Random Sampling

A typical random numbers chart follows on the next two pages. Here is how you use it to select a random number. A. The area under the bell curve, the normal distribution curve is segmented into

1000 equal pieces. Each of these areas is represented by a 3 digit decimal number. The first number is .001, the 23rd number is .023, the 552nd number is .552, etc., and the last number is 1.000.

B. The chart is printed on two pages. You may combine them on one sheet for

convenience. It is a good practice to alternate pages. Use the page on the left then the page on the right. For the next number use the page on the right then the page on the left. (You select these numbers by simply pointing at them with your fingers or a pencil, with your eyes shut.

C. Point at a number. Write down the first number you’ve selected. Assume it is

0.272. This is the first number in the chart. Point again. Use the second half of the chart on the right. Write down the second

number you’ve selected. Assume it is 0.119. This is the last number in the chart. D. The rows of numbers that go up and down (vertical) are the line numbers. There

are 100 lines. Use the first two digits of our first number, 0.272 which are 2 and 7 or 27. This

identifies line 27. The rows of numbers that go across (horizontal) are the column numbers. There

are 10 columns. Note that the first column number is 0. Use the first digit of our second number, 0.119, which is 1. This identifies the

second column. Our random number is 0.235. The key thought to remember when using this method for statistical sampling is “It

takes two numbers to get one number.” E. There are nine exceptions to this procedure. Those exceptions are .001, .002,

.003, .004, .005, .006, .007, .008, and .009. (The number 0.000 is not in the chart). In the event that one of these numbers is selected in the pointing process, disregard that number and point at another.

Student Question: What happens if you select 1.000 in the pointing process? Answer:

Use line 100.


CHART OF RANDOM NUMBERS

0 1 2 3 4 5 6 7 8 9

1 0.272 0.519 0.098 0.459 1.000 0.554 0.250 0.246 0.736 0.432

2 0.994 0.978 0.693 0.593 0.690 0.028 0.831 0.319 0.073 0.268

3 0.039 0.449 0.737 0.501 0.960 0.254 0.239 0.474 0.031 0.720

4 0.144 0.695 0.339 0.621 0.128 0.032 0.413 0.617 0.764 0.257

5 0.312 0.138 0.670 0.894 0.682 0.061 0.832 0.765 0.226 0.745

6 0.871 0.838 0.595 0.576 0.096 0.581 0.245 0.786 0.412 0.867

7 0.783 0.874 0.795 0.430 0.265 0.059 0.260 0.563 0.632 0.394

8 0.358 0.424 0.684 0.074 0.109 0.345 0.618 0.176 0.352 0.748

9 0.494 0.839 0.337 0.325 0.699 0.083 0.043 0.809 0.981 0.499

10 0.642 0.514 0.297 0.869 0.744 0.824 0.524 0.656 0.608 0.408

11 0.485 0.240 0.292 0.335 0.088 0.589 0.127 0.396 0.401 0.407

12 0.728 0.819 0.557 0.050 0.152 0.816 0.404 0.079 0.703 0.493

13 0.029 0.262 0.558 0.159 0.767 0.175 0.979 0.521 0.781 0.843

14 0.918 0.348 0.311 0.232 0.797 0.921 0.995 0.225 0.397 0.356

15 0.641 0.013 0.780 0.478 0.529 0.520 0.093 0.426 0.323 0.504

16 0.208 0.468 0.045 0.798 0.065 0.315 0.318 0.742 0.597 0.080

17 0.346 0.429 0.537 0.469 0.697 0.124 0.541 0.525 0.281 0.962

18 0.900 0.206 0.539 0.308 0.480 0.293 0.448 0.010 0.836 0.233

19 0.228 0.369 0.513 0.762 0.952 0.856 0.574 0.158 0.689 0.579

20 0.746 0.170 0.974 0.306 0.145 0.139 0.417 0.195 0.338 0.901

21 0.363 0.103 0.931 0.389 0.199 0.488 0.915 0.067 0.878 0.640

22 0.663 0.942 0.278 0.785 0.638 0.002 0.989 0.462 0.927 0.186

23 0.545 0.185 0.054 0.198 0.717 0.247 0.913 0.975 0.555 0.559

24 0.360 0.349 0.569 0.910 0.420 0.492 0.947 0.115 0.884 0.452

25 0.789 0.815 0.464 0.484 0.020 0.007 0.547 0.941 0.365 0.261

26 0.279 0.609 0.086 0.852 0.890 0.108 0.076 0.089 0.662 0.607

27 0.680 0.235 0.706 0.827 0.572 0.769 0.310 0.036 0.329 0.477

28 0.078 0.444 0.178 0.651 0.423 0.672 0.517 0.660 0.657 0.972

29 0.676 0.830 0.531 0.888 0.305 0.421 0.307 0.502 0.112 0.808

30 0.861 0.899 0.643 0.771 0.037 0.241 0.582 0.578 0.634 0.077

31 0.111 0.364 0.970 0.669 0.548 0.687 0.639 0.510 0.105 0.549

32 0.289 0.857 0.948 0.980 0.132 0.094 0.298 0.870 0.309 0.441

33 0.961 0.893 0.392 0.377 0.864 0.472 0.009 0.946 0.766 0.287

34 0.637 0.986 0.753 0.566 0.213 0.807 0.017 0.460 0.515 0.630

35 0.834 0.121 0.255 0.453 0.376 0.583 0.422 0.371 0.399 0.366

36 0.284 0.490 0.402 0.151 0.044 0.436 0.747 0.694 0.136 0.585

37 0.038 0.814 0.594 0.911 0.324 0.322 0.895 0.411 0.160 0.367

38 0.351 0.283 0.027 0.220 0.685 0.527 0.943 0.556 0.853 0.612

39 0.143 0.384 0.645 0.479 0.489 0.052 0.187 0.990 0.912 0.750

40 0.512 0.056 0.018 0.122 0.303 0.803 0.553 0.729 0.205 0.925

41 0.296 0.705 0.156 0.616 0.534 0.168 0.564 0.866 0.739 0.850

42 0.451 0.536 0.768 0.518 0.481 0.880 0.835 0.734 0.427 0.847

43 0.837 0.405 0.591 0.370 0.104 0.848 0.004 0.414 0.354 0.707

44 0.724 0.153 0.841 0.829 0.470 0.391 0.388 0.163 0.817 0.790

45 0.665 0.825 0.671 0.623 0.770 0.400 0.068 0.440 0.019 0.944

46 0.573 0.716 0.266 0.456 0.434 0.467 0.603 0.169 0.721 0.779

47 0.332 0.702 0.300 0.570 0.945 0.968 0.649 0.097 0.118 0.242

48 0.755 0.951 0.937 0.550 0.879 0.162 0.791 0.810 0.625 0.674

49 0.439 0.491 0.855 0.446 0.773 0.542 0.416 0.350 0.957 0.419

50 0.700 0.877 0.442 0.286 0.526 0.071 0.154 0.988 0.333 0.626


CHART OF RANDOM NUMBERS Continued

0 1 2 3 4 5 6 7 8 9

51 0.523 0.613 0.752 0.733 0.528 0.072 0.820 0.929 0.777 0.461

52 0.905 0.182 0.567 0.249 0.227 0.229 0.604 0.304 0.217 0.142

53 0.373 0.120 0.602 0.793 0.692 0.863 0.954 0.873 0.107 0.675

54 0.057 0.953 0.041 0.090 0.223 0.508 0.806 0.438 0.203 0.586

55 0.967 0.040 0.708 0.271 0.189 0.342 0.740 0.801 0.985 0.263

56 0.917 0.715 0.758 0.005 0.666 0.599 0.934 0.100 0.987 0.085

57 0.131 0.646 0.659 0.047 0.051 0.562 0.435 0.731 0.362 0.317

58 0.326 0.605 0.443 0.601 0.386 0.560 0.378 0.172 0.445 0.636

59 0.299 0.106 0.237 0.732 0.796 0.476 0.099 0.804 0.735 0.950

60 0.101 0.055 0.776 0.686 0.171 0.533 0.936 0.095 0.982 0.211

61 0.267 0.598 0.754 0.658 0.274 0.215 0.177 0.218 0.330 0.628

62 0.471 0.102 0.454 0.568 0.963 0.357 0.882 0.507 0.157 0.580

63 0.535 0.881 0.014 0.966 0.958 0.190 0.180 0.759 0.433 0.355

64 0.277 0.458 0.295 0.196 0.772 0.148 0.466 0.291 0.688 0.046

65 0.719 0.167 0.181 0.653 0.328 0.070 0.015 0.155 0.631 0.063

66 0.385 0.858 0.713 0.883 0.916 0.084 0.561 0.999 0.379 0.668

67 0.862 0.928 0.822 0.812 0.977 0.395 0.788 0.920 0.673 0.698

68 0.486 0.938 0.757 0.749 0.991 0.219 0.264 0.932 0.898 0.006

69 0.091 0.872 0.959 0.922 0.727 0.811 0.075 0.374 0.133 0.730

70 0.146 0.482 0.930 0.611 0.179 0.011 0.248 0.886 0.344 0.926

71 0.709 0.184 0.390 0.409 0.191 0.117 0.860 0.135 0.406 0.134

72 0.996 0.896 0.760 0.347 0.053 0.372 0.193 0.756 0.565 0.914

73 0.971 0.859 0.147 0.114 0.418 0.889 0.792 0.064 0.652 0.288

74 0.202 0.538 0.026 0.949 0.696 0.008 0.846 0.259 0.415 0.425

75 0.212 0.321 0.778 0.940 0.496 0.231 0.664 0.903 0.473 0.909

76 0.207 0.799 0.487 0.022 0.813 0.891 0.500 0.368 0.725 0.437

77 0.818 0.503 0.906 0.224 0.904 0.892 0.455 0.343 0.924 0.197

78 0.701 0.984 0.174 0.141 0.704 0.908 0.048 0.828 0.997 0.058

79 0.035 0.380 0.001 0.381 0.251 0.497 0.214 0.794 0.552 0.588

80 0.221 0.200 0.587 0.353 0.584 0.270 0.885 0.110 0.956 0.711

81 0.647 0.403 0.530 0.738 0.280 0.457 0.650 0.276 0.661 0.973

82 0.667 0.722 0.327 0.723 0.410 0.635 0.012 0.907 0.316 0.677

83 0.644 0.590 0.021 0.269 0.042 0.062 0.387 0.183 0.964 0.544

84 0.302 0.123 0.116 0.282 0.851 0.256 0.648 0.845 0.782 0.993

85 0.633 0.933 0.331 0.546 0.842 0.016 0.236 0.164 0.923 0.976

86 0.060 0.681 0.683 0.775 0.624 0.955 0.126 0.655 0.919 0.113

87 0.165 0.532 0.431 0.341 0.092 0.244 0.222 0.336 0.034 0.216

88 0.875 0.691 0.383 0.382 0.596 0.301 0.275 0.188 0.868 0.805

89 0.726 0.902 0.252 0.130 0.238 0.398 0.763 0.463 0.615 0.140

90 0.273 0.393 0.285 0.161 0.619 0.865 0.551 0.030 0.571 0.258

91 0.253 0.821 0.600 0.023 0.606 0.849 0.610 0.577 0.082 0.774

92 0.340 0.654 0.173 0.495 0.498 0.992 0.192 0.506 0.751 0.129

93 0.194 0.290 0.592 0.983 0.509 0.998 0.522 0.627 0.741 0.540

94 0.166 0.450 0.210 0.204 0.840 0.826 0.833 0.516 0.965 0.375

95 0.712 0.314 0.033 0.823 0.629 0.939 0.887 0.066 0.743 0.081

96 0.622 0.800 0.710 0.575 0.678 0.465 0.802 0.969 0.150 0.784

97 0.313 0.294 0.897 0.718 0.614 0.876 0.025 0.049 0.620 0.125

98 0.137 0.087 0.003 0.483 0.201 0.209 0.320 0.935 0.447 0.787

99 0.243 0.679 0.844 0.069 0.024 0.543 0.714 0.234 0.505 0.428

100 0.361 0.359 0.230 0.761 0.334 0.149 0.511 0.475 0.854 0.119


This material explains in detail the WisDOT method for statistical sampling. This doesn’t replace the AASHTO Standards (i.e. T-2, etc.) or the ASTM standards (i.e. D-3665, etc.) that are referenced in those AASHTO Standards. You can get a copy of the AASHTO Standards at:

American Association of State Highway & Transportation Officials 444 N. Capitol Street, N.W.

Suite 249 Washington, DC 20001

(202) 624-5800 www.transportation.org

http://www.transportation.org/


The following information is an expanded summary of the topic.

1

Topic C: Random Sampling

1


Definitions

Quality Control Testing –

Contractor Process Control Testing –

Verification Testing –

Independent Assurance –

Engineer Directed Testing –

2


Sample Size

Minimum Size from C & M Manual

Larger Sample can be used

Goal – Obtain Representative Sample

Double size when Split Samples Required

3

2


Random Sampling required for Tests:

Fine & Coarse Aggregate Gradations

Roadway Sampling

For Both Dense & Open Graded Aggregates

Material finer than #200 sieve (P200)

% Fractured Particles

Plasticity

4


Why do Random Sampling?

Eliminates Bias

More Representative Sample

Greater Reliability of Test Results

Improved Strength of Data

5

Topic C Random Sampling

How can Random Sampling be done?

ASTM D 3665 Instructions

Calculator with # Generator

Spreadsheet such as Excel

6

3


QC Personnel

Select Random Sampling Points

Only those who need to know locations are told

Do not advise Operators

Collusion can cause Decertification

7


How to use random numbers

When to get your sample

Where to get your sample on the roadway

8


Frequency for Sampling

Test gradation once per 3000 tons of estimated placement up to a maximum of 3 tests per day.

9

4


Demonstration –


Example Problem (One test per 3000 tons)

Split into appropriate lots

Sample 1: 0 to 3000

Sample 2: 3000 to 6000

10


11

Sample 1st Random

Number

2nd Random

Number

Line

Number

Column

Number

Random

Number

1

2

3

.767 .713 76 7 .368

.833 .468 83 4 .042

Do we need

this line?


12

Sample Tonnage

Range

Random

Number

Increments

x Rand No.

+ Final

Previous

=Increment

Tonnage

for

Sampling

1 x = + =

2 x = + =

3 x = + =

3000 .368 1104 0 1104

3000 .042 3000 3126

Do we need

this line?

126

5


Work Problem –




Sample 1: 0 - 3000

Sample 2: 3000 - 6000

13


Work Problem –




Sample 1: 0 - 3000

Sample 2: 3000 - 6000

14


Where on the roadway do we sample?

Find out tonnage at Truck Scale

Follow truck out to Roadway

Sample first station where load is placed

15


Student Notes:

6


16

What is Stationing?


17

How do we plot locations?

1-X

2-X

3-X


18

Sample 1st Random

Number

2nd Random

Number

Line

Number

Column

Number

Random

Number

1

2

3

4

5

6

.298 .794 29 7 .502

.608 .813 60 8 .982

.338

.073

.925

.352

.627

.751

.164

.964

33

07

92

35

6

7

1

9

.009

.563

.654

.366

7


19

1st Increment Random

Number

Location

Dimensions

1 x =

2 x =

2nd Increment

3 x =

4 x =

3rd Increment

5 x =

6 x =

100

36

36

36

100

100

.502

.982

.009

.563

.654

.366

50

35

1

20

65

13

Increments in Third Station


20

Where are the locations?

1-X

2-X

3-X 36’ Width

TOPIC D: Sampling Aggregates

TOPIC D: Sampling Aggregates D-1

Sampling of Aggregates

Aggregates are the main ingredient in most highway construction. They are used in all phases from base construction, pavement mixes, granular shoulders, granular surfacing, and erosion control. For aggregates to perform as intended, they must meet certain physical requirements such as proper gradation, durability to resist the effects of weathering, and resistance to abrasion loss. At this point, all the money and time which will be expended on the remaining activities of testing and evaluation may be lost or rendered useless by an improper sampling technique. In other words, if the samples taken are not representative of the total material, it is impossible to end up with meaningful test results. At the completion of this instruction, the technician must know how to obtain a proper sample. Without this knowledge, it is useless to proceed further into the areas of the test procedures. Test samples should represent the total amount of the material being produced or used. During production at the source, care must be taken to ensure the virgin material being processed is normal to the overall consistency of the available material. Clay pockets, boulders, or varying seams in a gravel pit, mine, or quarry may create short-term variations in the consistency of the product.

AGGREGATES “are the main ingredient in most

highway construction.”

Importance of Sampling “If the samples taken are not representative of the total material, it is impossible to end up with meaningful test results. At the completion of this instruction, the technician must know how to obtain a proper sample. Without this knowledge, it is useless to proceed further into the areas of the test procedures.”


SAMPLING AGGREGATES


1. General. The minimum weight of the field sample depends on the nominal maximum particle size of the aggregate that is to be sampled. The weight of the field sample will always be greater than that portion required for testing and shall meet the requirements of Table 1.

TABLE 1 - SIZE OF SAMPLES

Nominal Maximum Size of Particles Passing Sieve

Minimum Weight of Field Samples

Kg Lb

Fine Aggregate

2.0 mm (No. 10) 5 10

4.75 mm (No. 4) 5 10

Coarse Aggregate

9.5 mm (3/8 in.) 5 10

12.55 mm (1/2 in.) 10 25

19.0 mm (3/4 in.) 15 35

25.0 mm (1 in.) 25 55

31.75 mm (1 1/4 in.) 25 55

37.5 mm (1 ½ in.) 30 70

50 mm (2 in.) 40 90

62.5 mm (2 ½ in.) 45 100

Larger than 2 ½ in. 115 250

Reference should be made to CMM 8.50, Materials Testing and Acceptance Guide, for specific sample sizes required for submittal to the Central Laboratory.

The sample should be reduced to the size needed for a specific test by using either a riffle splitter, quartering method or miniature stockpile method for damp fine aggregate only.

2. Definitions.

A. Field Sample. A composite of all increments sampled. B. The nominal maximum particle size as indicated by the appropriate

specification or description. If the specification or description does not indicate a nominal maximum size (for example a sieve size indicating 90-100% passing), use the maximum size (that sieve or size indicating 100% passing).

NOTE: Nominal maximum particle size definition for HMA = One size larger than the

first sieve to retain more that 10% and is distinct from other aggregates.


SAMPLING FROM A CONVEYOR BELT After normal flow has been established, randomly obtain at least three approximately equal increments from the unit being sampled and combine them to form a field sample of the required size. Stop the conveyor belt while the sample increments are being obtained. Separate the increments at their ends and collect all the material, including the fines, and place in a container. If the angle of the conveyor belt is such that the aggregates roll, place templates, with forms fitting the configuration of the conveyor belt, through the increments at their ends before collecting the material. SAMPLING FROM A CONVEYOR BELT DISCHARGE

Randomly select units to be sampled from production after normal flow has been established. Obtain at least three approximately equal increments from the unit being sampled and combine to form a field sample. Take each increment from the entire cross-section of the material as it is being discharged.

SAMPLING FROM STOCKPILES 1. Alternate 1. Obtain increment samples from

each quarter point of the working face of the stockpile, the working face being the face of the pile from which the aggregate is being removed. Obtain each quarter point sample by cutting deep into the face of the pile with an end loader or other similar power equipment. Dump each quarter point sample in a separate pile, level the pile, and take at least three shovels full to form one increment. The total sample will consist of three increments, one increment from each quarter point sample.


2. Alternate 2. Obtain increments with a square-

nosed shovel from quarter points of the pile perimeter at both 1/3 and 2/3 levels of slope length from bottom to top. Increments shall be obtained by holding a protective barrier above the sampling location to prevent aggregate slide and discarding 254 - 305 mm (10 - 12 inches, of surface aggregate. Total sample = 8 increments.

SAMPLING FROM ROADBED WINDROWS A windrow to be considered for sampling should be uniform in cross-section and well mixed. A slightly moist condition of the aggregate is desirable both for mixing and sampling purposes. When the contract is in English units, a 100-foot unit should be selected to represent the area to be evaluated. When the contract is in metric units, a 40 m unit if in a rural area, a 20 m unit if in an urban area,

should be selected for evaluation. If the above units cannot be selected, than another length may be selected and so noted in the project records. Obtain at least three random samples of approximately equal size within the unit selected. Prior to obtaining the sample increments, the outside surface of the windrow should be removed at each selected location.

SAMPLING AFTER BEING PLACED ON ROADBED A visual inspection for uniformity of the area to be sampled should be made after the material has been mixed and laid out. Lack of uniformity should be corrected before proceeding with the sampling. Obtain at least three approximately equal increments, selected at random, from the unit being sampled. When the contract is in English units, a 100 foot unit should be selected to represent the area to be evaluated. When the contract is in metric units, a 40 m unit if in a rural area or a 20 m unit if in an urban area, should be selected for evaluation. If the above units cannot be selected, than another length may be selected and so noted in the project records.


Take increments for the depth of the material under consideration, being careful not to contaminate the sample with any underlying material. When a shovel is used, it shall be squared-nosed. Care should be taken not to cause degradation of the aggregate during the sampling process. Care should also be taken to keep the sides as vertical as possible during the excavation.

STUDENT EXERCISE:

Nominal Maximum Particle Size 1. Determine the appropriate aggregate sample size for a 3/4 in. (19.0 mm)

nominal maximum particle size to be utilized on a project when split samples are required by the provision.

a) 25 lb. (10 kg) b) 35 lb. (15 kg) c) 50 lb. (20 kg) d) 70 lb. (30 kg)

2. Determine the appropriate aggregate sample size for a 3/4 in. (19.0 mm)

nominal maximum particle size to be utilized on a project when split samples are not required by the provision.

a) 25 lb. (10 kg) b) 35 lb. (15 kg) c) 50 lb. (20 kg) d) 70 lb. (30 kg)


STUDENT EXERCISE - ANSWER

Nominal Maximum Particle Size


nominal maximum particle size to be utilized on a project when split samples are required by the provision.

a) 25 lb. (10 kg) b) 35 lb. (15 kg) c) 50 lb. (20 kg) d) 70 lb. (30 kg) – correct answer


nominal maximum particle size to be utilized on a project when split samples are not required by the provision.

a) 25 lb. (10 kg) b) 35 lb. (15 kg) – correct answer c) 50 lb. (20 kg) d) 70 lb. (30 kg)


The following information is an expanded summary of the topic.

TOPIC E: Sampling Asphaltic Mixtures from Truck Box E-0

Video: Hot Mix Asphalt-Truck Box Sampling

http://mediasite.uwplatt.edu/uwp/Play/6907f0169a664a748d28aae9a4adfdfe1d?catalog=fe890230-e467-4d26-ad5f-22b286b6d3d2

TOPIC E: Sampling Asphaltic Mixtures from Truck Box E-1

Truck Loading Procedures Proper truck loading procedure may help alleviate problems with segregation (typically consisting of larger-sized aggregate particles rolling down the side of the pile) of Hot-Mix Asphalt (HMA) during load-out. When loading HMA into a truck, a single dump will produce segregation of HMA material all around the inside edges of the truck box (refer to figure I-1, Single Dump Loading). Figure I-1. Single Dump Loading Figure I-2. Multiple Dumps

(Produces segregation all around the inside (Minimizes the segregated area within edges of the truck box) the truck box) Using multiple dumps reduces the surface area exposed to segregation, which, in turn, minimizes the segregation problem. The multiple dumps should be made as close as possible to the front and rear and the final dump should be placed in the center (refer to Figure I-2, Multiple Dumps). Sampling From the Truck Box Sampling from a truck box is the contractor’s responsibility. This sampling presents some safety hazards because it is necessary to climb atop the truck box and stand on the hot mixture while sampling. Special care should be exercised by the contractor (or his designated representative) as the sample is obtained to prevent falls or burns. Sample Device. The shovel or other approved sampling device shall be of such size and configuration that each increment of a sample can be obtained in one attempt without spilling or roll off. In order to satisfy this requirement with a flat bottom shovel, it is necessary to attach two to four inch vertical sides to the shovel. The total sample size is required to be enough material to meet the testing and retained requirements as set by the QMP. For guidance on amount of material needed see Topic Q (Procedure 4-15-52, page 4).

Sampling Asphaltic Mixtures from Truck Box

When the last batch has been dumped into the truck box, establish a reference point on the surface of the load, either at the high point if a conical shape exists or near the middle of the truck box if the surface shows no such conical shape. Then establish at least three incremental sample points about midway between the previously established point and the sides of the truck and equally spaced around the load (see sketch). At these sampling points, remove the upper two to three inches of mixture and then insert the sampling shovel or other approved device into the mixture to extract the sample increments and place increments in a sample container.

The total sample for a 12.5 mm mix shall weigh at least 70 lb.

X - Reference Point A - Sample Point B - Sample Point C - Sample Point

Figure I-3. Sampling Plan for a Truck Box

Sample Identification The contractor is responsible for procuring and splitting of samples. When the sample is an aggregate sample, it shall be split, placed in bags with plastic liners, and labeled as directed below. When a mixture sample is procured, it shall be quartered, placed in a bag and labeled as directed below. The label shall include:

1. Contractor 2. QC, QC-ret, QV, or QV-ret 3. State Project ID 4. Date 5. Sample Number 6. Type of Asphaltic Mixture 7. State Verification Mix Design Number 8. Percent Binder 9. Tonnage Sampled 10. Current Gsb

Figure I-4. Example of Sample Labeling

HTCP QC-ret

Prj. ID : 1130-02-72

7 / 15 / 01 sple 4 – 3

E – 1 12.5mm 250-0088-2001

5.5% AC 1,206 ton

Sampling Asphaltic Mixtures from Truck Box Page 1

Checklist for HMA Sampling Observe sample to be random by asking for documentation

Observe sample to be representative

Insure complete identifying/label information:

Paving Contractor Type of Asphalt Mixture

QV/QV-ret WisDOT Mix Design ID #

State Project ID # Percent Binder (%AC)

Date Daily Tonnage Sampled

Previous QC Sple # Current Gsb

Full name of sampler (and contact phone #)

Obtain a copy of mixture loadout ticket

Minimum sample size

< 12.5mm (1/2”) 70 LB

19.0mm -25mm (3/4” – 1”) 100 LB

> 37.5mm (1-1/2”) 160 LB

Separate trucks for QC & QV samples

Expedite samples to the Regional Lab (same/next day)

as there are specification requirements for completion

of testing.

Checklist for HMA Sampling Observe sample to be random by asking for documentation

Observe sample to be representative

Insure complete identifying/label information:

Paving Contractor Type of Asphalt Mixture

QV/QV-ret WisDOT Mix Design ID #

State Project ID # Percent Binder (%AC)

Date Daily Tonnage Sampled

Previous QC Sple # Current Gsb

Full name of sampler (and contact phone #)

Obtain a copy of mixture loadout ticket

Minimum sample size

< 12.5mm (1/2”) 70 LB

19.0mm -25mm (3/4” – 1”) 100 LB

> 37.5mm (1-1/2”) 160 LB

Separate trucks for QC & QV samples

Expedite samples to the Regional Lab (same/next day)

as there are specification requirements for completion

of testing.

TOPIC F: Data Entry F-0

Note: Check the CMM link to verify the latest version

http://roadwaystandards.dot.wi.gov/standards/cmm/


TOPIC F: Data Entry F-1

MATERIAL DATA REPORTING FOR QC, QA, QV, IA ON HIGHWAY CONSTRUCTION PROJECTS

The above is from the Atwood Systems website: http://www.atwoodsystems.com/resources/

http://www.atwoodsystems.com/resources/

June 2013 Page 1

Construction and Materials Manual Wisconsin Department of Transportation Chapter 8 Materials Testing, Sampling, Acceptance Section 10 Materials - General

Materials sampling and testing methods and documentation procedures prescribed in chapter 8 of the CMM are mobilized into the contract by standard spec 106.3.4.1 and standard spec 106.3.4.3.1.

8-10.1 Control of Materials

8-10.1.1 Approval of Materials Used in Work

The service life of a highway is dependent upon the quality of the materials used in its construction, as well as the method of construction. Control of materials is discussed in standard spec 106.1. The spec provides that only materials conforming to the requirements of the contract must be used, and the contractor is responsible for furnishing materials meeting specified requirements. Only with permission of the engineer can the contractor provide materials that have not been approved, as long as the contractor can provide evidence that the material will be approved later. The department's intention is to hold payment of items until the required materials information is provided by the contractor.

The standard specs encourage recovered and recycled materials to be incorporated into the work to the maximum extent possible, consistent with standard engineering practice. Standard spec 106.2.2 and Wisconsin statute 16.754 require the use of American made materials to the extent possible. On federally funded projects, all steel products must be produced in the United States, and manufacturing and coating processes must be performed in the U.S. These "Buy America" requirements are discussed in CMM 2-28.

8-10.1.2 Contractor and Department Designated Materials Persons

Standard spec 106.1.2 requires the contractor to designate a dedicated materials person (CDMP) who will be responsible for submitting all contractor materials information to the engineer. The department should also designate a dedicated materials person (WDMP) who will be in direct contact with the contractor's designee.

Standard spec 106.1.2 requires the CDMP to communicate with all subcontractors to ensure that sampling, testing, and associated documentation conforms to the contract. The contract also makes the CDMP responsible for submitting materials information from the prime contractor and subcontractors to the WDMP, promptly reporting out-of-specification test results, collecting and maintaining all required materials certifications, and regularly communicating with the WDMP regarding materials issues on the contract.

The WDMP should provide a project-specific sampling and testing guide (E-Guide) to the contractor at the preconstruction conference. The E-Guide is created from the following site:

http://www.atwoodsystems.com/sysportal.htm

Both the CDMP and WDMP should review and supplement the E-guide before work operations begin to ensure that testing methods, frequencies, and documentation requirements conform to the contract.

The CDMP and WDMP are charged with working together throughout the life of the contract to ensure that contract materials requirements are met and any issues that might arise related to either non-conformance or non-performance are dealt with promptly. The ultimate goal is to make sure that problems with materials are brought to light and timely corrective action taken before those materials problems compromise the quality or acceptability of the completed work.

The CDMP should coordinate contractor materials related activities and do the following:

- Establish methods and work expectations with the WDMP.

- Provide all QMP test data and control charts from the prime contractor and subcontractors.

- Deal with all materials-related concerns from the WDMP.

The WDMP is responsible for administration of the contract with regards to contract materials requirements and should do the following:

- Communicate or meet weekly with the CDMP to discuss outstanding materials issues on the contract.

- Monitor the submittals from the CDMP to ensure timeliness and completeness.

- Review contractor submittals to verify materials requirements are met.

- Inform the Project Leader of non-conforming materials issues and discuss actions to be taken.

- Prepare materials documentation for inclusion into the project files.

http://roadwaystandards.dot.wi.gov/standards/stndspec/ss-01-06.pdf#ss106.3.4.1

http://roadwaystandards.dot.wi.gov/standards/stndspec/ss-01-06.pdf#ss106.3.4.3.1

http://roadwaystandards.dot.wi.gov/standards/stndspec/ss-01-06.pdf#ss106.1

http://roadwaystandards.dot.wi.gov/standards/stndspec/ss-01-06.pdf#ss106.2.2

http://roadwaystandards.dot.wi.gov/standards/cmm/cm-02-28.pdf#cm2-28






CMM 8-10 Materials - General

June 2013 Page 2

8-10.2 Approval of Materials

All materials used in a project are subject to the engineer's approval before incorporation into the work. Approval of materials is discussed in standard spec 106.3. Approval is generally accomplished by material tests and/or analysis. This can be done by using approved product lists, certification, or sampling and testing. Unless the contract specifies otherwise, the contractor must follow manufacturer's recommended procedures for products incorporated into the work. Refer to CMM 8-45 for details of acceptance types.

8-10.3 Quality Management Program

Sampling and testing on WisDOT projects is performed according to the Quality Management Program (QMP). QMP is presented in CMM 8-30 and the following CMM sections.

8-10.4 Independent Assurance Program

The Independent Assurance Program (IAP) is an element of the Quality Management Program intended to ensure that test data from project acceptance testing is reliable, including sampling procedures, testing procedures, and testing equipment. Quality verification (QV), quality assurance, (QA), and quality control (QC) are integral parts of the IAP. Further information about the Independent Assurance Program can be found in CMM 8-20.

8-10.4.1 Quality Verification (QV)

Quality verification (QV) sampling is done by a department representative, and is taken independently from the quality control samples to validate the quality of the material.

8-10.4.2 Quality Assurance (QA)

Under the quality assurance (QA) program, a department representative observes sampling and testing performed by the contractor, by testing split samples. Further detail about quality verification and quality assurance is provided in CMM 8-20.

8-10.4.3 Quality Control (QC)

Quality control for materials testing includes all contractor/vendor operational techniques and activities that are performed or conducted to fulfill the contract requirements.

8-10.5 Nonconforming Materials

8-10.5.1 General

The department does not want material not meeting contract specifications incorporated into the work. Standard spec 106.5 gives the engineer the authority to either reject nonconforming materials or to allow the nonconforming materials to remain in place. If materials are found to be unacceptable before or after placement into the work, the engineer may reject the materials, and the contractor must remove the materials from the site at no cost to the department. Materials that have been tested and approved at their source or otherwise previously approved, but have become damaged or contaminated before use in the work, are also subject to rejection by the engineer.

To ensure consistency in the decisions made for acceptance of non-conforming material or workmanship, the engineer should involve the region oversight engineer before finalizing any decision. This will help keep central office informed about contractor or material problems that may require action with a change in specifications or discipline of a contractor. If any technical questions remain about the acceptance or rejection of nonconforming materials refer to the appropriate technical expert in the Bureau of Technical Services.

8-10.5.2 Nonconforming Materials Allowed to Remain in Place

8-10.5.2.1 Deciding Whether or not to Allow Material to Stay in Place

Good engineering judgment is required when making decisions on nonconforming materials. The engineer may choose to approve nonconforming materials, allow them to remain in place, and adjust the contract price. When making the decision to direct the contractor to remove and replace the materials versus leave the materials in place, it's important to consider the following:

- Long-term consequences on quality and durability.

- Implications on the project's life cycle costs, service life, serviceability, and maintenance.

- Socioeconomic, environmental, and aesthetic considerations.

- Impacts on traffic, staging, and construction timeframes.

8-10.5.2.2 Deciding Whether or Not to Apply Price Reduction

After the engineer has decided to allow nonconforming materials to remain in place, he or she must carefully evaluate each situation in deciding whether to take a price reduction. The goal is to achieve consistency statewide in administering price reductions for nonconforming materials that are allowed to remain in place.









CMM 8-10 Materials - General

June 2013 Page 3

Results of retests and related quality tests should be considered. The following list includes some examples of the types of factors the engineer must consider to decide if a price reduction is warranted and how much it should be:

- Has the contractor been conscientious to provide quality by carefully controlling materials and construction operations?

- Has the contractor been proactive and made good use of QC data to maintain and improve quality?

- Did the engineer provide the contractor with non-conforming test results within the contractual timeframe, if specified?

- If timeframes are not specified, did the engineer provide non-conforming test results in time for the contractor to make process or materials corrections?

- Upon becoming aware of a materials quality problem, has the contractor responded quickly to correct it?

- Is the nonconforming test an isolated incident or a recurring situation?

- How does the nonconforming test compare to the rest of the project data:

- Have material test results been well within specification requirements or consistently at the very limit of what is acceptable?

- How many tests are nonconforming vs. how many tests have passed?

- How far out of spec is the non-conforming test?

8-10.5.3 Price Reductions Specified in the Contract with Administrative Items

If price reductions are included in the specifications or special provisions for certain nonconforming items, the price reductions should be administered using the appropriate 800 series administrative items. Since the price reductions are included in the contract language, the engineer can add the 800 series items to the contract without going through the complete change order process. Approval by a DOT representative and contractor representative are not necessary, though it's good practice to communicate the changes to all parties. Further guidance on the 800 series administrative items is provided in CMM 2-38.

For payment of nonconforming items with associated administrative items, pay for the installed quantity and bid price of the work item under the original bid item. The pay reduction will be accounted for using the administrative item. Compute the price reduction by multiplying the quantity of nonconforming material by the original unit price and the percent price reduction. The pay units of all administrative items are DOL. Document all calculations, and pay for the (negative) total calculated price reduction as the pay quantity, with 1 dollar as the pay unit.

Example 1

- Contractor placed total of 19,000 SY of Concrete Pavement 9 inch - 670 SY (12' x 500') is 1/8" - 1/2" under plan thickness - Standard spec 415.5.2 directs to pay 80% contract price for this range (20% reduction) - Bid unit cost is $35/SY Using original bid item, pay 19,000 SY at $35/SY = $655,000 Compute price reduction = 670 SY x $35 x -0.20 = -$4,690 Add the administrative item 804.6005 Nonconforming Thickness Pavement to the contract, with

unit price of $1.00 Pay quantity of -$4,690 Net pay = $655,000 - $4,690 = $650,310

Paying for nonconforming items this way allows for clean tracking of as-built quantities. The use of administrative items can easily be tracked to monitor specific items that are frequently the target of price reductions. This can help the department develop improved specifications and construction methods.

8-10.5.4 Price Reductions Not Specified in the Contract

If specific price reductions are not outlined in the contract specifications or special provisions, standard spec 106.5 gives the engineer the option to take a price reduction on nonconforming materials allowed to remain in place. The engineer has latitude to decide whether a price reduction is appropriate, and what amount the price reduction should be.

For payment of nonconforming items, use full quantity and bid price of the work item. Apply the price reduction by submitting a change order that creates a new item with the same bid item number but with the supplemental





July 2014 Page 1

Construction and Materials Manual Wisconsin Department of Transportation Chapter 8 Materials Testing, Sampling, Acceptance Section 45 Materials Testing and Acceptance - General

Materials sampling and testing methods and documentation procedures prescribed in chapter 8 of the CMM are mobilized into the contract by standard spec 106.3.4.1 and standard spec 106.3.4.3.1.

8-45.1 Acceptance Procedures, Documentation, and Reporting

Documentation and reporting for materials acceptance is equal in importance to Item Record Account documentation. The basis of acceptance for contract materials is accomplished in several ways, depending on the material. The type of reporting and documentation is a function of the acceptance type.

Materials test reporting and documentation is to be done using the WisDOT electronic Materials Tracking System (MTS). The MTS is a computerized filing and reporting system for construction materials tests and documents. All construction materials tested and inspected for WisDOT projects are reported on the MTS. The overall MTS has three basic components, the MTS (LAN/WAN attached), Materials Information Tracking System (MIT), and the Materials Tracking website. Region and central office laboratory personnel can enter data directly into the Oracle database via a Local Area Network (LAN) attachment provided through the MTS. The MIT is used for entering tests from the field.

The engineer should follow these guidelines for material documentation:

- Inspect all manufactured products as soon as possible after delivery.

- Include all approved lists, certified sources, and pre-qualified products.

- Record in the project record relevant inspection information.

- Verify that products delivered match the certifications, approved list, etc.

- Review all Certifications of Compliance and Certified Reports of Test and Analysis.

- Reference all Certifications, shop inspection reports, and other external documents using the MTS/MIT prefix 900 report.

All materials documentation and reporting must be completed and entered in the MTS no more than 60 working days after the work completion date.

Manufactured products must be inspected at the job site as soon as possible after arrival for evidence of damage or noncompliance even though these materials are covered by prior inspection testing or certification.

Those materials normally source inspected, but which arrive at the job without appropriate marking, indicating that they have been accepted at the source, must be field inspected or tested and the basis for acceptance must be documented in the inspector’s diary.

8-45.1.1 Materials Testing and Acceptance Guide

The Materials Testing and Acceptance Guide, CMM 8-50 details many of the sampling, testing, and documentation requirements for various materials. The instructions shown in this guide are recommended minimum requirements. In many cases, it may be appropriate to increase the frequency and scope of certain testing and acceptance activities in order to properly administer the materials specifications. In all cases, it is appropriate to closely observe produced materials for visual evidence of changes in quality and to then adjust testing frequencies, as required, to adequately evaluate their quality.

Sampling and testing procedures of certain unique materials are described in the standard specs and other contract documents. The instructions in this guide are intended to supplement those in other contract documents.

8-45.1.2 E-Guide

E-Guide is an automated system that produces condensed sampling, testing and documentation guidance for material requirements for a project. It generates the guidance in two basic ways. For the project bid items, the system automatically generates guidance. For non-standard special provision (SPV) items, the system requires manual input of the SPV material requirements contained in the project proposal. CMM 8-50 should be cross checked when an E-Guide is developed since it contains detailed information and it breaks material information out by type. The E-Guide system for developing a project specific sampling and testing guide is available at:

http://www.atwoodsystems.com/syslinks.cfm

The WisDOT project material coordinator shall prepare the E-Guide and provide a copy to the contractor's material coordinator. Consult the region materials engineer or region person responsible for construction

http://roadwaystandards.dot.wi.gov/standards/stndspec/ss-01-06.pdf#ss106.3.4.1

http://roadwaystandards.dot.wi.gov/standards/stndspec/ss-01-06.pdf#ss106.3.4.3.1



CMM 8-45 Materials Testing and Acceptance - General

July 2014 Page 2

materials for guidance when developing the E-Guide.

The E-Guide does not supersede material requirements in the Standard Spec or the CMM. The contractor is contractually bound to supply the information if required in the Standard Spec, CMM or Special Provisions.

The region materials engineer or region person responsible for this area must be consulted regarding doubts as to the adequacy of compliance of source inspected materials, need for field inspection and reports, waiver of testing, unlisted items, evaluation of certifications, or other questions regarding acceptance procedures.

Table 1 below defines the general documentation requirements for each materials acceptance type. Table 2 provides the MTS prefixes for all material types. Figure 1, Figure 2, and Figure 3 show example test reports.

CMM 8-45 Materials Testing and Acceptance - General

July 2014 Page 3

Table 1 Documentation Requirements for Different Acceptance Types

Documentation Required

Acceptance Type

MIT/MTS Document

MTS Documentation

Time Line Remarks

MTS Report. Verification tests- C.O. Laboratory

Various MTS prefixes as appropriate. See Table 2 for a list of prefixes.

No later than one week after completion of test.

Test entry by C.O. Lab personnel.

Materials Diary entry

MTS reference report.

Approved Product Lists- WisDOT

Reference on MTS prefix 900 or 155

No later than 60 days after contract work completion date.

Test entry by project personnel.

Form DT 1823, Report of Shop Inspection.


Materials Diary entry.

Source or Shop Inspection



Test entry by project personnel.

Source sampled materials tested and reported by C.O. personnel (see verification tests C.O. Lab above).

Cert. of Compliance


Materials Diary entry.

Manufacturers Certification of Compliance



See note below [1].

Cert. Report of Test


Materials Diary entry

Certified Report of Test



See note below [1].

Verification tests-MTS Report.

Field Sampling and Testing

Aggregates- MTS prefix 162, 217

HMA- MTS prefix 254

HMA Nuclear Density- MTS prefix 262

Concrete Cylinders – MTS prefix 130

Earth Work Density- MTS prefix 232

No later than one week after completion of test.

All aggregate and HMA QV testing done must be entered by the qualified lab doing the testing.

When QV and Companion Cylinder testing is done the data must be entered by the qualified laboratory doing the testing.

Quality Management Program (QMP) Quality Control (QC) tests.

MTS Report.

MRS Report (Structures Masonry Data)- contractor entry.

MRS Report (IRI ride data) contractor entry.

Field Sampling and Testing

MTS Report 155 No later than 60 days after contract work completion date- prefix 155 data.

MRS data is to be input by the contractor as it is developed.

Refer to Figure 1, Figure 2, and Figure 3 for examples of prefix 155 reports for verification of contractor QMP and QC testing.

[1] Certifications must be evaluated promptly for adequacy, completeness, and compliance with the specifications. The certification reviewer must make appropriate notations, initial, and date the document when the review is completed.

Topic G: WisDOT Standard Specifications PART 3: BASES AND SUBBASES (for Aggregate Gradations) Section 301, 305 PART 4: PAVEMENTS (for Aggregate Gradations) Section 460-460.2.2.3 PART 5: STRUCTURES (for Aggregate Gradations) Section 501-501.2, 501.2.5.1-501.2.5.5 QMP: Base Aggregates Note: Check the Standard Specification link to verify the latest version



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Effective with the December 2014 Letting 122 2015 Standard Specifications

Section 301 General Requirements for Base Aggregates

301.1 Description

(1) This section describes requirements common to aggregate bases constructed with crushed materials. Exceptions and additional requirements for crushed aggregate bases are specified in:

- 305 for dense graded bases.

- 310 for open graded bases.

301.2 Materials

301.2.1 General

(1) Provide coarse aggregates from a department-approved source as specified under 106.3.4.2.

301.2.2 Definitions

(1) Interpret these terms, used throughout part 3, as follows:

Aggregate A composite mixture of hard, durable mineral materials that have been mechanically processed.

Virgin materials Mineral materials in a native or raw form, not previously-used.

Gravel Naturally occurring rounded particles of rock that will be retained on a No. 10 sieve.

Sand Granular material having at least 90 percent passing the No. 4 sieve and predominantly retained on the No. 200 sieve.

Crushed stone Crushed angular particles of rock retained on a No. 10 sieve.

Fractured face An angular, rough, or broken particle surface with sharp edges.

Reprocessed material Waste material for which a commercially demonstrated process uses the material as a raw material.

Reclaimed asphaltic material Crushed or processed asphaltic pavement or surfacing recovered from a contractor-designated source.

Salvaged asphaltic material Crushed or processed asphaltic pavement or surfacing recovered from a department-designated source.

Breaker run Aggregate resulting from the mechanical crushing of quarried stone or reclaimed concrete not screened or processed after primary crushing.

Pit run Unprocessed aggregate, with predominately 1 1/2-inch or larger sized particles, obtained from a gravel pit.

Select crushed material Crushed and screened aggregate with particles predominately larger than 1 1/2 inches.

301.2.3 Sampling and Testing

(1) Department and contractor testing shall conform to the following:

Sampling[1] .............................................................................................................................................. AASHTO T2

Percent passing the 200 sieve[1] ........................................................................................................... AASHTO T11

Gradation[1] ........................................................................................................................................... AASHTO T27

Gradation of extracted aggregate ......................................................................................................... AASHTO T30

Moisture content[1] .............................................................................................................................. AASHTO T255

Liquid limit ............................................................................................................................................. AASHTO T89

Plasticity index ...................................................................................................................................... AASHTO T90

Wear ..................................................................................................................................................... AASHTO T96

Sodium sulfate soundness[2] ............................................................................................................... AASHTO T104

Freeze/thaw soundness ...................................................................................................................... AASHTO T103

Deleterious Materials[3] .............................................................................................. AASHTO T113 and CMM 8-60

Fracture ..................................................................................................................................................... CMM 8-60

Moisture/density[1] ................................................................................................................................. AASHTO T99

In-place density[1] ................................................................................................................................ AASHTO T191

Asphaltic material extraction .......................................................................... CMM 8-36 WisDOT Test Method 1560




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[1] As modified in CMM chapter 8.

[2] Use aggregate retained on the No. 4 sieve using 5 cycles of the sodium sulfate soundness test.

[3] Use these tests to determine the acceptability of aggregates that have excessive deleterious material.

(2) Contact the engineer to collect sample aggregates proposed for the project. The engineer and contractor will jointly obtain the sample. The sampler must be HTCP certified to sample aggregates. Do not place base until the engineer tests and approves the material, except as allowed in 106.1.

301.2.4 Aggregate Requirements

301.2.4.1 General

(1) Furnish aggregates substantially free of deleterious materials.

(2) The department may prohibit the use of crushed stone from limestone/dolomite deposits that have thinly bedded strata or strata of a shale nature. The department may also prohibit the use of aggregate from deposits or sources known to produce unacceptable material.

301.2.4.2 Aggregate Classifications

(1) Provide aggregate conforming to one of the following classifications based on weight percentages.

Crushed stone or crushed gravel >= 85 percent virgin aggregates

Crushed concrete >= 90 percent crushed concrete that is free of steel reinforcement and includes < 10 percent asphaltic pavement or surfacing, base, or a combination of asphaltic pavement, surfacing, and base, incorporated during the removal operation.

Reclaimed asphaltic pavement >= 75 percent asphaltic pavement or surfacing.

Reprocessed material Consists of crushed concrete, reclaimed asphaltic pavement, crushed stone or gravel, or other construction materials that is thoroughly mixed and conforms to the following:

1. >= 80 percent is a combination of crushed concrete and asphaltic pavement or surfacing; where:

- < 90 percent is crushed concrete, or else the material is classified as crushed concrete.

- < 75 percent is reclaimed asphaltic pavement, or else the material is classified as reclaimed asphaltic pavement.

2. < 20 percent is crushed stone or gravel, concrete block, brick, cinder, or slag particles; where:

- < 10 percent of the final mixture is concrete block particles.

- < 5 percent of the final mixture is brick, cinder, or slag particles.

Blended material A blend of crushed stone, crushed gravel, crushed concrete, reclaimed asphaltic pavement, or reprocessed material thoroughly mixed and meeting the following:

1. Each individual component material, incorporated into the blend must meet the requirements of table 301-2 except for gradation. The final blend must conform to the specified gradation.

2. < 75 percent is reclaimed asphaltic pavement, or else the material is classified as reclaimed asphaltic pavement

3. < 90 percent is crushed concrete, or else the material is classified as crushed concrete.

4. < 80 percent is a combination of crushed concrete and asphaltic pavement or surfacing, or else the material is classified as reprocessed material.

5. < 85 percent is crushed stone or gravel, or else the material is classified as virgin aggregate.

301.2.4.3 Uses For Aggregate Classifications

(1) The contractor may furnish the aggregate classifications, at the contractor's option, for the specified base types as allowed in table 301-1.

http://roadwaystandards.dot.wi.gov/standards/cmm/cm-08-00toc.pdf#0

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TABLE 301-1 USES FOR VARIOUS AGGREGATE BASE CLASSIFICATIONS

BASE TYPE CRUSHED STONE

and CRUSHED GRAVEL

CRUSHED CONCRETE

RECLAIMED ASPHALTIC PAVEMENT

REPROCESSED MATERIAL

BLENDED MATERIAL

Dense 3/4-inch Yes Yes No Yes[1] Yes[1]

Dense 1 1/4-inch Yes Yes Yes Yes Yes

Dense 3-inch Yes Yes Yes Yes Yes

Open graded Yes Yes No No No

[1] The contractor may provide reprocessed material or blended material as 3/4-inch base only if the material contains 50 percent or less reclaimed asphaltic pavement, by weight.

301.2.4.4 By-Product Materials

(1) The contractor may provide an aggregate with one of the following by-product materials mixed with crushed gravel, crushed concrete, or crushed stone up to the listed maximum percentage, by weight.

Glass ............ 12% Foundry slag ............ 7%

Steel mill slag ............ 75% Bottom ash ............ 8% Pottery cull ............ 7%

(2) Furnish by-product materials substantially free of deleterious substances.

(3) Crush, screen, and combine materials to create a uniform mixture conforming to the predominant material specifications.

(4) If the aggregate contains a by-product material, the department will test the final product for gradation, wear, soundness, liquid limit, plasticity, and fracture as required for the predominant material.

(5) Do not use aggregate containing a by-product material in the top 3 inches of a temporary or permanent aggregate wearing surface.

301.2.4.5 Aggregate Base Physical Properties

(1) Furnish aggregates conforming to the following:

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TABLE 301-2 AGGREGATE BASE PHYSICAL PROPERTIES

PROPERTY CRUSHED STONE

and CRUSHED GRAVEL

CRUSHEDCONCRETE

RECLAIMEDASPHALTICPAVEMENT

REPROCESSED MATERIAL

BLENDED MATERIAL

Gradation AASHTO T27

dense 305.2.2.1 305.2.2.1 305.2.2.2 305.2.2.1 305.2.2.1[1]

open 310.2 310.2 ---- ---- ----

Wear AASHTO T96 loss by weight

<=50% note[2] ---- note[2] note[3]

Sodium sulfate soundness

AASHTO T104 loss by weight

dense <=18% ---- ---- ---- note[3]

open <=12% ---- ---- ---- note[3]

Freeze/thaw soundness AASHTO T103 loss by weight

dense <=18% ---- ---- ---- note[3]

open <=18% ---- ---- ---- note[3]

Liquid limit AASHTO T89

<=25 <=25 ---- ---- note[3]

Plasticity AASHTO T90

<=6[4] <=6[4] ---- ---- note[3]

Fracture CMM 8-60

min one face by count

dense 58% 58% ---- note[5] note[3]

open 90% 90% ---- ---- ----

[1] The final aggregate blend must conform to the specified gradation.

[2] No requirement for material taken from within the project limits. Maximum of 50 percent loss, by weight, for material supplied from a source outside the project limits.

[3] Required as specified for the individual component materials defined in columns 2 - 5 of the table before blending.

[4] For base placed between old and new pavements, use crushed stone, crushed gravel, or crushed concrete with a plasticity index of 3 or less.

[5] >=75 percent by count of non-asphalt coated particles.

301.3 Construction

301.3.1 Equipment

(1) Use specialized pneumatic or vibratory compaction equipment or a combination of both types of machines. Do not use tamping rollers. Use pneumatic compaction equipment conforming to 207.3.6.2. The engineer may allow the contractor to compact the shoulder foreslopes with other equipment.

301.3.2 Preparing the Foundation

(1) Prepare the subgrade, or resurface the previously placed base layer, as specified in 211.3.3 before placing base. Do not place base on foundations that are soft, spongy, or covered by ice or snow. Do not place base on frozen foundations unless the engineer approves otherwise. Water and rework or re-compact dry foundations as necessary to ensure proper compaction, or as the engineer directs.


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301.3.3 Stockpiling

(1) If continuous compliance with material specifications is questionable, the engineer may require the contractor to supply material from a stockpile of previously tested material. Maintain a sufficiently large stockpile to preclude the use of material not previously approved.

(2) Build and maintain stockpiles using methods that minimize segregation and prevent contamination. If the contract specifies location, place stockpiles where specified. Clear and prepare stockpile areas to facilitate the recovery of the maximum amount of stockpiled material.

301.3.4 Constructing Base

301.3.4.1 General

(1) Place aggregate in a way that minimizes hauling on the subgrade. Do not use vehicles or operations that damage the subgrade or in-place base. Deposit material in a way that minimizes segregation.

(2) Construct the base to the width and section the plans show. Shape, and compact the base surface to within 0.04 feet of the plan elevation.

(3) Ensure there is adequate moisture in the aggregate during placing, shaping, and compacting to prevent segregation and achieve adequate compaction.

(4) Maintain the base until paving over it, or until the engineer accepts the work, if paving is not part of the contract. The contractor is not responsible for maintaining material placed on detours, unless the special provisions specify otherwise.

301.3.4.2 Standard Compaction

(1) Compact the base until there is no appreciable displacement, either laterally or longitudinally, under the compaction equipment. Route hauling equipment uniformly over previously placed base. Compact each layer before placing a subsequent layer. If the material is too dry to readily attain the required compaction, add water as necessary to achieve compaction.

301.3.4.3 Special Compaction

(1) If the contract requires special compaction, compact each layer to 95 percent of maximum density, or more, before placing the subsequent layer. The engineer will determine the maximum density according to AASHTO T99 method C or D and in-place density according to AASHTO T191.

301.3.5 Excavation Below Subgrade

(1) The engineer may request EBS in areas of placed base. Restore the surface in EBS areas to the plan grade and cross section or as the engineer directs.

301.3.6 Controlling Dust

(1) Apply water or other engineer-approved dust control materials to control dust during construction and maintenance of the base and shoulders.

301.4 Measurement

301.4.1 General

(1) For aggregate measured by the ton, the department will determine the weight based on contractor-provided tickets. Give the engineer a ticket, for each load delivered to the project, showing the net weight of the load, the type of material, the date, and project number.

(2) For weighed aggregate delivered with a moisture content greater than 7 percent, the department will reduce the ticket weight by the weight of water exceeding 7 percent. The department will determine the aggregate moisture content based on and expressed as a percent of the aggregate dry weight.

(3) For aggregate measured by the cubic yard, the department will determine the volume in the vehicle.

301.4.2 Alternate Measurement Procedures

(1) The department may convert the measurement method from weight to volume or volume to weight as specified in 109.1. The engineer may adjust the conversion factor daily or with changing conditions, such as moisture content, as specified in 301.4.1.

301.5 Payment

(1) Contractor testing for department-approved aggregate sources is incidental to the work.

(2) The department will only pay for engineer-approved EBS to correct problems beyond the contractor's control. Work performed under 105.3 to correct unacceptable work is the contractor's responsibility. For

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EBS performed after placing subbase or base in the EBS area, the department will pay for EBS as follows:

1. For excavation, the department will pay 3 times the contract unit price for the Excavation Common bid item under the EBS Post Placing Subbase or EBS Post Placing Base administrative item.

2. For backfill and restoration with the materials the engineer directs, the department will pay 3 times the contract unit price for the bid items of each material used to fill the excavation and restore the subbase or base under the Restoration Post Completion administrative item.

3. For excavation, backfill, or restoration work without contract bid items, as extra work.

(3) Payment also includes water for compaction and dust control except, if the contract contains the Water bid item, the department will pay separately for compaction and dust control water under 624.5.

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Section 305 Dense Graded Base

305.1 Description

(1) This section describes constructing a dense graded base using one of the following aggregates at the contractor's option:

Crushed stone Reclaimed asphaltic pavement

Crushed gravel Reprocessed material

Crushed concrete Blended material

305.2 Materials

305.2.1 General

(1) Provide aggregate conforming to 301.2 for crushed stone, crushed gravel, crushed concrete, reclaimed asphaltic pavement, reprocessed material, or blended material.

305.2.2 Gradations

305.2.2.1 General

(1) Except for reclaimed asphaltic pavement, conform to the following gradation requirements: PERCENT PASSING BY WEIGHT

SIEVE 3-INCH 1 1/4-INCH 3/4-INCH

3-inch 90 - 100 ____ ____

1 1/2-inch 60 - 85 ____ ____

1 1/4-inch ____ 95 - 100 ____

1-inch ____ ____ 100

3/4-inch 40 - 65 70 - 93 95 - 100

3/8-inch ____ 42 - 80 50 - 90

No. 4 15 - 40 25 - 63 35 - 70

No. 10 10 - 30 16 - 48 15 - 55

No. 40 5 - 20 8 - 28 10 - 35

No. 200 2.0 - 12.0 2.0 - 12.0[1][3] 5.0 - 15.0[2]

[1] Limited to a maximum of 8.0 percent for base placed between old and new pavement.

[2] 8.0 - 15.0 percent if base is >= 50 percent crushed gravel.

[3] 4.0 - 10.0 percent if base is >= 50 percent crushed gravel.

(2) Unless the plans or special provisions specify otherwise, do the following:

1. Use 1 1/4-inch base in top 4 or more inches of base. Use 3-inch base or 1 1/4-inch base in the lower base layers.

2. Use 3/4-inch base in the top 3 inches of the unpaved portion of the shoulder. Also, if using 3-inch base in the lower base layers, use 3/4-inch base in the top 3 inches of the shoulder foreslopes. Use 3/4-inch base or 1 1/4-inch base elsewhere in shoulders.

305.2.2.2 Reclaimed Asphaltic Pavement

(1) For reclaimed asphaltic pavement, furnish material conforming to the following:

- 100 percent passing a 1 1/4-inch sieve.

- 75 percent or less of the aggregate passing a No. 4 sieve.

- Asphalt content between 3 percent and 6.5 percent inclusive.

(2) The department will assess these properties primarily by visual inspection but may test questionable material. If testing the material, the department will determine the properties as follows:

- For the percent passing the 1 1/4-inch sieve, the department will test without conducting an asphaltic material extraction.

- For the percent passing the No. 4 sieve and percent of asphalt content, the department will test by conducting an asphaltic material extraction as specified in 301.2.3.

(3) The contractor may use reclaimed asphaltic pavement as 3-inch base, or 1 1/4-inch base without regard to the gradation requirements under 305.2.2.1.

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305.3 Construction

305.3.1 General

(1) Construct dense graded base conforming to 301.3.

305.3.2 Compaction

305.3.2.1 General

(1) Compact each base layer, including shoulder foreslopes, with equipment specified in 301.3.1. Use standard compaction conforming to 301.3.4.2, unless the special provisions specify other methods. Final shaping of shoulder foreslopes does not require compaction.

305.3.2.2 Compacting 1 1/4-Inch Base and 3/4-Inch Base

(1) If using a pneumatic roller, do not exceed a compacted thickness of 6 inches per layer. For the first layer placed over a loose sandy subgrade, the contractor may, with the engineer's approval, increase the compacted layer thickness to 8 inches.

(2) If using a vibratory roller, do not exceed a compacted thickness of 8 inches per layer.

305.3.2.3 Compacting 3-Inch Base

(1) Compact with a vibratory or pneumatic roller. Do not exceed a compacted thickness of 9 inches per layer.

305.3.3 Constructing Aggregate Shoulders

305.3.3.1 General

(1) Construct aggregate shoulders to the elevations and typical sections the plans show, except for minor modifications needed to conform to other work.

(2) Use equipment that does not damage or mar the pavement surface, curbs, or appurtenances.

(3) Place aggregate directly on the shoulder area between the pavement edge and the outer shoulder limits. Recover uncontaminated material deposited outside the limits and place within the limits.

(4) Do not deposit aggregate on the pavement during placement, unless the engineer specifically allows. Do not leave aggregate on the pavement overnight. After placing the shoulder aggregate, keep the pavement surface free of lose aggregate.

(5) Spread and compact the aggregate in compacted layers of 6 inches or less. Use standard compaction conforming to 301.3.4.2, unless the special provisions specify otherwise.

(6) After final compaction, shape the shoulders to remove longitudinal ridges to ensure proper drainage.

305.3.3.2 Shoulders Adjacent to Concrete Pavement or Base

(1) Construct shoulders along concrete pavement or concrete base so the completed shoulder is at the approximate grade and cross-section before opening the pavement to public traffic.

305.3.3.3 Shoulders Adjacent to Asphaltic Pavement or Surfacing

(1) If the roadway is closed to through traffic during construction, construct the aggregate shoulders before opening the road.

(2) If the roadway remains open to through traffic during construction and a 2-inch or more drop-off at the pavement edge exists, eliminate the drop-off within 48 hours after completing the asphalt work. Unless the special provisions specify otherwise, provide aggregate shoulder material compacted to a 4:1 or flatter cross slope from the surface of the pavement edge.

(3) Provide and maintain signing and other traffic protection and control devices, as specified in 643, until completing shoulder construction to the required cross-section and flush with the asphaltic pavement or surfacing.

305.3.4 Shaping Shoulders

(1) Under the Shaping Shoulders bid item, blade, shape, and compact the existing shoulder aggregate, before the end of the day's work, to ensure proper drainage while salvaging existing pavement and constructing new pavement. Do not contaminate the shoulder aggregate with deleterious material. Incorporate material obtained from shaping shoulders in the new shoulder, in widening the roadbed, or as the plans show.

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305.3.5 Constructing Detours

(1) Under the Aggregate Detours bid item, provide aggregate on the designated detour at the locations the plans show or the engineer directs. Use 3/4-inch base unless the plans or special provisions specify otherwise.

305.4 Measurement

(1) The department will determine weight or volume, adjust for moisture, and convert between weight and volume as specified in 301.4. The department may deduct for contaminated aggregate or unrecovered aggregate deposited outside the outer shoulder limits.

(2) The department will measure the Base Aggregate Dense and Aggregate Detours bid items under this section by the ton or cubic yard acceptably completed.

(3) The department will measure Shaping Shoulders by the station acceptably completed, measured along the centerline for each shoulder separately.

305.5 Payment

(1) The department will pay for measured quantities at the contract unit price under the following bid items:

ITEM NUMBER DESCRIPTION UNIT

305.0110 Base Aggregate Dense 3/4-Inch TON

305.0115 Base Aggregate Dense 3/4-Inch CY

305.0120 Base Aggregate Dense 1 1/4-Inch TON

305.0125 Base Aggregate Dense 1 1/4-Inch CY

305.0130 Base Aggregate Dense 3-Inch TON

305.0135 Base Aggregate Dense 3-Inch CY

305.0410 Aggregate Detours TON

305.0415 Aggregate Detours CY

305.0500 Shaping Shoulders STA

(2) Payment for the Base Aggregate Dense bid items is full compensation for preparing the foundation; and for stockpiling, placing, shaping, compacting, and maintaining the base.

(3) Payment for Shaping Shoulders is full compensation for blading, shaping, compacting, and maintaining the existing aggregate shoulders.

(4) For the bid items under this section except for Aggregate Detours, the department will pay for EBS in areas of placed base, dust control water, and compaction water as specified in 301.5.

(5) Payment for Aggregate Detours is full compensation for preparing the foundation; and for stockpiling, placing, shaping, and compacting aggregate on detours. The department will pay for EBS in areas of placed base, and compaction water as specified in 301.5.

(6) If the contractor uses 3-inch material in the lower base layer, as allowed under 305.2.2.1, and the special provisions do not require 3-inch material, the department will pay for that material at the contract unit price for Base Aggregate Dense 1 1/4-Inch.

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Section 460 Hot Mix Asphalt Pavement

460.1 Description

(1) This section describes HMA mixture design, providing and maintaining a quality management program for HMA mixtures, and constructing HMA pavement. Unless specifically indicated otherwise, references within 460 to HMA also apply to WMA.

460.2 Materials

460.2.1 General

(1) Furnish a homogeneous mixture of coarse aggregate, fine aggregate, mineral filler if required, SMA stabilizer if required, recycled material if used, warm mix asphalt additive or process if used, and asphaltic material.

460.2.2 Aggregates

460.2.2.1 General.

(1) Provide coarse aggregates from a department-approved source as specified under 106.3.4.2. Obtain the engineer's approval of the aggregates before producing HMA mixtures.

(2) Furnish an aggregate blend consisting of hard durable particles containing no more than a combined total of one percent, by weight, of lumps of clay, loam, shale, soft particles, organic matter, adherent coatings, and other deleterious material. Ensure that the aggregate blend conforms to the percent fractured faces and flat & elongated requirements of table 460-2. If the aggregate blend contains materials from different deposits or sources, ensure that material from each deposit or source has a LA wear percent loss meeting the requirements of table 460-2.

460.2.2.2 Freeze-Thaw Soundness

(1) If the aggregate blend contains materials from different deposits or sources, ensure that material from each deposit or source has a freeze-thaw loss percentage meeting the requirements of table 460-2 and 106.3.4.2.2.

460.2.2.3 Aggregate Gradation Master Range Revise table 460-1 to increase VMA by 0.5% for E-3 mix designs with 12.5 and 9.5 mm aggregates. This change was implemented in ASP 6 effective with the January 2014 letting.

(1) Ensure that the aggregate blend, including recycled material and mineral filler, conforms to the gradation requirements in table 460-1. The values listed are design limits; production values may exceed those limits.

TABLE 460-1 AGGREGATE GRADATION MASTER RANGE AND VMA REQUIREMENTS

SIEVE

PERCENTS PASSING DESIGNATED SIEVES

NOMINAL SIZE

37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm SMA 12.5 mm SMA 9.5 mm

50.0-mm 100

37.5-mm 90 –100 100

25.0-mm 90 max 90 -100 100

19.0-mm ___ 90 max 90 -100 100 100

12.5-mm ___ ___ 90 max 90 -100 100 90 - 97 100

9.5-mm ___ ___ ___ 90 max 90 -100 58 - 72 90 - 100

4.75-mm ___ ___ ___ ___ 90 max 25 - 35 35 - 45

2.36-mm 15 – 41 19 - 45 23 - 49 28 - 58 20 - 65 15 - 25 18 - 28

75-µm 0 – 6.0 1.0 - 7.0 2.0 - 8.0 2.0 - 10.0 2.0 - 10.0 8.0 - 12.0 10.0 - 14.0

% MINIMUM VMA

11.0 12.0 13.0 14.0[1] 15.0[2] 16.0 17.0

[1] 14.5 for E-3 mixes.

[2] 15.5 for E-3 mixes.

(2) Unless the contract designates otherwise, ensure that the nominal size of the aggregate used in the mixture conforms to 460.3.2 and the following:

PAVEMENT LAYER NOMINAL SIZE

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Section 501 Concrete

501.1 Description

(1) This section describes proportioning, mixing, placing, and protecting concrete mixtures.

501.2 Materials

501.2.1 Portland Cement

(1) Use cement conforming to ASTM specifications as follows:

- Type I portland cement; ASTM C150.

- Type II portland cement; ASTM C150.

- Type III portland cement; ASTM C150, for high early strength.

- Type IP portland-pozzolan cement; ASTM C595, except maximum loss on ignition is 2.0 percent.

- Type IS portland blast-furnace slag cement; ASTM C595.

- Type IL portland-limestone cement; ASTM C595, except maximum nominal limestone content is 10 percent with no individual test result exceeding 12.0 percent.

(2) Store cement of different types, brands, and sources separately. Keep batches of concrete made from different types, brands, and sources from becoming intermixed in the work, unless the engineer approves otherwise.

(3) The engineer will reject cement that is partially set or that contains lumps.

(4) The engineer may reject cement if, the temperature at the time of delivery to the mixer exceeds 165 F. To avoid this, store it until it cools to at least 165 F before incorporating into the batch.

501.2.1.1 Testing

(1) Test according to AASHTO standard methods.

(2) Determine fineness by the air permeability test method performed according to AASHTO T153.

(3) If testing for setting time, base results on the Gillmore test method according to AASHTO T154.

501.2.1.2 Certification

(1) Obtain cement from manufacturers whose products comply with the department's certification method of acceptance for cement, unless the engineer agrees to accept cement under alternate procedures allowed in the department's certification method.

(2) Provide a manufacturer's written certification for blended cements stating the source, amount, and composition of essential constituents and the composition of the final cement provided under the contract.

501.2.2 Air-Entraining Admixtures

(1) If using an air-entraining admixture, the contractor must submit evidence based on tests made in a recognized laboratory to show that the material conforms to AASHTO M154 for 7- and 28-day compressive and flexural strengths and resistance to freezing and thawing, except as specified in 501.2.2(2). The engineer will not require tests for bleeding and setting time. Within 501, a recognized laboratory is any state department of transportation, FHWA, or any cement and concrete laboratory regularly inspected by the Cement and Concrete Reference Laboratory. The department may test samples taken from a quantity that the contractor submits for use on the project, or it may test samples the manufacturer submits and certifies as representative of the admixture it is supplying.

(2) Admixtures manufactured by neutralizing vinsol resin with caustic soda (sodium hydroxide) are an exception to the requirements in the above paragraph. If the contractor plans to use this admixture, then it must submit a certification of the admixture in the following form:

"This is to certify that the product (trade name) as manufactured and sold by the (company) is an aqueous solution of vinsol resin that has been neutralized with sodium hydroxide. The ratio of sodium hydroxide to vinsol resin is one part of sodium hydroxide to (number) parts of vinsol resin. The percentage of solids based on the residue dried at 221 F is (number). No other additive or chemical agent is present in this solution."

(3) If the contractor offers to use an admixture that is essentially the same, with only minor differences in concentration, as another previously department-approved material, the department will require a

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certification stating it is essentially the same as the department-approved admixture, and that it contains no other admixture or chemical agent.

(4) The department will not require a certification for admixtures on the department's approved products list.

(5) Either before, or at any time during construction the engineer may require further testing on the admixture the contractor selects to determine its effect on the strength of the concrete. If tested, the 7-day compressive strength of the concrete sample made with enough of the admixture to produce the specified percent, +/- the specified tolerance percent, of entrained air in the plastic concrete shall not be less than 88 percent of the concrete strength made with the same materials, cement content, and consistency but without the admixture.

(6) Calculate the percentage reduction in strength from the average strength of at least five standard 6-inch by 12-inch cylinders of each type of concrete. Make and cure these specimens in the laboratory according to AASHTO T126 and test according to AASHTO T22. Determine the percentage of entrained air according to AASHTO T152.

(7) The department will reject admixtures failing to conform to the above requirements.

501.2.3 Retarding, Water Reducing, and Non-Chloride Accelerating Admixtures

501.2.3.1 General

(1) The engineer must approve all retarding and water reducing admixtures not on the department's approved products list before using them.

(2) The engineer will base approval of retarding and water reducing admixtures on tests made in the department's laboratory, or evaluation of results of tests made in a recognized laboratory as defined in 501.2.2(1). The manufacturer shall furnish test result data. Provide to the engineer a manufacturer's certification that the materials it is furnishing are essentially identical to those used in the performance testing.

(3) The department will maintain an approved products list for admixtures. The contractor may use admixtures included in the current approved products list, provided they produce the required properties in the concrete.

(4) Based on manufacturer-furnished data, the indicated relationships between temperature of mix, quantity of admixture, and time of initial set must satisfy the engineer.

(5) The contractor shall provide the laboratory and the engineer with manufacturer's data required for evaluations indicated above and for determining quantities of admixture for job conditions.

(6) Retarding and water reducing admixtures, as specified in this section, may or may not increase the amount of air entrained in the mix. If using admixtures in air-entrained concrete, ensure the concrete mix air content is within the range specified for air-entrained concrete under 501.3.2.4.

501.2.3.2 Retarding Admixtures

(1) All admixtures used to retard concrete setting as specified for set retarder under 501.3.2.4.3 shall conform to AASHTO M194, type D.

501.2.3.3 Water Reducing Admixtures

(1) If using water-reducing admixtures in concrete, conform to AASHTO M194, type A or type D, except that if adding a retarding admixture as specified for set retarder under 501.3.2.4.3, do not use type A.

501.2.3.4 Non-Chloride Accelerating Admixtures

(1) Conform to AASHTO M194, type C or type E.

501.2.4 Water

501.2.4.1 General

(1) Use water with cement in concrete, mortar, neat cement paste, or wash, and in other cement mixing operations conforming to 501.2.4.

501.2.4.2 Requirements

(1) The contractor may use drinking water from municipal water supplies for cement, except the engineer may test this water for compliance with the requirements specified below.

(2) Water from other sources shall comply with the following: Acidity, maximum amount of 0.1N NaOH to neutralize 200 mL of water ............................................................ 2 mL

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Alkalinity, maximum amount of 0.1N HCL to neutralize 200 mL of water ......................................................... 15 mL

Maximum sulphate (S04) ........................................................................................................................ 0.05 percent

Maximum chloride ................................................................................................................................... 0.10 percent

Maximum total solids:

Organic ................................................................................................................................................... 0.04 percent

Inorganic ................................................................................................................................................. 0.15 percent

(3) Use water that is not brackish and is clean and free of injurious amounts of sugar, oil, or other deleterious substances.

(4) Use water that causes no indication of unsoundness, no significant change in the time of setting, and varies no more than 10 percent in the strength of standard 1:3 mortar briquettes from strengths obtained with mixtures containing distilled water and the same cement and sand.

501.2.4.3 Sampling and Testing

(1) Submit samples that each consist of at least 2 quarts of water, obtained and shipped in clean plastic or glass containers, carefully packed and labeled. The engineer will supervise sampling. Test according to AASHTO T26.

501.2.4.4 Source

(1) Do not use water from shallow, muddy, or marshy sources. The contractor shall not use water from suspected sources until the engineer tests and approves it. If supply sources are relatively shallow, enclose the suction pipe intake to keep out silt, mud, grass, and other foreign materials. Position the suction pipe to provide at least 2 feet of water beneath the pipe intake.

501.2.5 Aggregates

501.2.5.1 General

(1) Furnish material conforming to the individual component requirements of 501.2.5.3 for fine aggregates and 501.2.5.4 for coarse aggregates except as follows:

1. If testing for gradation during concrete production, the department will accept material based on the combined properties as batched. The department will determine combined values and combined spec limits for both size and deleterious substances mathematically. The department will use the actual batch percentages for component aggregates in this calculation.

2. If the contractor is using a QMP paving or structures mix for other work on the project, the department will accept the aggregate for the affected mixes as specified in the applicable QMP provisions. Increase the testing frequency as necessary to ensure adequate testing for non-paving and non-structure material.

(2) The engineer may prohibit using aggregates from any source, plant, pit, quarry, or deposit if the character of the material or method of operation makes it unlikely to furnish aggregates conforming to specified requirements; or from deposits or formations known to produce unsound materials.

(3) Before use, furnish samples of materials from previously untested sources and from previously tested sources if the engineer requires.

(4) If procuring aggregates from pits or quarries, conform to 104.9 for final cleanup.

501.2.5.2 Definitions

(1) Use the definitions in 301.2, 450.2.1, and the following:

Fine aggregates Those aggregates that entirely pass the 3/8-inch sieve, almost entirely pass the No. 4 sieve and are predominantly retained on the No. 200 sieve.

Coarse aggregates Those aggregates predominantly retained on the No. 4 sieve.

501.2.5.3 Fine Aggregates

(1) Fine aggregate consists of a combination of sand with fine gravel, crushed gravel, or crushed stone consisting of hard, strong, durable particles.

501.2.5.3.1 Deleterious Substances

(1) Do not exceed the following percentages: SUBSTANCE PERCENT BY WEIGHT

Material passing the No. 200 sieve ..................................................................................................................... 3.5[1]

Coal ....................................................................................................................................................................... 1.0

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Clay lumps ............................................................................................................................................................. 1.0

Shale ..................................................................................................................................................................... 1.0

Other local deleterious substances like alkali, mica, coated grains, soft and flaky particles .................................. 1.0

[1] Reduce to 2.3 percent if used in grade E concrete.

(2) The total percentage of coal, clay lumps, shale, and other deleterious substances shall not exceed 3.0 percent by weight. There is no requirement to wash fine aggregate for concrete if produced otherwise to conform to all specified requirements. When used, the fine aggregate shall not contain any of the following: frozen material, and foreign material like wood, hay, burlap, paper, or dirt.

501.2.5.3.2 Organic Impurities

(1) Fine aggregate shall not contain harmful amounts of organic impurities. The engineer will reject aggregates, subjected to the colorimetric test for organic impurities, producing a darker than standard color, unless they pass the mortar strength test.

501.2.5.3.3 Mortar Strength

(1) Fine aggregates, if tested for the effects of organic impurities on strength of mortar, using type I portland cement, must produce a relative strength at 7 days, calculated according to section 8 of AASHTO T71, of not less than 95 percent.

501.2.5.3.4 Size Requirements

(1) Use well-graded fine aggregate conforming to the following gradation requirements: SIEVE PERCENT PASSING BY WEIGHT

3/8-inch. ................................................................................................................................................................ 100

No. 4 ............................................................................................................................................................. 90 - 100

No. 16 ............................................................................................................................................................. 45 - 85

No. 50 ............................................................................................................................................................... 5 - 30

No. 100 ............................................................................................................................................................. 0 – 10

501.2.5.4 Coarse Aggregates

501.2.5.4.1 General

(1) Provide coarse aggregates from a department-approved source as specified under 106.3.4.2.

(2) Use clean, hard, durable gravel, crushed gravel, crushed stone or crushed concrete free of an excess of flat & elongated pieces, frozen lumps, vegetation, deleterious substances or adherent coatings considered injurious. Do not use coarse aggregates obtained from crushing concrete in concrete for bridges, culverts, or retaining walls.

501.2.5.4.2 Deleterious Substances

(1) The amount of deleterious substances shall not exceed the following percentages: DELETERIOUS SUBSTANCE PERCENT BY WEIGHT

Shale ..................................................................................................................................................................... 1.0

Coal ....................................................................................................................................................................... 1.0

Clay lumps ............................................................................................................................................................. 0.3

Soft fragments ....................................................................................................................................................... 5.0

Any combination of above ..................................................................................................................................... 5.0

Flat & elongated pieces based on a 3:1 ratio ....................................................................................................... 15.0

Materials passing the No. 200 sieve ...................................................................................................................... 1.5

Chert[1] for all grades of concrete other than concrete for prestressed concrete members ................................ 5.0[2]

Chert[1] for concrete for prestressed concrete members ........................................................................................ 2.0

[1] Material classified lithologically as chert and having a bulk specific gravity (saturated surface-dry basis) of less than 2.45. Determine the percentage of chert by dividing the weight of chert in the sample retained on a 3/8-inch sieve by the weight of the total sample.

[2] The engineer may accept aggregates exceeding this value if aggregates from the same deposit or from one of similar geological origin demonstrated a satisfactory service record, or tests the engineer select indicate no inferior behavior.

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(2) If using 2 sizes of coarse aggregates, the engineer will determine the percentages of harmful substances based on one of the following: a sample consisting of 50 percent of size No. 1, and 50 percent of size No. 2; or a sample consisting of the actual percent of size No. 1 and No. 2 used in the work.

(3) The engineer will not require the contractor to wash coarse aggregate produced within specified gradations, free of coatings considered injurious, and conforming to the above limits for harmful substances.

501.2.5.4.3 Physical Properties

(1) The percent wear shall not exceed 50, the weighted soundness loss shall not exceed 12 percent, and the weighted freeze-thaw average loss shall not exceed 18 percent.

(2) The department may prohibit using crushed stone from limestone/dolomite deposits having thinly bedded strata, or strata of a shale nature; it may also prohibit using aggregates from deposits or formations known to produce unsound material.

(3) If all coarse aggregates used are produced from the same deposit or source, ensure that testing for wear, sodium sulfate soundness, and soundness by freezing and thawing uses a composite sample. This sample will contain equal percentages of each component coarse aggregate used. If the component coarse aggregates are produced from more than one deposit or source, ensure that testing for wear, sodium sulfate soundness, and soundness by freezing and thawing uses one sample from each deposit or source.

501.2.5.4.4 Size Requirements

(1) Use well graded coarse aggregate conforming to the following gradation requirements: PERCENT PASSING BY WEIGHT

SIEVE SIZE NO. 1 SIZE NO. 2

AASHTO No. 67[1] AASHTO No. 4[1]

2-inch - 100

1 1/2-inch - 90-100

1-inch 100 20-55

3/4-inch 90-100 0-15

3/8-inch 20-55 0-5

No. 4 0-10 -

No. 8 0-5 -

[1] Size No. according to AASHTO M43.

(2) Furnish coarse aggregates in the separate sizes indicated, and store each size separately to prevent mixture until proportioned into each batch. The engineer will allow the contractor to combine 2 aggregate fractions to produce a gradation within the limits specified for size No. 1 or size No. 2, provided they are proportioned separately by weight into the batch in proportions the engineer approves.

(3) Except as provided below, furnish coarse aggregate conforming to size No. 1 and size No. 2, combined in the proportions specified for the pertinent grade of concrete under 501.3.2.2.

(4) Provide coarse aggregate consisting entirely of size No. 1 as follows:

1. If the engineer approves, for grade A, A2, A3, A-FA, A-S, A-S2, A-T, A-IS, or A-IP concrete.

2. Except for concrete pavement repair and replacement and if substituting grade C, C-FA, C-S, C-IS, or C-IP for grade A air-entrained high early strength concrete as specified in 501.3.1.1, for grade C, C-FA, C-S, C-IS, or C-IP concrete.

3. For curb, curb and gutter, sidewalk and steps.

4. Except for concrete pavement repair and replacement, for grade E concrete.

5. For concrete in prestressed concrete members.

501.2.5.5 Sampling and Testing

(1) Sample and test aggregates for concrete according to the following: Sampling aggregates .............................................................................................................................. AASHTO T2

Lightweight pieces in aggregate ......................................................................................................... AASHTO T113

Material finer than No. 200 sieve .......................................................................................................... AASHTO T11

Unit weight of aggregate ....................................................................................................................... AASHTO T19

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Organic impurities in sands .................................................................................................................. AASHTO T21

Sieve analysis of aggregates ................................................................................................................ AASHTO T27

Effect of organic impurities in fine aggregate ........................................................................................ AASHTO T71

Los Angeles abrasion of coarse aggregate .......................................................................................... AASHTO T96

Freeze-thaw soundness of coarse aggregate ..................................................................................... AASHTO T103

Sodium sulfate soundness of aggregates ........................................................................................... AASHTO T104

Specific gravity and absorption of fine aggregate ................................................................................. AASHTO T84

Specific gravity and absorption of coarse aggregate ............................................................................ AASHTO T85

Flat & elongated pieces based on a 3:1 ratio ..................................................................................... ASTM D4791[1]

Sampling fresh concrete ...................................................................................................................... AASHTO R60

Making and curing concrete compressive strength test specimens ...................................................... AASHTO T23

Compressive strength of molded concrete cylinders ............................................................................ AASHTO T22

[1] As modified in CMM 8-60.

(2) Test for chert and soft or non-durable particles conforming to department laboratory methods. The engineer will field evaluate or laboratory test to determine aggregate acceptability relative to excessive clay lump quantities.

501.2.6 Fly Ash

(1) Fly ash is defined as a finely divided residue resulting from the combustion of coal in a base loaded electric generating plant, transported from the boiler by flue gases, and later collected, generally by precipitators. Use fly ash in concrete manufactured by facilities and processes known to provide satisfactory material.

(2) Conform to ASTM C618 class C except limit the loss on ignition to a maximum of 2 percent.

(3) Test fly ash using a recognized laboratory, as defined in 501.2.2(1), starting at least 30 days before its proposed use, and continuing at ASTM-required frequencies as the work progresses. The manufacturer shall test the chemical and physical properties listed in tables 1 and 2 of ASTM C618 at the frequencies and by the test methods prescribed in ASTM C311.

(4) Use only one source of fly ash for a bid item of work under the contract, unless the engineer directs otherwise in writing.

(5) Prequalify any proposed fly ash source as follows: The contractor shall obtain a copy of the certified report of tests or analysis made by a qualified independent laboratory, recognized by the department under 501.2.2, showing full and complete compliance with the above specification from the fly ash manufacturer and furnish it to the engineer. Provide this report to the engineer at least 14 calendar days before using the fly ash.

(6) The manufacturer shall retain all test records for at least 5 years after completing the work, and provide these records upon request.

501.2.7 Slag

(1) For grade A-S, A-T, A-S2, B-S, and C-S concrete, provide ground granulated blast furnace slag conforming to ASTM C989, grade 100 or 120.

501.2.8 Pozzolans

(1) The contractor may use pozzolans as a direct replacement for fly ash in concrete mixes. Conform to the replacement limits specified under 501.3.2.2 for fly ash. Use only as a complete replacement for fly ash. Do not combine pozzolans or use pozzolans with fly ash in the same mix.

(2) Furnish pozzolans conforming to the physical, chemical, and performance requirements specified for Class C fly ash in ASTM C618, except the definition of origin of the material does not apply. Obtain material from a manufacturer on the department's approved products list with an in-place quality management program that includes the following daily uniformity tests:

- Specific gravity.

- Percent retained on the No. 325 sieve.

- Loss on ignition.

- Moisture content.

- Activity index with cement.


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QMP Base Aggregate.

A Description A.1 General (1) This special provision describes contractor quality control (QC) sampling and testing

for base aggregates, documenting those test results, and documenting related production and placement process changes. This special provision also describes department quality verification (QV), independent assurance (IA), and dispute resolution.

(2) Conform to standard spec 301, 305, and 310 as modified here in this special

provision. Apply this special provision to material placed under all of the Base Aggregate Dense and Base Aggregate Open Graded bid items, except do not apply this special provision to material classified as reclaimed asphaltic pavement placed under the Base Aggregate Dense bid items.

(3) Do not apply this special provision to material placed under the Aggregate Detours,

Salvaged Asphaltic Pavement Base, Breaker Run, Select Crushed, Pit Run, Subbase, or Riprap bid items.

(4) Provide and maintain a quality control program, defined as all activities related to and

documentation of the following: 1. Production and placement control and inspection. 2. Material sampling and testing.

(5) Chapter 8 of the department’s construction and materials manual (CMM) provides

additional detailed guidance for QMP work and describes required sampling and testing procedures. The contractor may obtain the CMM from the department’s web site at:

http://roadwaystandards.dot.wi.gov/standards/cmm/index.htm A.2 Contractor Testing for Small Quantities (1) The department defines a small quantity, for each individual Base Aggregate bid

item, as a plan quantity of 9000 tons or less of material as shown in the schedule of items under that bid item.

(2) The requirements under this special provision apply equally to a small quantity for an

individual bid item except as follows: 1. The contractor need not submit a full quality control plan but shall provide an

organizational chart to the engineer including names, telephone numbers, and current certifications of all persons involved in the quality control program for material under affected bid items.

2. Divide the aggregate into uniformly sized sublots for testing as follows: Plan Quantity Minimum Required Testing

≤ 1500 tons One test from production, load-out, or

http://roadwaystandards.dot.wi.gov/standards/cmm/index.htm

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placement at the contractor’s option[1] > 1500 tons and ≤ 6000 tons Two tests of the same type, either from

production, load-out, or placement at the contractor’s option[1]

> 6000 tons and ≤ 9000 tons Three placement tests[2] [3] [1] If using production tests for acceptance, submit test results to the engineer for

review prior to incorporating the material into the work. Production test results are valid for a period of 3 years.

[2] For 3-inch material, obtain samples at load-out. [3] If the actual quantity overruns 9000 tons, create overrun sublots to test at a rate of

one additional placement test for each 3000 tons, or fraction of 3000 tons, of overrun.

3. No control charts are required. Submit aggregate load-out and placement test results to the engineer within one business day of obtaining the sample. Assure that all properties are within the limits specified for each test.

4. Department verification testing is optional for quantities of 6000 tons or less. (3) Material represented by a sublot with any property outside the specification limits is

nonconforming. The department may reject material or otherwise determine the final disposition of nonconforming material as specified in standard spec 106.5.

B Materials B.1 Quality Control Plan (1) Submit a comprehensive written quality control plan to the engineer at or before the

pre-construction meeting. Do not place base before the engineer reviews and comments on the plan. Construct the project as that plan provides.

(2) Do not change the quality control plan without the engineer’s review. Update the plan

with changes as they become effective. Provide a current copy of the plan to the engineer and post in each of the contractor’s laboratories as changes are adopted. Ensure that the plan provides the following elements: 1. An organizational chart with names, telephone numbers, current certifications

and/or titles, and roles and responsibilities of QC personnel. 2. The process used to disseminate QC information and corrective action efforts to

the appropriate persons. Include a list of recipients, the communication means that will be used, and action time frames.

3. A list of source and processing locations, section and quarter descriptions, for all aggregate materials requiring QC testing.

4. Test results for wear, sodium sulfate soundness, freeze/thaw soundness, and plasticity index of all aggregates requiring QC testing. Obtain this information from the region materials unit or from the engineer.

5. Descriptions of stockpiling and hauling methods. 6. Locations of the QC laboratory, retained sample storage, and where control charts

and other documentation is posted. 7. An outline for resolving a process control problem. Include responsible personnel,

required documentation, and appropriate communication steps.

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B.2 Personnel (1) Have personnel certified under the department’s highway technician certification

program (HTCP) perform sampling, testing, and documentation as follows: Required Certification Level: Sampling or Testing Roles:

Aggregate Technician IPP Aggregate Sampling Technician Aggregate Assistant Certified Technician (ACT-AGG)

Aggregate Sampling[1]

Aggregate Technician IPP Aggregate Assistant Certified Technician (ACT-AGG)

Aggregate Gradation Testing, Aggregate Fractured Particle Testing, Aggregate Liquid Limit and Plasticity Index Testing

[1] Plant personnel under the direct observation of an aggregate technician certified at level one or higher may operate equipment to obtain samples.

(2) A certified technician must coordinate and take responsibility for the work an ACT

performs. Have a certified technician ensure that all sampling and testing is performed correctly, analyze test results, and post resulting data. No more than one ACT can work under a single certified technician.

B.3 Laboratory (1) Perform QC testing at a department-qualified laboratory. Obtain information on the

Wisconsin laboratory qualification program from: Materials Management Section 3502 Kinsman Blvd. Madison, WI 53704 Telephone: 608-246-5388

http://www.dot.state.wi.us/business/engrserv/lab-qualification.htm B.4 Quality Control Documentation B.4.1 General (1) Submit base aggregate placement documentation to the engineer within 10 business

days after completing base placement. Ensure that the submittal is complete, neatly organized, and includes applicable project records and control charts.

B.4.2 Records (1) Document all placement observations, inspection records, and control adjustments

daily in a permanent field record. Also include all test results in the project records. Provide test results to the engineer within 6 hours after obtaining a sample. For 3-inch base, extend this 6-hour limit to 24 hours. Post or distribute tabulated results using a method mutually agreeable to the engineer and contractor.

B.4.3 Control Charts

http://www.dot.state.wi.us/business/engrserv/lab-qualification.htm

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(1) Plot gradation and fracture on the appropriate control chart as soon as test results are available. Format control charts according to CMM 8.30. Include the project number on base placement control charts. Maintain separate control charts for each base aggregate size, source or classification, and type.

(2) Provide control charts to the engineer within 6 hours after obtaining a sample. For 3-

inch base, extend this 6-hour limit to 24 hours. Post or distribute charts using a method mutually agreeable to the engineer and contractor. Update control charts daily to include the following: 1. Contractor individual QC tests. 2. Department QV tests. 3. Department IA tests. 4. Four-point running average of the QC tests.

(3) Except as specified under B.8.2.1 for nonconforming QV tests, include only QC tests

in the running average. The contractor may plot process control or informational tests on control charts, but do not include these tests, conforming QV tests, or IA tests in the running average.

B.5 Contractor Testing (1) Test gradation, fracture, liquid limit and plasticity index during placement for each

base aggregate size, source or classification, and type. (2) Test gradation once per 3000 tons of material placed. Determine random sample

locations and provide those sample locations to the engineer. Obtain samples after the material has been bladed, mixed, and shaped but before compacting; except collect 3-inch samples from the stockpile at load-out. Do not sample from material used to maintain local traffic or from areas of temporary base that will not have an overlying pavement. On days when placing only material used to maintain local traffic or only temporary base that will not have an overlying pavement, no placement testing is required.

(3) Split each contractor QC sample and identify it according to CMM 8.30. Retain the

split for 7 calendar days in a dry, protected location. If requested for department comparison testing, deliver the split to the engineer within one business day.

(4) The engineer may require additional sampling and testing to evaluate suspect material

or the technician’s sampling and testing procedures. (5) Test fracture for each gradation test until the fracture running average is above the

lower warning limit. Subsequently, the contractor may reduce the frequency to one test per 10 gradation tests if the fracture running average remains above the warning limit.

(6) Test the liquid limit and plasticity index for the first gradation test. Subsequently, test

the liquid limit and plasticity index a minimum of once per 10 gradation tests.

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B.6 Test Methods B.6.1 Gradation (1) Test gradation using a washed analysis conforming to the following as modified in

CMM 8.60: Gradation............................................................................................... AASHTO T 27 Material finer than the No. 200 sieve.................................................... AASHTO T 11 (2) For 3-inch base, if 3 consecutive running average points for the percent passing the

No. 200 sieve are 8.5 percent or less, the contractor may use an unwashed analysis. Wash at least one sample out of 10. If a single running average for the percent passing the No. 200 sieve exceeds 8.5 percent, resume washed analyses until 3 consecutive running average points are again 8.5 percent passing or less.

(3) Maintain a separate control chart for each sieve size specified in standard spec 305 or

310 for each base aggregate size, source or classification, and type. Set control and warning limits based on the standard specification gradation limits as follows: 1. Control limits are at the upper and lower specification limits. 2. There are no upper warning limits for sieves allowing 100 percent passing and no

lower control limits for sieves allowing 0 percent passing. 3. Dense graded warning limits, except for the No. 200 sieve, are 2 percent within

the upper and lower control limits. Warning limits for the No. 200 sieve are set 0.5 percent within the upper and lower control limits.

4. Open graded warning limits for the 1-inch, 3/8-inch, and No. 4 sieves are 2 percent within the upper and lower control limits. Upper warning limits for the No. 10, No. 40, and No. 200 sieves are 1 percent inside the upper control limit.

B.6.2 Fracture (1) Test fracture conforming to CMM 8.60. The engineer will waive fractured particle

testing on quarried stone. (2) Maintain a separate fracture control chart for each base aggregate size, source or

classification, and type. Set the lower control limit at the contract specification limit, either specified in another special provision or in table 301-2 of standard spec 301.2.4.5. Set the lower warning limit 2 percent above the lower control limit. There are no upper limits.

B.6.3 Liquid Limit and Plasticity (1) Test the liquid limit and plasticity according to AASHTO T 89 and T 90. (2) Ensure the material conforms to the limits specified in standard spec table 301-2. B.7 Corrective Action B.7.1 General (1) Consider corrective action when the running average trends toward a warning limit.

Take corrective action if an individual test exceeds the contract specification limit.

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Document all corrective actions both in the project records and on the appropriate control chart.

B.7.2 Placement Corrective Action (1) Do not blend additional material on the roadbed to correct gradation problems. (2) Notify the engineer whenever the running average exceeds a warning limit. When 2

consecutive running averages exceed a warning limit, the engineer and contractor will discuss appropriate corrective action. Perform the engineer’s recommended corrective action and increase the testing frequency as follows: 1. For gradation, increase the QC testing frequency to at least one randomly sampled

test per 1000 tons placed. 2. For fracture, increase the QC testing frequency to at least one test per gradation

test. (3) If corrective action improves the property in question such that the running average

after 4 additional tests is within the warning limits, the contractor may return to the testing frequency specified in B.5.3. If corrective action does not improve the property in question such that the running average after 4 additional individual tests is still in the warning band, repeat the steps outlined above starting with engineer notification.

(4) If the running average exceeds a control limit, material starting from the first running

average exceeding the control limit and ending at the first subsequent running average inside the control limit is nonconforming and subject to pay reduction.

(5) For individual test results significantly outside the control limits, notify the engineer,

stop placing base, and suspend other activities that may affect the area in question. The engineer and contractor will jointly review data, data reduction, and data analysis; evaluate sampling and testing procedures; and perform additional testing as required to determine the extent of potentially unacceptable material. The engineer may direct the contractor to remove and replace that material. Individual test results are significantly outside the control limits if meeting one or more of the following criteria: 1. A gradation control limit for the No. 200 sieve is exceeded by more than 3.0

percent. 2. A gradation control limit for any sieve, except the No. 200, is exceeded by more

than 5.0 percent. 3. The fracture control limit is exceeded by more than 10.0 percent.

B.8 Department Testing B.8.1 General (1) The department will conduct verification testing to validate the quality of the product

and independent assurance testing to evaluate the sampling and testing. The department will provide the contractor with a listing of names and telephone numbers

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of all QV and IA personnel for the project, and provide test results to the contractor within 2 business days after the department obtains the sample.

B.8.2 Verification Testing B.8.2.1 General (1) The department will have an HTCP technician, or ACT working under a certified

technician, perform QV sampling and testing. Department verification testing personnel must meet the same certification level requirements specified in B.2 for contractor testing personnel for each test result being verified. The department will notify the contractor before sampling so the contractor can observe QV sampling.

(2) The department will conduct QV tests of each base aggregate size, source or

classification, and type during placement conforming to the following: 1. One non-random test on the first day of placement. 2. At least one random test per 30,000 tons, or fraction of 30,000 tons, placed.

(3) The department will sample randomly, at locations independent of the contractor’s

QC work, collecting one sample at each QV location. The department will collect QV samples after the material has been bladed, mixed, and shaped but before compacting; except, for 3-inch aggregates, the department will collect samples from the stockpile at load-out. The department will split each sample, test half for QV, and retain half.

(4) The department will conduct QV tests in a separate laboratory and with separate

equipment from the contractor’s QC tests. The department will use the same methods specified for QC testing.

(5) The department will assess QV results by comparing to the appropriate specification

limits. If QV test results conform to the specification, the department will take no further action. If QV test results are nonconforming, add the QV to the QC test results as if it were an additional QC test.

B.8.3 Independent Assurance (1) Independence assurance is unbiased testing the department performs to evaluate the

department’s QV and the contractor’s QC sampling and testing including personnel qualifications, procedures, and equipment. The department will perform an IA review according to the department’s independent assurance program. That review may include one or more of the following: 1. Split sample testing. 2. Proficiency sample testing. 3. Witnessing sampling and testing. 4. Test equipment calibration checks. 5. Reviewing required worksheets and control charts. 6. Requesting that testing personnel perform additional sampling and testing.

(2) If the department identifies a deficiency, and after further investigation confirms it,

correct that deficiency. If the contractor does not correct or fails to cooperate in

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resolving identified deficiencies, the engineer may suspend placement until action is taken. Resolve disputes as specified in B.9.

B.9 Dispute Resolution (1) The engineer and contractor should make every effort to avoid conflict. If a dispute

between some aspect of the contractor’s and the engineer’s testing program does occur, seek a solution mutually agreeable to the project personnel. The department and contractor may review the data, examine data reduction and analysis methods, evaluate sampling and testing procedures, and perform additional testing. Use ASTM E 178 to evaluate potential statistically outlying data.

(2) Production test results, and results from other process control testing, may be

considered when resolving a dispute. (3) If the project personnel cannot resolve a dispute, and the dispute affects payment or

could result in incorporating non-conforming product, the department will use third party testing to resolve the dispute. The department’s central office laboratory, or a mutually agreed on independent testing laboratory, will provide this testing. The engineer and contractor will abide by the results of the third party tests. The party in error will pay service charges incurred for testing by an independent laboratory. The department may use third party test results to evaluate the quality of questionable materials and determine the appropriate payment. The department may reject material or otherwise determine the final disposition of nonconforming material as specified in standard spec 106.5.

C (Vacant) D (Vacant) E Payment (1) Costs for all sampling, testing, and documentation required under this special

provision are incidental to this work. If the contractor fails to perform the work required under this special provision, the department may reduce the contractor’s pay. The department will administer pay reduction under the non-performance of QMP administrative item.

(2) For material represented by a running average exceeding a control limit, the

department will reduce pay by 10 percent of the contract price for the affected Base Aggregate bid items listed in subsection A. The department will administer pay reduction under the Nonconforming QMP Base Aggregate Gradation or Nonconforming QMP Base Aggregate Fracture Administrative items. The department will determine the quantity of nonconforming material as specified in B.7.2.

301-010 (20100709)

Laboratory Exam ___________

STUDENT ____________________________ DATE ________________________________

HIGHWAY TECHNICIAN CERTIFICATION PROGRAM THE UNIVERSITY OF WISCONSIN - PLATTEVILLE AGGREGATE SAMPLING TECHNICIAN QUALIFYING LABORATORY EXAM

AREA OF QUALIFICATION PASS/FAIL INSTRUCTOR A. Sampling from a Conveyor Belt

Discharge

B. Sampling from Roadbed Windrows

C. Sampling after Being Placed on Roadbed

D. Sampling from a Conveyor Belt

E. Sampling from Stockpiles: Alternate 1 Alternate 2

Sampling from a Conveyor Belt Discharge Randomly select units to be sampled after steady flow has been established. Obtain at least three approximately equal increments and combine to form a

representative composite sample before splitting. Sample each increment from entire cross-section of material flow. Refer to Construction Materials Manual Sampling from Roadbed Windrows Unacceptable sampling method for Coarse Aggregate Base course on

QC/QA projects. Although, this sampling method can be used for sampling granular subbase on QC/QA projects.

Sample from a uniform cross-section well-mixed windrow. Windrow aggregate shall be in a damp condition during mixing and sampling. Sample shall be taken within a 100 LF interval using random number table for

QC/QA projects. Obtain at least three approximately equal increments and sample by using a

square-point shovel. Remove external surface before extracting samples at each sample location. All increments shall be combined to form a representative composite sample

before splitting. Refer to Construction Materials Manual Sampling after Being Placed on Roadbed Area sample locations shall be selected by random number table on QC/QA

projects. Visually inspect the area to be sample for uniformity. Cavity walls shall be as vertical as possible. Care must be taken to avoid including any underlying material. Obtain at least three approximately equal increments sampled by a square-

point shovel. All increments shall be combined to form a representative composite sample

before splitting. Refer to Construction Materials Manual

Sampling from a Conveyor Belt Randomly select units to be sampled after steady flow has been established. Stop conveyor belt while samples are being obtained. Obtain at least three approximately equal increments off the conveyor belt,

and combine to form a composite sample. Separate the increments at their ends; if the angle of the conveyor belt is

such that the aggregates roll, insert templates, which fit the configuration of conveyor belt for each sample location.

Collect cross-section of material on conveyor belt or between templates, and also brush fines into sample container.

All increments shall be combined to form a representative composite sample. Refer to Construction Materials Manual Sampling from Stockpiles Alternate 1 Obtain increments from each quarter point from which the aggregate is being

extracted. Obtain each quarter point sample by cutting deep into the face of the pile with

a front-end loader or with similar power equipment. Dump each quarter point sample in a separate pile, and level each pile. Obtain at least three approximately equal increments from each pile, and

sample by using a square-point shovel. Samples of all quarter points shall be combined to form a representative

composite sample. Alternate 2 Obtain increments with a scoop shovel from quarter points of pile perimeter at

both 1/3 and 2/3 levels of slope length from top to bottom. Sample shall be obtained by placing protective barrier above sampling

location to prevent aggregate slide. Remove 10” to 12” of surface aggregate before obtaining sample. Samples of all quarter points shall be combined to form a representative

composite sample. Refer to Construction Materials Manual

APPENDIX: QMP Award Nomination Form

The Quality Management Program Award recognizes outstanding certified highway materials technicians who have displayed exceptional leadership roles in developing quality materials used in highway construction projects.

These winners are chosen from contractors, consultants, and the

Wisconsin Department of Transportation. It is this industry support and joint partnering that makes this program a success.

Some of the qualities attributed to the award winners include

HTCP certification, HTCP promotion, development of cost savings, development of time savings, quality improvement, being a team player and possessing a positive attitude.

Quality Management Program Award

Nomination Application

This Outstanding Individual or Team is Nominated to Receive this Year’s “Quality Management Program Award”

Individual/Team: Employer: Address: Work Address: City/State/Zip: City/State/Zip: Telephone: Telephone: Fax :

List individual or team nominated: Identify outstanding individual or team achievement(s) that exemplify this nomination for the “Quality Management Program Award : *Application submitted by: Date: Do you wish to remain anonymous? Yes No (* Required for nomination) Please fax (608) 342-1982 or send completed application before November 1 of each year to Highway Technician Certification Program, University of Wisconsin-Platteville, 049 Ottensman Hall, 1 University Plaza, Platteville, WI 53818-3099.

Quality Management Program Award

Nomination Application

This Outstanding Individual or Team is Nominated to Receive this Year’s “Quality Management Program Award”

Individual/Team: Employer: Address: Work Address: City/State/Zip: City/State/Zip: Telephone: Telephone: Fax :

List individual or team nominated: Identify outstanding individual or team achievement(s) that exemplify this nomination for the “Quality Management Program Asphalt Award : *Application submitted by: Date: Do you wish to remain anonymous? Yes No (* Required for nomination) Please fax (608) 342-1982 or send completed application before November 1 of each year to Highway Technician Certification Program, University of Wisconsin-Platteville, 049 Ottensman Hall, 1 University Plaza, Platteville, WI 53818-3099.

Correction’s Form and Evaluation

OOPS! Found an error?

Course Title: ____________________________ Please describe the error and the page or topic where you found it: We might have questions. How can we reach you? Name: E-Mail: Phone: Note to Development Team: Send updates to [email protected], or call 608.342.1545, or mail to HTCP, 1 University Plaza, University of Wisconsin-Platteville, Platteville, WI 53818.

THANK YOU!

mailto:[email protected]

Course Evaluation

HIGHWAY TECHNICIAN CERTIFICATION PROGRAM

(HTCP) EVALUATION

The HTCP would appreciate your thoughtful completion of all items on this evaluation. Your comments and constructive suggestions will be carefully studied and will serve as a valuable resource to improve our course presentations: Course: Date: 1. Overall rating of this program:

Outstanding Above Average

Average Below Average

Unacceptable

Did the course meet your expectations?

5

4

3

2

1

How well were you satisfied with the quality and quantity of the course materials?

5

4

3

2

1

Comments about course materials/visual aids: 2. Instructor:



Unacceptable

Effectiveness of course presentation:

5

4

3

2

1

Responsiveness and interaction with students:

5

4

3

2

1

Ability to communicate: 5 4 3 2 1 Knowledge of course content: 5 4 3 2 1

3. Please fill in and rate overall effectiveness of laboratory instructor(s)/guest lecturer(s):



Unacceptable

5

4

3

2

1

5

4

3

2

1

5

4

3

2

1

Comments: Please make additional comments about individual laboratory instructor(s)/guests lecturer(s) quality of instruction:

4. Administrative Evaluation:



Unacceptable

Registration procedure:

5

4

3

2

1

Classroom atmosphere:

5

4

3

2

1

Laboratory equipment:

5

4

3

2

1

Parking

5

4

3

2

1

Comments: Please make additional comments about registration procedures, classroom atmosphere, laboratory equipment, and parking:

5. What did you like most about the course? 6. What did you like least about the course? 7. Please comment about overall course quality and length: 8. The HTCP may wish to use your comments in our next brochure To use your comments, we must have your name and address: Name: Title: Organization: Address: City/State/Zip: Phone:

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